Yaris 2007

Hydraulic Control Module

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Removal & Installation



With Vehicle Stability Control
  1. Drain the brake fluid.
    NOTE
    Immediately wash off any brake fluid that comes into contact with any painted surfaces.

  2.  
  3. Remove the battery, battery tray and carrier.
  4.  
  5. Release the lock lever and disconnect the brake actuator connector.
    NOTE
    Be careful not to allow brake fluid to enter the removed connector.

  6.  
  7. Using a union nut wrench (10 mm) and a union nut wrench (12 mm), separate the 6 brake tubes from the brake actuator.
    1. Use tags or labels to identify the place to reconnect each brake tube.
    2.  
    3. Remove the 3 bolts and brake actuator with bracket.
    4.  

  8.  
  9. Remove the 3 bolts and actuator bracket.

    Click image to see an enlarged view

    Fig. Identifying the brake tubes



    Click image to see an enlarged view

    Fig. View of the HCU assembly-With VSC

  10.  

To install:

  1. Install the actuator bracket with the 3 bolts in the sequence shown in the illustration. Tighten to 48 inch lbs. (5.4 Nm).
    NOTE
    Do not remove the hole plug before connecting the brake tube. New actuators are filled with brake fluid. Do not carry with the connector part of an actuator.



    Click image to see an enlarged view

    Fig. Install the brake actuator bracket with the 3 bolts in the sequence shown

  2.  
  3. Install the brake actuator with bracket with the 3 bolts in the sequence shown in the illustration.
    NOTE
    Do not damage the brake tubes or wire harness.



    Click image to see an enlarged view

    Fig. Install the brake actuator with the 3 bolts in the sequence shown

  4.  
  5. Temporarily install each brake tube in the correct positions of the brake actuator as shown in the illustration.

    Click image to see an enlarged view

    Fig. Identifying the brake tubes

  6.  
  7. Using a union nut wrench (10 mm) and a union nut wrench (12 mm), install the 6 brake tubes onto the brake actuator.

    Click image to see an enlarged view

    Fig. Identifying and tightening the flare nuts

  8.  
  9. Connect the brake actuator connector.
    NOTE
    Make sure that the connector is locked securely. Make sure that the actuator connector can be connected smoothly. Do not allow entry of water, oil or dirt.

  10.  
  11. Install the batter and tray assembly.
  12.  
  13. Fill reservoir with brake fluid.
  14.  
  15. Bleed master cylinder.
  16.  
  17. Bleed brake line.
  18.  
  19. Bleed brake actuator.
  20.  
  21. Inspect for brake fluid leak.
  22.  
  23. Inspect fluid level.
  24.  
  25. Inspect actuator with Techstream.
  26.  
  27. Perform yaw rate and acceleration sensor zero point calibration.
  28.  
  29. Check and clear DTC.
  30.  

Yaw Rate & Acceleration Sensor Zero Point Calibration



With VSC

Specific to:

Toyota Yaris 2007-2009


NOTE
After replacing the VSC relevant components or performing "Front wheel alignment adjustment", clear and read the sensor calibration data.

Follow the chart to perform calibration.

Click image to see an enlarged view

Fig. Calibration chart

  1. Obtain zero point of yaw rate and acceleration sensor (when using Techstream):
    NOTE
    While obtaining the zero points, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) Be sure to perform this procedure on a level surface (with an inclination of less than 1 degree).

    1. Clear the zero point calibration data:
      NOTE
      If the ignition switch is turned to ON for more than 15 seconds with the shift lever in P (for automatic transaxle model) or the parking brake applied (for manual transaxle model) after zero point of the yaw rate and acceleration sensor has been cleared, only the zero point of the yaw rate sensor will be stored. If the vehicle is driven under these conditions, the skid control ECU will store the zero point calibration for the acceleration sensor as not being completed. The skid control ECU will then also indicate this as a malfunction of the VSC system using the warning lights.



      Turn the ignition switch off.
       
      Check that the steering wheel is in the straight-ahead position.
       
      for Automatic Transaxle model: Check that the shift lever is in P and apply the parking brake.
       
      for Manual Transaxle model: Check that the shift lever is in N and apply the parking brake.
       
      Connect the Techstream to the DLC3.
       
      Turn the ignition switch to ON. Turn the ignition switch to ON.
       
      Turn the Techstream on.
       
      Enter the following menus: Chassis / ABS/VSC/TRAC / Reset Memory.
       
      Check that the SLIP indicator light comes on.
       
      Turn the ignition switch off.
       

    2.  
    3. Perform zero point calibration of the yaw rate and acceleration sensor.
      NOTE
      DTCs C1210 (zero point calibration of yaw rate sensor undone) and C1336 (zero point calibration of acceleration sensor undone) will be recorded if the shift lever is not in P (for automatic transaxle model) or the parking brake is not applied (for manual transaxle model)


      NOTE
      The TRAC OFF indicator light remains on during Test Mode because traction control is prohibited (The TRAC OFF indicator light goes off when the VSC OFF switch is ON). If the SLIP indicator light does not blink, perform zero point calibration again. The zero point calibration is performed only once after the system enters the Test Mode. Calibration cannot be performed again until the stored data is cleared.


      NOTE
      While obtaining the zero points, keep the vehicle stationary and do not vibrate, tilt, move, or shake it. (Do not start the engine.) Be sure to perform this procedure on a level surface (with an inclination of less than 1 degree).



      Turn the ignition switch off.
       
      Check that the steering wheel is in the straight-ahead position.
       
      For Automatic Transaxle model: Check that the shift lever is in P and apply the parking brake.
       
      For Manual Transaxle model: Check that the shift lever is in N and apply the parking brake.
       



      Connect the Techstream to the DLC3.
       
      Turn the ignition switch to ON.
       
      Turn the Techstream on.
       
      Switch the skid control ECU to Test Mode using the Techstream. Enter the following menus: Chassis / ABS/VSC/TRAC / Test Mode.
       
      After the Test Mode has been entered, keep the vehicle stationary on a level surface for 2 seconds or more.
       
      Check that the ABS warning and SLIP indicator lights come on for several seconds and then blink in the Test Mode.
       



      Turn the ignition switch off and disconnect the Techstream.
       

    4.  

  2.  
  3. Obtain zero point of yaw rate and acceleration sensor (when using SST check wire):
    1. Clear the zero point calibration data:

      Clear the zero point calibration data.
       
      Check that the steering wheel is in the straight-ahead position.
       
      for Automatic Transaxle model: Check that the shift lever is in P and apply the parking brake.
       
      for Manual Transaxle model: Check that the shift lever is in N and apply the parking brake.
       
      Turn the ignition switch to ON.
       
      The warning light and indicator light come on for 3 seconds to indicate that the initial check is completed.
       
      Using SST, connect and disconnect terminals 12 (TS) and 4 (CG) of the DLC3 4 times or more within 8 seconds.

      Click image to see an enlarged view

      Fig. Calibration chart

       

    2.  

  4.  

Without VSC

Specific to:

Toyota Yaris 2007-2009

  1. Drain the brake fluid.
  2.  
  3. Remove the battery and tray assembly.
  4.  
  5. For sedan models:
    1. Disengage the clamp.
    2.  
    3. Move the lock lever in the direction indicated by the arrow to release the lock and disconnect the brake actuator connector from the actuator.
    4.  
    5. Using a union nut wrench, separate the brake tube from the front flexible hose.
    6.  
    7. Using a union nut wrench, separate the 2 brake tubes from the brake tube No. 1 way.
    8.  
    9. Using a union nut wrench, separate the 2 brake tubes from the brake master cylinder.
    10.  
    11. Using a union nut wrench, separate the 6 brake tubes from the brake actuator.
    12.  
    13. Use tags or labels to identify the place to reconnect each brake tube.

      Click image to see an enlarged view

      Fig. Labeling and identifying the brake tubes

    14.  
    15. Disconnect the brake tube clamp.
    16.  
    17. Remove the 3 bolts and the actuator with bracket.
      NOTE
      Do not damage the brake tubes or wire harness.



      Click image to see an enlarged view

      Fig. View of the HCU and related components-Sedan

    18.  

  6.  
  7. For hatchback models:
    1. Release the lock lever and disconnect the brake actuator connector.
      NOTE
      Be careful not to allow brake fluid to enter the removed connector.

    2.  
    3. Using a union nut wrench, separate the brake tube from the front flexible hose.
    4.  
    5. Using a union nut wrench, separate the 2 brake tubes from the brake tube No. 1 way.
    6.  
    7. Using a union nut wrench, separate the 2 brake tubes from the brake master cylinder.
    8.  
    9. Using a union nut wrench, separate the 6 brake tubes from the brake actuator. Use tags or labels to identify the place to reconnect each brake tube.

      Click image to see an enlarged view

      Fig. Identifying the brake tubes

    10.  
    11. Disconnect the brake tube clamp.
    12.  
    13. Remove the 3 bolts and brake actuator with bracket.

      Click image to see an enlarged view

      Fig. View of the HCU and related components-Sedan

    14.  

  8.  
  9. For sedans, remove the 2 nuts and the actuator bracket.
  10.  
  11. For hatchbacks, remove the 3 bolts and the actuator bracket.
  12.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. Refer to the exploded illustrations for torque values.
  4.  
  5. Fill reservoir with brake fluid.
  6.  
  7. Bleed master cylinder.
  8.  
  9. Bleed brake line.
  10.  
  11. Check fluid level in reservoir.
  12.  
  13. Check for brake fluid leakage.
  14.  
  15. Check actuator with Techstream.
  16.  

 
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