Disc brake TOYOTA AVENSIS 2002 Repair Manual

320VZ±01
G24211
To Master Cylinder Front
G24212
To Master Cylinder Rear
To Front Wheel RH
To Rear Wheel LH
To Rear Wheel RH
To Front Wheel LH
G24213
32±54
± BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surfaces.
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER LINER RH
4. REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Release the latch of the brake actuator connector to dis-
connect the connector.
(b) Using SST, disconnect the brake tubes from the brake ac-
tuator.
SST 09023±00100
(c) Use tags or make a memo to identify the place to recon-
nect.
(d) Remove the nut, 2 bolts and brake actuator with bracket.

G24213
To Master Cylinder Front
G24212
To Master Cylinder Rear
To Front Wheel RH
To Rear Wheel LH
To Rear Wheel RH
To Front Wheel LH
±
BRAKE BRAKE ACTUATOR ASSY(W/O VSC)
32±55
AVENSIS REPAIR MANUAL (RM1018E)
5.REMOVE BRAKE ACTUATOR ASSY
(a)Remove the 2 nuts and brake actuator from the brake acutuator bracket.
6.REMOVE SKID CONTROL ECU
(a)Disconnect the connector from the skid control ECU.
(b)Using a torx driver (T20), remove the 4 screws and the skid control EC\
U from the brake actuator.
7.INSTALL SKID CONTROL ECU
(a)Install the skid control ECU and 4 screws with a torx driver (T20).
(b)Connect the connector to the skid control ECU.
8.INSTALL BRAKE ACTUATOR ASSY
(a)Install the brake actuator with the 2 nuts to the brake actuator bracket\
.
Torque: 7.0 N
m ( 71 kgf
cm, 62 in.
lbf)
9.INSTALL BRAKE ACTUATOR WITH BRACKET
(a)Install the brake actuator with bracket with the nut and 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b)Using SST, connect each brake line to the correct position of the brake actuator, as shown in the illustration.
SST09023±00100
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
(c)Connect the brake actuator connector.
10.INSTALL FRONT FENDER LINER RH
11.INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
12.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
13.BLEED MASTER CYLINDER (See page 32±4) SST 09023±00100
14.BLEED BRAKE LINE (See page 32±4)
15.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
16. CHECK BRAKE FLUID LEAKAGE
17.CHECK BRAKE ACTUATOR WITH HAND±HELD TESTER (See page 05±699)

3201G±07
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
G24221
Ventilation No Ventilation
± BRAKEBRAKE BOOSTER ASSY (LHD)
32±17
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (LHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

320W7±01
F40019
F42620
±
BRAKE BRAKE BOOSTER ASSY (LHD)
32±19
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 AIR CLEANER ASSEMBLY WITH HOSE
3. SEPARATE ENGINE ROOM RELAY BLOCK
4. REMOVE CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
5.REMOVE FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
6.REMOVE BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
7.REMOVE HEATER ASSY (W/ COLD AREA) (See page 55±100)
8. REMOVE FRONT WHEEL LH
9. DISCONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, disconnect the brake line fromthe flexible hose of the front brake LH.
SST 09023±00100
10. REMOVE BRAKE BOOSTER ASSY
(a) Disconnect the vacuum hose from the brake booster assy.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts.
(d) Pull out the brake booster assy.
11. REMOVE BRAKE BOOSTER GASKET
(a) Pull out the brake booster gasket from the brake booster assy.
12. REMOVE CHECK VALVE
(a) Remove the check valve and grommet from the brake booster assy.
13. INSTALL CHECK VALVE
(a) Install the check valve and grommet to the brake booster assy.
14. INSTALL BRAKE BOOSTER GASKET
(a) Install a new brake booster gasket to the brake booster assy.

320GN±02
BR2238
GOOD NO GOOD
2nd3rd
1st
BR2237
G24221
Ventilation No Ventilation
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±21
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE BOOSTER ASSY (RHD)
ON±VEHICLE INSPECTION
1. INSPECT BRAKE BOOSTER
(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. De-
press the brake pedal several times slowly.
HINT:
If the pedal can be depressed to the f;oor the first time, but on
the 2nd or 3rd time cannot be depreesed as far, the booster is
airtight.
(2) Depress the brake pedal while the engine is run-
ning, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b) Operating check.
(1) Depress the brake pedal several times with the igni-
tion switch off and check that there is no change in
the pedal reserve distance.
(2) Depress the brake pedal and start the engine.
HINT:
If the pedal goes down slightly, operation is normal.
2. INSPECT VACUUM CHECK VALVE
(a) Inspect vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to
the engine, and no ventilation from the engine to the
booster.
(4) If any fault is found, replace the vacuum check
valve.

320W4±01
G24211
F42291
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±25
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 BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
3.REMOVE CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
4. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
5. REMOVE ENGINE COVER NO.1
6.REMOVE IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
7.REMOVE CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
8.REMOVE TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)
9.REMOVE CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
10.REMOVE INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
11. REMOVE FRONT WHEEL RH
12. REMOVE BRAKE TUBE
(a) w/o VSC:Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100
(b) w/ VSC: Using SST, disconnect the 6 brake tubes from the brake
actuator.
SST 09023±00100, 09023±38400

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80802
C80806
32±26
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Use tags or make a memo to identify the place to recon-
nect.
(d) Using SST and a spanner, disconnect the brake tube from
the flexible hose of the front brake RH.
SST 09023±00100
(e) Remove the 2 bolts and disconnect the 2 brake tube
clamps.

F45361
F45362
F45367
F45363Vacuum tank
C81275
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±27
AVENSIS REPAIR MANUAL (RM1018E)
(f) Using SST, disconnect the 3 brake tubes from the ways.
SST 09023±00100
(g) Disconnect the brake tube from the clamp and remove
the brake tubes.
(h) Disconnect the 3 brake tubes from the clamp and remove
the brake tubes.
13. REMOVE BRAKE BOOSTER ASSY
(a) Gasoline engine type:
Remove the 2 bolts and separate the vacuum pipe from
the body.
(b) Diesel engine type:
Remove the 2 bolts and remove the vacuum tank from the
body.
(c) Disconnect the vacuum hose from the brake booster
assy.
(d) Remove the engine under cover.
(e) Remove the 2 nuts from the engine mounting bracket RH.
(f) Remove the bolt from the rear engine mounting bracket.
(g) Remove the bolt and nut from the front engine mounting
bracket.

F45363Vacuum tank
F45362
F45361
C80802
32±30
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
(k) Diesel engine type:
Install the vacuum tank with 2 bolts.
Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
19. INSTALL BRAKE TUBE
(a) Disconnect the 3 brake tubes from the clamp and remove
the brake tubes.
(b) Using SST, connect the 3 brake tubes to the ways.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(c) Connect the brake tube to the clamp.
(d) Using SST and a spanner, connect the brake tube to the
flexible hose of front brake RH.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)

3201C±08
G24222
G24223
G24224
32±4
± BRAKEBRAKE 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 FLUID
Fluid: 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.