TOYOTA AVALON 2001 Service Repair Manual

BR151-01
F09746
F09747
- BRAKEPARKING BRAKE PEDAL
BR-1 1
1410 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH PANEL INSERT AND NO. 2 HEATER TO REG-
ISTER DUCT (See page BO-87)
2. RELEASE PARKING BRAKE PEDAL
3. REMOVE PARKING BRAKE PEDAL ASSEMBLY
(a) Disconnect the parking brake switch connector.
(b) Remove the clip, and disconnect the parking brake cable.
(c) Remove the 3 nuts and parking brake pedal assembly.
Torque: 61 N´m (620 kgf´cm, 45 ft´lbf)
(d) Remove the parking brake switch and cushion from the
parking brake pedal assembly.

BR159-01
F09741
Air Cleaner Cover With Air Cleaner Hose
Level Warning Switch Connector
Master Cylinder
Precharge Pump Precharge Pump Assembly
Master Cylinder Pressrue Sensor
3-way
Precharge Pump Bracket
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable partCushion
15 (155, 11)
Holder
13 (130, 9)
19 (195, 14)
19 (195, 14)
13 (130, 9)8.0 (82, 71in.´lbf)
Washer CushionCollar
20 (200, 15)
15 (155, 11)
O-Ring

Spacer
81 (830, 60)
BR-56
- BRAKEPRECHARGE PUMP
1455 Author
: Date
:
2001 AVALON (RM808U)
PRECHARGE PUMP
COMPONENTS

BR15B-01
BR-58
- BRAKEPRECHARGE PUMP
1457 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-57).
HINT:

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

Check for fluid leaks.

BR15A-01
F09742
F09743
SST
F09744
F09745
- BRAKEPRECHARGE PUMP
BR-57
1456 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER CASE WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. DISCONNECT PRECHARGE PUMP CONNECTOR
4. REMOVE PRECHARGE PUMP ASSEMBLY
(a) Remove the 3 bolts and precharge pump assembly.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(b) Using SST, disconnect the 2 brake lines from the prechar-
ge pump.
SST 09751-3601 1
Torque:
10 mm nut: 15 N´m (155 kgf´cm, 11 ft´lbf)
12 mm nut: 20 N´m (200 kgf´cm, 15 ft´lbf)
5. REMOVE PRECHARGE PUMP
(a) Remove the 2 nuts, 2 bolts and precharge pump from the
pump bracket.
Torque:
Nut: 13 N´m (130 kgf´cm, 9 ft´lbf)
Bolt: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
(b) Remove the 2 holders, 2 collars, 2 washers and 4 cush-
ions.
6. REMOVE MASTER CYLINDER PRESSURE SENSOR
(a) Place the precharge pump in a vise with a cloth shown in
the illustration on the left.
(b) Using 30 mm deeper socket wrench, and remove the
master cylinder pressure sensor, O-ring and spacer.
Torque: 81 N´m (830 kgf´cm, 60 ft´lbf)

BR0LA-03
F09724
Brake Caliper
Torque Plate Piston Seal
Set Ring Piston
Dust Boot
Pad Support Plate
Sliding Bushing
Inner Pad
Anti-squeal Shim
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
Lithium soap bass glycol grease
Disc brake grease
Bleeder Plug
29 (300, 22)
8.3 (85, 74 in.´lbf)
47 (475, 34)
Inner Anti-squeal Shim Anti-squeal Shim
Plug
47 (475, 34)
Boot
Pad Support Plate
Outer Pad
Inner Anti-squeal Shim
34 (350, 25)
34 (350, 25)
Flexble Hose
Disc
Gasket


Gasket


- BRAKEREAR BRAKE CALIPER
BR-37
1436 Author
: Date
:
2001 AVALON (RM808U)
REAR BRAKE CALIPER
COMPONENTS

BR153-01
F09726
F09727
F09728
- BRAKEREAR BRAKE CALIPER
BR-39
1438 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the cylinder.
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seal from the cylinder.
4. REMOVE 2 DUST BOOTS

BR0LD-03
F09729
BR-40
- BRAKEREAR BRAKE CALIPER
1439 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. MEASURE PAD LINING THICKNESS (See page
BR-31)
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2. MEASURE DISC THICKNESS
(See step 2 on page BR-31)
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
3. MEASURE DISC RUNOUT
(See step 3 on page BR-31)
Maximum disc runout: 0.15 mm (0.0059 in.)
If the disc's runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA-45). If the bearing play and axle hub runout are
not abnormal, adjusting the disc runout or grind it on a ºOn-Carº
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5
of a turn round from its original position on the hub. Install
and torque the hub nuts.
Torque: 103 N´m (1050 kgf´cm, 76 ft´lbf)
Remeasure the disc runout. Make a note of the runout
and the disc's position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.15 mm (0.0059 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.15 mm (0.0059 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and torque the mounting bolts.
Torque: 47 N´m (475 kgf´cm, 34 ft´lbf)

BR0LF-03
BR-42
- BRAKEREAR BRAKE CALIPER
1441 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-38).
HINT:

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

Check for fluid leaks.

BR0LE-01
- BRAKEREAR BRAKE CALIPER
BR-41
1440 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-39).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-37).

BR0LB-02
F09725
BR-38
- BRAKEREAR BRAKE CALIPER
1437 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
HINT:
At the time of installation, insert the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
NOTICE:
At the time of installation, insert the sliding pin with sliding
bushing into the bottom side.
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 4 PAD SUPPORT PLATES
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or disc.