TOYOTA AVENSIS 2003 Service Repair Manual

3201C±08
G24222
G24223
G24224
32±4
±
BRAKE BRAKE FLUID
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE FLUID
BLEEDING
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surfaces.
HINT:
When working on the brake system or when air in the brake lines is suspected,\
bleed the air from the system. 1. FILL RESERVOIR WITH BRAKE FLUIDFluid: SAE J1704 or FMVSS No. 116 DOT4
2. BLEED MASTER CYLINDER
HINT:
After disassembling the master cylinder or when the reservoir
becomes empty, bleed the air out of the brake master cylinder.
(a) w/o VSC: Using SST, Disconnect the brake lines from the brake
master cylinder.
SST 09023±00100
(b) w/ VSC:
Using SST, Disconnect the brake lines from the brake
master cylinder.
SST 09023±38400
(c) Slowly depress and hold the brake pedal it.
(d) Cover off the outer holes with your fingers, and release the brake pedal.
(e) Repeat (b) and (c) 3 or 4 times.
http://vnx.su

F42258
G24222
±
BRAKE BRAKE FLUID
32±5
AVENSIS REPAIR MANUAL (RM1018E)
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal depressed.
(c) At the point when the fluid stops, coming out tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the brake line for each wheel.
Torque: 10 N
m (102 kgf
cm, 7 ft.
lbf)
4. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary. Fluid: SAE J1704 or FMVSS No. 116 DOT4
http://vnx.su

320W5±01
G24285
LHD Steering Position Type:Charcoal Canister Assy
Brake Fluid Level
Switch Connector Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type: Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch Connector Brake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1
w/ ABS:*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in.
lbf)
Fuel Filter Assy Diesel Engin Type:
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS
http://vnx.su

G24284
Cap
Strainer
Brake Master Cylinder Reservoir Sub±Assy
Brake Master Cylinder
Reservoir Grommet
Brake Master Cylinder
Straight Pin
Screw
Lithium soap base glycol grease


Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Brake Master Cylinder
Reservoir Grommet
LHD Steering Position Type
RHD Steering Position Type


O±Ring
Retianer Washer
32±12
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
http://vnx.su

320W6±01
G24218
G24217
F45393
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle: Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way. SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.
http://vnx.su

G24225
F45394
F45395Lithium soap base glycol grease
Grommets
Retainer
Washer
32±14
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (RHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle:
Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Remove the 2 nuts and pull out the accelerator control cable support and brake master cylinder sub±assy.
(f) Remove the O±ring from the brake master cylinder sub± assy.
8. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB±ASSY
(a) Using a screwdriver, remove the screw from the brake master cylinder.
(b) Remove the brake master cylinder reservoir sub±assy and 2 brake master cylinder reservoir grommets from the brake master cylinder.
(c) Remove the cap and strainer from the master cylinder reservoir. 9. INSTALL BRAKE MASTER CYLINDER RESERVOIRSUB±ASSY
(a) Apply lithium soap base grycol grease to the 2 brake mas- ter cylinder reservoir grommets.
(b) Install the retainer washer to the brake master cylinder.
(c) Install the 2 brake master cylinder reservoir grommets to the brake master cylinder.
(d) Using a screwdriver, install the brake master cylinder re-
sevoir sub±assy with the screw.
http://vnx.su

F45393
G24217
G24218
F45394
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±15
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL BRAKE MASTER CYLINDER SUB±ASSY
(LHD STEERING POSITION TYPE)
(a) Install the new O±ring from the brake master cylinder
sub±assy.
(b) Install the brake master cylinder sub±assy and way bracket with the 2 nuts.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(c) Using SST, connect the 2 brake lines to the way. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) w/o VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(e) w/ VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±38400
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
(f) M/T transaxle: Slide the clip and connect the clutch reservoir tube.
(g) Connect the brake fluid level switch connector.
11. INSTALL BRAKE MASTER CYLINDER SUB±ASSY (RHD STEERING POSITION TYPE)
(a) Install the new O±ring from the brake master cylinder
sub±assy.
(b) Install the brake master cylinder sub±assy and accelera- tor control cable support with the 2 nuts.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
http://vnx.su

G24225
32±16
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
(c) w/o VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) w/ VSC: Using SST, connect the 2 brake lines to the brake master
cylinder sub±assy.
SST 09023±38400
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
(e) M/T transaxle: Slide the clip and connect the clutch reservoir tube.
(f) Connect the brake fluid level switch connector.
12. INSTALL CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
13. INSTALL ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
14. INSTALL AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
15. INSTALL FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
16.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
17.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
18.BLEED BRAKE LINE (See page 32±4)
19.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
20.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
21. CHECK BRAKE FLUID LEAKAGE
http://vnx.su

320VI±01
G23173
Stop Lamp Switch Assy
Push Rod Pedal Height
F43108
Stop Lamp Switch Assy
Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.)
32±6
±
BRAKE BRAKE PEDAL SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE PEDAL SUB±ASSY
ADJUSTMENT
1. CHECK AND ADJUST BRAKE PEDAL HEIGHT
(a) Inspect brake pedal height. Pedal height from dash panel:
RHD: 142.5 to 152.5 mm (5.610 to 6.004 in.)
LHD:
M/T: 148.1 to 158.1 mm (5.831 to 6.224 in.)
A/T: 149.9 to 159.9 mm (5.902 to 6.295 in.)
(b) Adjust brake pedal height. (1) Remove the instrument finish panel lower.
(2) Disconnect the connector from the stop lamp switchassy.
(3) Turn the stop lamp switch assy counterclokwise and remove the stop lamp switch assy.
(4) Loosen the brake master cylinder push rod clevis lock nut.
(5) Adjust the pedal height by turning the pedal push rod.
(6) Tighten the push rod lock nut.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
HINT:
If the pedal height is incorrect, check and adjust the stop lamp
switch clearance.
(c) Disconnect the stop lamp switch assy connector from the stop lamp switch assy.
(d) Turn the stop lamp switch assy counterclockwise and re- move the stop lamp switch assy.
(e) Insert the stop lamp switch assy until the body hits the cushion.
NOTICE:
When inserting the stop lamp switch assy, support the ped-
al from behind so that the pedal is not pushed in.
(f) Make a quarter turn clockwise to install the stop lamp
switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy.
Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf) or less
(g) Connect the stop lamp switch connector to the stop lamp switch assy.
http://vnx.su

G23176
Pedal Free Play
R00934
Pedal Reserve
Distance
±
BRAKE BRAKE PEDAL SUB±ASSY
32±7
AVENSIS REPAIR MANUAL (RM1018E)
(h) Check the protrusion of the rod.
Protrusion of the rod: 0.5 to 2.6 mm (0.020 to 0.102 in.)
(i) Install the clevis pin and clip.
(j) After adjusting the pedal height, check the pedal free
play.
2. CHECK PEDAL FREE PLAY
(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 until the beginning of the resistance is felt. Measure the distance, as shown.
Pedal free play: 1 to 6 mm (0.04 to 0.24 in.)
3. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake lever. 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 50 mm (1.97 in.)
If the distance is out of the specification , troubleshoot the brake
system.
http://vnx.su