clutch TOYOTA AVENSIS 2002 Repair Manual

320VU±01
F45162
Vacuum Hose
ClipBrake Vacuum
Check Valve
Check Valve
Grommet
Clevis Pin
Clip Wave Washer
13 (130, 9)
Engine Room Relay Block Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy Diesel Engine Type: Heater Assy w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2
w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
± BRAKEBRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS

F42620
F40019
32±20
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
15. INSTALL BRAKE BOOSTER ASSY
(a) Install the brake booster assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Install the clevis pin and clip to the brake master cylinder clevis.
(c) Connect the vacuum hose to the brake booster assy.
16. CONNECT FRONT BRAKE TUBE NO.5
(a) Using SST and spanner, connect the brake tube to the flexible hose.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
17. INSTALL FRONT WHEEL LH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
18.INSTALL HEATER ASSY (W/ COLD AREA) (See page 55±100)
19.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
20. INSTALL CHARCOAL CANISTER ASSY (GASOLINE ENGINE TYPE)
21.INSTALL FUEL FILTER ASSY (DIESEL ENGINE TYPE) (See page 11±82)
22. CONNECT ENGINE ROOM RELAY BLOCK
23. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
24.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
25.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC:
SST 09023±00100
(b) w/ VSC: SST 09023±38400
26.BLEED BRAKE LINE (See page 32±4)
27.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
28.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
29.CHECK PEDAL FREE PLAY (See page 32±6)
30.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
31. CHECK FUEL LEAK
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
33. CHECK BRAKE FLUID LEAKAGE

F45161
Brake Master
Cylinder Sub±assy
Clutch Master Cylinder AssyM/T Transaxle: Vacuum Tank Diesel Engine Type:
Brake Fulid Level
Switch Connector Accelerator Control
Cable Support
20 (204, 15)
19 (194, 14)
Clutch Reservoir
Hose M/T Transaxle: Brake Booster Assy
Brake Booster Gasket
Brake Master Cylinder
ClevisClip Clevis Pin
13 (130, 9)
15 (155, 11) *1
29 (296, 21) *2
15 (155, 11)
N
m (kgf
cm, ft
lbf)
: Specified torque
5.4 (55, 48 in.
lbf)
8.3 (85, 73 in.
lbf)
Wave Washer
Check Valve Grommet
15 (155, 11)
5.4 (55, 48 in.
lbf)
*1 w/ ABS:
*2 w/ VSC:
32±24
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)

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

32±32
±
BRAKE BRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
26. INSTALL ENGINE COVER NO.1
27.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
28.INSTALL CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
29.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
30.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
31.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100, 09023±00100
(b) w/ VSC: SST 09023±00100, 09023±00100
32.BLEED BRAKE LINE (See page 32±4)
33.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
34.CHECK PEDAL FREE PLAY (See page 32±6)
35.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
36.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
37.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (M/T TRANSAXLE) (See page 42±2)
38.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
39. CHECK BRAKE FLUID LEAKAGE
40. CHECK CLUTCH FLUID LEAKAGE (M/T TRANSAXLE)

320W5±01
G24285
LHD Steering Position Type:
Charcoal Canister Assy
Brake Fluid Level
Switch Connector
Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type:Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch ConnectorBrake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1

w/ ABS:*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in.
lbf)
Fuel Filter Assy Diesel Engin Type:
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS

320W6±01
G24218
G24217
F45393
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±13
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 ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY
(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle:
Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way.
SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master
cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.

G24225
F45394
F45395Lithium soap base glycol grease
Grommets
Retainer
Washer
32±14
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE BRAKE MASTER CYLINDER SUB±ASSY
(RHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle:
Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Remove the 2 nuts and pull out the accelerator control
cable support and brake master cylinder sub±assy.
(f) Remove the O±ring from the brake master cylinder sub±
assy.
8. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB±ASSY
(a) Using a screwdriver, remove the screw from the brake master cylinder.
(b) Remove the brake master cylinder reservoir sub±assy and 2 brake master cylinder reservoir grommets
from the brake master cylinder.
(c) Remove the cap and strainer from the master cylinder reservoir.
9. INSTALL BRAKE MASTER CYLINDER RESERVOIR
SUB±ASSY
(a) Apply lithium soap base grycol grease to the 2 brake mas-
ter cylinder reservoir grommets.
(b) Install the retainer washer to the brake master cylinder.
(c) Install the 2 brake master cylinder reservoir grommets to
the brake master cylinder.
(d) Using a screwdriver, install the brake master cylinder re-
sevoir sub±assy with the screw.

F45393
G24217
G24218
F45394
± BRAKEBRAKE MASTER CYLINDER SUB±ASSY
32±15
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL BRAKE MASTER CYLINDER SUB±ASSY
(LHD STEERING POSITION TYPE)
(a) Install the new O±ring from the brake master cylinder
sub±assy.
(b) Install the brake master cylinder sub±assy and way
bracket with the 2 nuts.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)
(c) Using SST, connect the 2 brake lines to the way.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(d) 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)
(e) 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)
(f) M/T transaxle:
Slide the clip and connect the clutch reservoir tube.
(g) Connect the brake fluid level switch connector.
11. INSTALL BRAKE MASTER CYLINDER SUB±ASSY
(RHD STEERING POSITION TYPE)
(a) Install the new O±ring from the brake master cylinder
sub±assy.
(b) Install the brake master cylinder sub±assy and accelera-
tor control cable support with the 2 nuts.
Torque: 20 N
m (204 kgf
cm, 15 ft
lbf)

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