master cylinder TOYOTA AVALON 2001 Service User Guide
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 2001, Model line: AVALON, Model: TOYOTA AVALON 2001Pages: 1897, PDF Size: 26.61 MB
Page 495 of 1897
BR152-01
F05420
SST Master
Cylinder
F05422
SST
F05421
SST
BR-24
- BRAKEBRAKE BOOSTER ASSEMBLY
1423 Author: Date:
2001 AVALON (RM808U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder, and lower the pin until
its tip slightly touches the piston.
SST 09737-0001 1
(b) Turn the SST upside down, and set it on the booster.
SST 09737-0001 1
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC:
INSTALL PRECHARGE PUMP ASSEMBLY (See page
BR-58)
4. INSTALL MASTER CYLINDER (See page BR-20)
5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
7. CHECK FOR LEAKS
8. CHECK AND ADJUST BRAKE PEDAL (See page
BR-6)
9. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
LH INSTRUMENT PANEL INSERT AND LOWER NO. 1
INSTRUMENT PANEL (See page BO-87)
10. DO OPERATIONAL CHECK (See page BR-21)
Page 497 of 1897
BR0KY-05
F06431
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-23
1422 Author: Date:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. w/ VSC:
REMOVE PRECHARGE PUMP ASSEMBLY (See page
BR-57)
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH INSTRUMENT PANEL INSERT AND NO. 2
HEATER TO REGISTER DUCT (See page BO-87)
6. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the pedal return spring.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster and gasket.
Page 498 of 1897
BR0KQ-04
F09712
3-way
2-wayMaster CylinderAir Cleaner Cover with
Air Cleaner Hose
Brake Booster
N´m (kgf´cm, ft´lbf) : Specified torquew/ VSC:
15 (155, 11)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Level Warning Switch Connetor
- BRAKEBRAKE MASTER CYLINDER
BR-13
1412 Author: Date:
2001 AVALON (RM808U)
BRAKE MASTER CYLINDER
COMPONENTS
Page 499 of 1897
F09748
Cap
Strainer
Reservoir Reservoir Set Screw
Grommet
Cylinder Body
Gasket
Stopper BoltNo. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
Grommet w/o VSC:
Cap
Strainer
Reservoir
Grommet Reservoir Set Screw
Grommet
Cylinder Body Straight Pin
Non-reusable part
Lithium soap base giycol grease
w/ VSC:
1.7 (17.5, 15.2 in.´lbf)
10 (100, 7)
1.7 (17.5, 15.2 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torque
O-Ring
O-Ring
No. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
BR-14
- BRAKEBRAKE MASTER CYLINDER
1413 Author: Date:
2001 AVALON (RM808U)
Page 500 of 1897
BR0KS-03
F09715
Soft Jows
F09716
Soft Jows
R12236
A BR-16
- BRAKEBRAKE MASTER CYLINDER
1415 Author: Date:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o VSC:
PLACE CYLINDER IN VISE
4. w/o VSC:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. w/o VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:
If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
Page 501 of 1897
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.
Page 502 of 1897
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.
Page 503 of 1897
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).
Page 504 of 1897
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).
Page 505 of 1897
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)