drain 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.

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.

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

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.

320W1±01
F45421
Union Bolt
G23232
F45419
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
± BRAKEFRONT BRAKE
32±41
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface.
3. REMOVE DISC BRAKE CYLINDER ASSY LH
(a) Remove the union bolt and gasket from the disc brake cyl-
inder assy LH, then disconnect the flexible hose.
(b) Hold the front disc brake cylinder slide pin and remove the
2 bolts.
4. REMOVE FRONT DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit front from the front disc
brake cylinder mounting LH.
(b) Remove the 2 front disc brake pad support plates No.2
and 2 front disc brake pad support plates No.1.
5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Remove the front disc brake cylinder slide pin (No.1) and
front disc brake cylinder slide pin (No.2) from the front disc
brake cylinder mounting LH.
(b) Remove the front disc brake cylinder slide bush from the
bottom side of the front disk brake cylinder slide pin
(No.2).

320W0±01
G23181
Union bolt
G23224
F45701
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
± BRAKEREAR BRAKE
32±47
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface.
3. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Remove the union bolt and gasket from the brake cylinder
assy rear LH, then disconnect the flexible hose from the
disc brake cylinder assy rear LH.
(b) Hold the rear disc brake cylinder slide pin and remove the
2 bolts.
4. REMOVE REAR DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit rear.
(b) Remove the 2 rear disc brake pad support plates No.1
and 2 rear disc brake pad support plates No.2 from the
rear disc brake cylinder mounting LH.
5. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Remove the rear disc brake cylinder slide pin (No.1) and
rear disc brake cylinder slide pin (No.2) from the disc
brake cylinder mounting LH.
(b) Remove the rear disc brake cylinder slide bush from the
bottom side of the rear disc brake cylinder slide pin (No.2).

4206E±01
D30068
D30069
SST(s)
D30782
RHD Steering Position Type:
LHD Steering Position Type:
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN CLUTCH FLUID
2. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE)
(See page 32±13)
3.REMOVE BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
4. DISCONNECT CLUTCH RESERVOIR TUBE
(a) Loosen the clip and disconnect the clutch reservoir tubefrom the clutch master cylinder assy.
HINT:
Use a container to catch the fluid.
5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.

160MK±01
A76724
A79300Upper Hook
±
COOLING RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
16±11
AVENSIS REPAIR MANUAL (RM1018E)
RADIATOR ASSY(1ZZ±FE/3ZZ±FE)
REPLACEMENT
1.REMOVE RADIATOR SUPPORT OPENING COVER (See page 14±27)
2.REMOVE ENGINE ROOM COVER SIDE (See page 14±27)
3.ENGINE UNDER COVER SUB±ASSY NO.1 (See page 14±27)
4.DRAIN ENGINE COOLANT (See page 16±1)
5. DISCONNECT RADIATOR HOSE INLET
(a) Disconnect the radiator hose inlet from the radiator.
6. DISCONNECT RADIATOR HOSE OUTLET
(a) Disconnect the radiator hose outlet from the radiator.
7. DISCONNECT OIL COOLER INLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler inlet tube from the radiator.
8. DISCONNECT OIL COOLER OUTLET TUBE NO.1 (A/T TRANSAXLE)
(a) Disconnect the oil cooler outlet tube from the radiator.
9. REMOVE RADIATOR ASSY
(a) Disconnect the fan connector and the 2 harness clamps.
(b) Remove the 2 bolts and the relay block.
(c) Remove the 2 bolts, the 2 radiator support upper and theradiator.
(d) Remove the 2 support radiator LWRs from the radiator.
(e) Pinch and push each upper hook on the fan shroud to re- lease and remove the fan shroud from the radiator.

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±16
± COOLINGCOOLING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
93 to 122 kPa (0.95 to 1.25 kgf/cm
2, 13.4 to 17.6 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm
2, 11.2 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.

Radiator CapRadiator Cap Tester
30
or more
A51912
A36661
Turn 16±28
± COOLINGCOOLING SYSTEM (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push / 3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
NOTICE:
The following pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Pump speed: 1 push within 1 second
Standard opening pressure:
74 to 103 kPa (0.75 to 1.05 kgf/cm
2, 10.7 to 14.9 psi)
Minimum opening pressure:
59 kPa (0.6 kgf/cm
2, 8.6 psi)
If the opening pressure is less than minimum, replace the radia-
tor cap.
HINT:
Use the tester's maximum reading as the opening pressure.
3. INSPECT WATER PUMP ASSY
(a) Visually check the drain hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and does not make noise.
If necessary, replace the water pump.