wheel torque TOYOTA AVENSIS 2002 Repair Manual

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)

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

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
C80806
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±31
AVENSIS REPAIR MANUAL (RM1018E)
(e) w/o VSC:
Using SST, connect the 6 brake tubes to the brake actua-
tor, as shown in the illustration.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(f) w/ VSC: Using SST, connect the 6 brake tubes to the brake actua-
tor as shown in the illustration.
SST 09023±00100, 09023±38400
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
B: 29 N
m (296 kgf
cm, 21 ft
lbf)
(g) Install the brake tube clamps with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
20. INSTALL FRONT WHEEL RH
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
22.INSTALL IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
23.INSTALL INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
24.INSTALL CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
25.INSTALL TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)

F42258
G24222
± BRAKEBRAKE FLUID
32±5
AVENSIS REPAIR MANUAL (RM1018E)
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal depressed.
(c) At the point when the fluid stops, coming out tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.
Torque: 10 N
m (102 kgf
cm, 7 ft.
lbf)
4. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary.
Fluid: SAE J1704 or FMVSS No. 116 DOT4

F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

32±52
± BRAKEREAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
33. CHECK BRAKE FLUID LEAKAGE
34. INSTALL REAR WHEEL
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)

G23168
F08658
SST
G23167
32±62
±
BRAKE SKID CONTROL SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
7. INSTALL SKID CONTROL SENSOR
(a) Clean the contacting surface of the axle hub and that of a new skid control sensor.
NOTICE:
Make sure the sensor rotor is clean.
(b) Place the skid control sensor on the axle hub so that the connector comes into the most downward position under
the on vehicle condition.
(c) Using SST and a press, install the skid control sensor to the axle hub.
NOTICE:

Do not tap the skid control sensor directly with a ham-
mer.

Check that there is no foreign matter on the skid con-
trol sensor detection portion.

Press in the skid control sensor straight and slowly.
SST 09830±36010, 09950±60010 (09951±00650), 09950±70010 (09951±07100)
8.INSTALL REAR AXLE HUB & BEARING ASSY LH (See page 30±31)
9. INSTALL REAR BRAKE DRUM SUB±ASSY
(a) Aligning the matchmarks, install the rear disc.
10. INSTALL REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper assy LH with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
11. CONNECT SKID CONTROL SENSOR WIRE
(a) Connect the connector from the skid control sensor.
12. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
13.INSPECT AND ADJUST REAR WHEEL ALIGNMENT (See page 27±4)
14.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)

3201P±05
G23166
F40024
G23165
G23165
± BRAKESPEED SENSOR FRONT LH
32±59
AVENSIS REPAIR MANUAL (RM1018E)
SPEED SENSOR FRONT LH
REPLACEMENT
HINT:
Replace the RH side by using the same procedures as those for the LH side.
1. REMOVE FRONT WHEEL
2. REMOVE FRONT FENDER LINER LH
3. REMOVE SPEED SENSOR FRONT LH
(a) Disconnect the resin clip and speed sensor wire harness
from the body and clamp.
(b) Disconnect the speed sensor connector.
(c) Remove the 2 clamp bolts holding the sensor harness
from the body and shock absorber.
(d) Remove the bolt and separate the speed sensor front LH.
NOTICE:
Prevent foeingn matter from attaching to the sensor tip.
4. INSTALL SPEED SENSOR FRONT LH
(a) Install the speed sensor front LH with the bolt.
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
NOTICE:
Prevent foeingn matter from attaching to the sensor tip.

F40024
A
B
G23166
32±60
±
BRAKE SPEED SENSOR FRONT LH
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the sensor harness clamp with the 2 bolts ºAº and ºBº to the body and shock absorber.
Torque:
Bolt A: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
Bolt B: 29 N
m (296 kgf
cm, 21 ft
lbf)
NOTICE:
Do not twist the sensor wire when installing the sensor.
(c)Connect the speed sensor connector.
(d)Connect the resin clip and speed sensor wire harness to the body and clamp.
5.INSTALL FRONT FENDER LINER LH
6.INSTALL FRONT WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
7.CHECK ABS SPEED SENSOR SIGNAL (See page 05±699)

4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:
Flywheel Sub±assyClutch Disc Assy
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline greasex6
Clutch Release
Bearing Assy
Release Bearing
Hub ClipClutch Release
Fork Sub±assy
Clutch Cover Assy
Clutch Release Fork Boot Release Fork Support
37 (375, 27)
19 (194, 14)
± CLUTCHCLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS