TOYOTA AVENSIS 2002 Manual PDF

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

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
± BRAKEBRAKE 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 switch
assy.
(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.

G23176
Pedal Free Play
R00934
Pedal Reserve
Distance
± BRAKEBRAKE 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.

320G0±02
G23174
Clip
Clevis Pin
Brake Pedal
Support Sub±assy

Bush

Bush
Brake Pedal Sub±assyStop Lamp Switch Connector
Stop Lamp Switch assy
Brake Pedal Sub±assy
Brake Pedal Pad
Brake Pedal Pad
Lithium soap base glycol grease
37 (375, 27)
24 (241, 17)

Non±reusable part
N
m (kgf
cm, ft
lbf)
: Specified torque A/T models:Brake Master Cylinder
Push Rod Clevis
13 (130, 9)
13 (130, 9)
Stop Lamp Switch Mounting Adjuster
Brake pedal shaft M/T models: 32±8
± BRAKEBRAKE PEDAL SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

320VT±01
G23220
G23175
F43108
Stop Lamp Switch Assy
Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.)
±
BRAKE BRAKE PEDAL SUB±ASSY
32±9
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE COMBINATION METER ASSEMBLY (See page 71±21)
2. REMOVE BRAKE PEDAL SUPPORT SUB±ASSY
(a) Remove the bolt from the brake pedal support sub±assy.
(b) Disconnect the stop lamp switch connector.
(c) Remove the clip and clevis pin, and disconnect the brakemaster cylinder push rod clevis from the brake pedal sub±
assy.
(d) Remove the 4 nuts and brake pedal support sub±assy.
3. REMOVE BRAKE PEDAL SUB±ASSY
(a) Remove the brake pedal shaft and nut from the brake pedal support sub±\
assy.
(b) Remove the brake pedal sub±assy and 2 bushes.
4. REMOVE STOP LAMP SWITCH ASSY
(a) Turn the stop lamp switch assy counterclockwise and remove the stop lamp \
switch assy.
(b) Remove the stop lamp switch mounting adjuster from the brake pedal suppo\
rt sub±assy.
5. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad from the brake pedal sub±assy.
6. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub±assy. 7. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch mounting adjuster to thebrake pedal support sub±assy.
(b) Install 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.
(c) 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

G23175
G23220
32±10
±
BRAKE BRAKE PEDAL SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
8. INSTALL BRAKE PEDAL SUB±ASSY
(a) Apply lithium soap base glycol grease to the inside surface of 2 new bus\
hes.
(b) Install the brake pedal sub±assy and 2 bushes to the brake pedal supp\
ort sub±assy with the brake pedal shaft and nut.
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
9. INSTALL BRAKE PEDAL SUPPORT SUB±ASSY
(a) Install the brake pedal support sub±assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Connect the stop lamp switch connector to the stop lamp switch assy.
(c) Apply lithium soap base glycol grease to the clevis pin.
(d) Install the clip and clevis pin, and connect the brake mas- ter cylinder push rod clevis with the clevis pin and clip.
(e) Install the bolt to the brake pedal support assy. Torque: 24 N
m (241 kgf
cm, 17 ft
lbf)
10.INSTALL COMBINATION METER ASSEMBLY (See page 71±21)
11.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
12.CHECK PEDAL FREE PLAY (See page 32±6)
13.CHECK PEDAL RESERVE DISTANCE (See page 32±6)

3201A±12
± BRAKEBRAKE SYSTEM
32±1
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the ones with parts having the same part number
or equivalent.

It is very important to keep the parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION.

3201B±12
32±2
±
BRAKE BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the probability of the
problems in descending order. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
3. Fluid leaks in brake system
4. Air in brake system
5. Piston seals (Worn or damaged)
6. Brake master cylinder (faulty)
7. Brake booster push rod (Out of adjustment) ±
32±4
32±41
32±47
32±13
32±13
Brake drag
1. Brake pedal free play (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Disk brake pad (Cracked or distorted)
5. Piston (Stuck or Frozen)
6. Brake booster push rod (Out adjustment)
7. Vacuum leaks in brake booster system
8. Brake master cylinder (Faulty)32±6
33±2
33±2
32±41
32±47
32±41
32±47
32±13
32±17
32±21
32±13
Brake pull
1. Piston (Stuck or Frozen)
2. Pad or lining (Oily)
3. Disc (Scored)
4. Pad (Cracked or distorted) 32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
Hard pedal but brake inefficient
1. Fluid leaks in brake system
2. Air in brake system
3. Pad (Worn)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glazed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster system ±
32±4
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±13
32±17
32±21

±
BRAKE BRAKE SYSTEM
32±3
AVENSIS REPAIR MANUAL (RM1018E)
Noise from brakes
1. Pad (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad (dirty)
7. Pad(Glazed)32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47

320GA±03
G23177
Disc Brake
Cylinder Assy LH
GasketFlexible Hose
Disc Brake
Pad Kit Front
Front Disc Brake
Pad Support Plate No.1
Front Disc Brake
Cylinder Slide Pin (No.2)
Front Disc Brake
Bush Dust Boot Front Disc Brake
Cylinder Slide Pin (No.1)
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Cylinder Mounting LH

Cylinder Boot
Piston Seal
Front Disc
Brake PistonFront Disc
30 (306, 22)
102 (1,040, 75)
30 (306, 22)
Bleeder Plug CapFront Disc Brake
Bleeder Plug

Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Lithium soap base glycol grease
29 (296, 21)
10 (102, 7)
Union bolt
Front Disc Brake
Pad Support Plate No.2
102 (1,040, 75)

Front Disc Brake
Bush Dust Boot
Bolt

Bolt




32±40
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BRAKE
COMPONENTS