TOYOTA AVALON 2001 Service Repair Manual

F09717
F09718
- BRAKEBRAKE MASTER CYLINDER
BR-17
1416 Author
: Date
:
2001 AVALON (RM808U)
6. w/ VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 piston and springs by hand, pulling straight
out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bly that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
HINT:
Insert the No. 2 piston with the groove positioning horizontally.

BR0KT-01
BR-18
- BRAKEBRAKE MASTER CYLINDER
1417 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

BR0KV-05
BR-20
- BRAKEBRAKE MASTER CYLINDER
1419 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-15).
HINT:

Before installation, adjust length of brake booster push rod (See page BR-24).

After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4), and
check for leaks.

Check and adjust brake pedal (See page BR-6).

BR0KU-01
- BRAKEBRAKE MASTER CYLINDER
BR-19
1418 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See-page BR-16).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR-13).

BR0KR-02
F09713SST
F09714
- BRAKEBRAKE MASTER CYLINDER
BR-15
1414 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
4. w/ VSC:
DISCONNECT RESERVOIR HOSE
5. DISCONNECT BRAKE LINES
(a) w/o VSC:
Using SST, disconnect the 4 brake lines from the master
cylinder and 2-way.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) w/ VSC:
Using SST, disconnect the 5 brake lines from the master
cylinder and 3-way.
SST 09023-00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
6. REMOVE MASTER CYLINDER
Remove the 2 mounting nuts, and pull out the 2 or 3-way, mas-
ter cylinder and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

BR14Z-01
F09707
F09708
F09709
R00699
BR-4
- BRAKEBRAKE FLUID
1403 Author
: Date
:
2001 AVALON (RM808U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines
is suspected, bleed the air from the system.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outlet plugs with your fingers, and release
the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. CONNECT VINYL TUBE TO BRAKE CALIPER BLEED-
ER PLUG
Insert other end of the tube in a half-full container of brake fluid.
NOTICE:
Bleed air of the rear brake first. If front brake is bled first,
rear brake air cannot be bled.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.

F10182
SST
F07901
2 1
(-)(+)
- BRAKEBRAKE FLUID
BR-5
1404 Author
: Date
:
2001 AVALON (RM808U)
(b) While an assistant depresses the pedal, loosen the
bleeder plug until fluid starts to run out. Then tighten the
bleeder plug.
(c) Repeat this procedure until there are no more air bubbles
in the fluid.
Bleeder plug tightening torque:
8.3 N´m (85 kgf´cm, 74 in.´lbf)
5. REPEAT PROCEDURE FOR EACH WHEEL
6. w/ VSC:
BLEED PRECHARGE PUMP
CAUTION:
When repairing the brake master cylinder or precharge
pump, bleed the precharge pump of the air.
(a) Install the SST to the reservoir.
SST 09992-00242, 09992-00350
(b) Using SST, apply pressure to the reservoir.
Pressure: 98.1 kpa (1.0 kgf/cm
2, 14.2 psi)
(c) Disconnect the precharge pump connector.
(d) Connect ML+ (2) terminal to the battery positive (+) and
ML- (1) terminal to the battery negative (-), and activate
the precharge pump about 20 seconds.
(e) Remove the SST from the reservoir.
(f) Connect the vinyl tube to the front brake caliper RH, and
loosen the bleeder plug.
(g) Activate the precharge pump again until there are no
more air bubbles in the fluid.
Bleeder plug tightening torque:
8.3 N´m (85 kgf´cm, 74 in.´lbf)
(h) Connect the precharge pump connector.
7. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3

BR150-01
F09720
Brake Pedal Bracket Lower LH Panel Insert
Lower No. 1 Instrument Panel
Stop Light Switch
Cruise Control ECU
Pedal Pad
Clip
Return Spring
Collar
Wave Washer
Clevis Pin
Cushion Plate

Bushing

Bushing
Brake Pedal
Lithium soap base glycol grease
Non-reusable part

Brake Pedal Assembly
N´m (kgf´cm, ft´lbf) : Specified torque
13 (130, 9)
39 (400, 29)
13 (130, 9)
5.0 (51, 44 in.´lbf)
BR-8
- BRAKEBRAKE PEDAL
1407 Author
: Date
:
2001 AVALON (RM808U)
COMPONENTS

R00954
Stop Light Switch
Push Rod
Pedal HeightBR0KI-04
R00935
Pedal Freeplay BR-6
- BRAKEBRAKE PEDAL
1405 Author
: Date
:
2001 AVALON (RM808U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
153.3 - 163.3 mm (6.035 - 6.429 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Remove the lower No. 1 instrument panel and lower LH
instrument panel insert (See page BO-87).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
(f) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(g) Install the stop light switch.
(h) Connect the connector to the stop light switch.
(i) Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push the brake pedal in 5 - 15 mm (0.20
- 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the lower LH instrument panel insert and lower No.
1 instrument panel (See page BO-87).
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the beginning of the resis-
tance is felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
Stop light switch clearance:
0.5 - 2.4 mm (0.020 - 0.094 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 in.)
at the pedal.

R00934
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
1406 Author
: Date
:
2001 AVALON (RM808U)
4. CHECK PEDAL RESERVE DISTANCE
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (3.0 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.