TOYOTA AVENSIS 2005 Service Repair Manual

330C8±01
F45710
Contract
F06409
G22379

G22380
33±14
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures as those of the LH side.
1. REMOVE REAR WHEEL
2.DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (See page 30±31) 3. REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:

Put matchmarks on the disc and the axle hub.

If the disc cannot be removed easily, turn the shoe adjust-
er until the wheel turns freely.
4. INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the in- side diameter of the disc.
Standard inside diameter: 173 mm (6.81 in.)
Maximum inside diameter: 174 mm (6.85 in.)
5. REMOVE PARKING BRAKE ADJUSTER KIT
(a) Using needle±nose pliers, remove the shoe upper side 2 tension springs.
(b) Remove the parking brake shoe strut LH.
6. REMOVE PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Using needle±nose pliers, remove the anchor side ten- sion spring.
(b) Remove the shoe adjusting screw set.


F45077
SST
F44822
SST
R00311
BR0828
F42661
± PARKING BRAKEPARKING BRAKE ASSY
33±15
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE PARKING BRAKE SHOE KIT
(a) Using SST, remove the parking brake shoe hold±down
compression spring, parking brake shoe hold±down
spring pin and parking brake shoe assy LH No.1.
SST 09718±00010
(b) Using SST, remove the parking brake shoe hold±down
compression spring and parking brake shoe hold±down
spring pin.
SST 09718±00010
(c) Disconnect the parking brake shoe assy LH No.2 from the
parking brake shoe lever LH, and remove the parking
brake shoe LH No.2.
8. INSPECT PARKING BRAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 3.5 mm (0.138 in.)
Minimum thickness: 1.0 mm (0.039 in.)
9. INSPECT BRAKE DISC AND PARKING BRAKE SHOE
LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind
down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is im-
proper, repair it using a brake shoe grinder or replace the brake
shoe assembly.
10. REMOVE PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, disconnect the parking brake
cable assy No.3 and remove the parking brake shoe lever
LH.


F44709
F42661
C80704
F44822
SST
F44705
SST
33±16
± PARKING BRAKEPARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
11. APPLY HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached
surface of backing plate.
12. INSTALL PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, connect the parking brake
cable assy No.3 to the parking brake shoe lever LH.
13. INSTALL PARKING BRAKE SHOE KIT
(a) Apply the high temperature grease to the contact part of
the parking brake shoe and parking brake shoe lever.
(b) Using SST, install the parking brake shoe LH No.2 with
the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010
(c) Using SST, install the parking brake shoe LH No.1 with
the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010

C80705

G22380
C80706
G22379
± PARKING BRAKEPARKING BRAKE ASSY
33±17
AVENSIS REPAIR MANUAL (RM1018E)
14. INSTALL PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Apply the high temperature grease to the adjusting bolt
and support piece.
(b) Install the parking brake shoe adjusting screw set LH.
(c) Using needle±nose pliers, install the tension spring.
15. INSTALL PARKING BRAKE ADJUSTER KIT
(a) Apply the high temperature grease to the contact part of
the shoe strut and tension spring.
(b) Install the parking brake shoe strut LH.
(c) Using needle±nose pliers, install the upper side 2 tension
springs.
HINT:
Install the 2 tension spring securely to the grooves of the shoe
strut.

F44823
RH
LH
Front
Front
F44708
Expand
Contract 33±18
± PARKING BRAKEPARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
16. CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease on the friction surface of the shoe lining and disc.
17. INSTALL REAR DISC
18. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expand
the shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate
smoothly.
Standard : Return 8 notches
(d) Check that there is no brake drag.
(e) Install the hole plug.
19. CONNECT REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
20. INSTALL REAR WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

±
PARKING BRAKE PARKING BRAKE ASSY
33±19
AVENSIS REPAIR MANUAL (RM1018E)
21. SETTLING PARKING BRAKE SHOES AND DISC
(a) Drive the vehicle at about 50km/h (31 mph) on a safe,level and dry roa\
d.
(b) With the parking brake release button pushed in, pull on the lever with 98 N\
(10kgf, 19.8 lbf) of force.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this condition.
(d) Repeat this procedure 2 or 3 times.
22.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
23.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)

3306E±05
Parking Brake
Shoe Hold±Down
Compression Spring
Parking Brake Shoe
Adjusting Screw SetParking Brake
Shoe Strut LH
F44821
Parking Brake
Shoe Lever LH
Parking Brake
Shoe Assy LH No.2
Parking Brake
Shoe Assy LH No.1
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Compression Spring
Tension Spring
Tension Spring
Tension Spring
Rear Disc
Rear Disc Brake
Caliper Assy LH
47(475, 34)
N
m (kgf
cm, ft
lbf) : Specified torque
High temperature grease
± PARKING BRAKEPARKING BRAKE ASSY
33±13
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE ASSY
COMPONENTS

330C7±01
F44818
33±10
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
For parking brake cable assy No.2, perform the same procedure to the RH sid\
e.
1. REMOVE REAR WHEEL
2.DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (See page 30±31)
3.REMOVE REAR DISC(See page 33±14)
4.REMOVE PARKING BRAKE ADJUSTER KIT (See page 33±14)
5.REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET(See page 33±14)
6.REMOVE PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
7. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Using needle±nose pliers, and disconnect the parkingbrake cable assy No.3 from the backing plate.
8. REMOVE EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
9. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(See page 33±7)
10. REMOVE FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE) (See page 33±7)
11. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 3 nuts and fuel tank protector No.1 (When re-placing parking brake cable assy No.2).
(b) Remove the 4 bolts and cable retainer from the body.
(c) Disconnect the parking brake cable assy No.3 from the equalizer, and remove the parking brake cable assy No.3.

F44819
F44820
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
33±11
AVENSIS REPAIR MANUAL (RM1018E)
12. INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the equaliz-
er.
(b) Install the parking brake cable assy No.3 with the 4 bolts. Torque: 5.0 N
m (55 kgf
cm, 48 in.
lbf)
(c) Install the fuel tank protector No.1 and 3 nuts (When re- placing parking brake cable assy No.2).
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
13. INSTALL FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE) (See page 33±7)
14. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE) (See page 33±7)
15. INSTALL EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
16. CONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the backingplate.

33±12
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
17.APPLY HIGH TEMPERATURE GREASE (See page 33±14)
18.INSTALL PARKING BRAKE SHOE LEVER LH (See page 33±14)
19.INSTALL PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
20.INSTALL PARKING BRAKE SHOE ADJUSTING SCREW SET (See page 33±14)
21.INSTALL PARKING BRAKE ADJUSTER KIT (See page 33±14)
22. INSTALL REAR DISC
23.CONNECT REAR DISC BRAKE CALIPER ASSY LH(See page 30±31)
24.ADJUST PARKING BRAKE SHOE CLEARANCE(See page 33±14)
25. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
26.SETTLING PARKING BRAKE SHOES AND DISC (See page 33±14)
27.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
28.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
29. CHECK EXHAUST LEAKAGE