boot TOYOTA AVENSIS 2003 Service User Guide

320GE±03
G23180

Gasket
Flexible Hose
30 (306, 22)
Disc Brake Cylinder
Assy Rear LH
Disc Brake
Pad Kit Rear


Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Lithium soap base glycol grease
Rear Disc Brake
Bush Dust Boot
Rear Disc Brake
Pad Support Plate No.1
Rear Disc Brake
Cylinder Mounting LH
RearDisc
Brake Piston
Cylinder Boot


Piston Seal
Rear Disc Brake
Cylinder Slide Pin (No.2)
Bleeder Plug Cap
Rear Disc Brake
Bleeder Plug
Rear Disc Brake
Cylinder Slide Bush
Rear Disc Brake
Cylinder Slide Pin (No.1)
Rear Disc Brake
Bush Dust Boot
Rear Disc
Parking Brake Shoe
Adjusting Hole Plug
47 (475, 34)
30 (306, 22)
47 (475, 34)
29 (296, 21)
10 (102, 7)
Rear Disc Brake
Pad Support Plate No.2
Union Bolt






Bolt


Bolt
32±46
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
REAR DISC BRAKE
COMPONENTS
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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
F45704
F42270
G23222
G23223
32±48
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH.
7. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Remove the 2 bolts and rear disc brake cylinder mounting LH.
8. REMOVE REAR DISC BRAKE PISTON
(a) Place a shop rug between the rear disc brake piston and the disc brake cylinder assy rear LH.
(b) Use compressed air to remove the rear disc brake piston from the disc brake cylinder assy rear LH.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
NOTICE:
Do not spatter the brake fluid.
9. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the cylinder boot.
10. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal.
NOTICE:
Do not damage the inner cylinder and cylinder groove.
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F45708
F45750Lithium soap base glycol grease
Cylinder Boot
Piston
G23231Cylinder Boot
Piston
F45704
32±50
±
BRAKEREAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
19.INSPECT DISC RUNOUT
(a)Temporarily fasten the rear disc with the hub nuts. Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b)Using a dial indicator, measure the disc runout 10 mm (0.39 in.) away from the outer edge of the rear disc.
Maximum disc runout: 0.15 mm (0.0059 in.)
(c)If the disc runout is maximum value or greater, check the
bearing play in the axial direction and check for the axle
hub runout (See page 30±2). If the bearing play and axle
hub runout are normal, adjust the disc runout or grind it
on a ºOn±carº brake lathe.
20. TEMPORARILY TIGHTEN REAR DISC BRAKE BLEEDER PLUG
(a) Temporarily install the rear disc brake bleeder plug to the disc brake cy\
linder assy rear LH.
21. INSTALL PISTON SEAL
(a) Apply the lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy rear LH. 22. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear discbrake piston and a new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
23. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the disc brake cylinder assy rear LH.
SST 09710±06051
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder rear LH.
24. INSTALL REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Install the rear disc brake cylinder mounting LH with the
2 bolts.
Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
F45701
Cylinder Slide Pin
Lithium soap base glycol grease
G23181
Union bolt
±
BRAKEREAR BRAKE
32±51
AVENSIS REPAIR MANUAL (RM1018E)
25.INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a)Apply lithium soap base glycol grease to the sealing sur-
face of 2 new bush dust boots.
(b)Install the 2 bush dust boots to the rear disc brake cylinder mounting LH.
26.INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a)Apply lithium soap base glycol grease to sealing surface of a new cylinder slide bush.
(b)Install the rear disc brake cylinder slide bush to the bottom side of the rear 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 rear disc brake cylinder
slide pins.
(d)Install the rear disc brake cylinder slide pin (No.1) and rear
disc brake cylinder slide pin (No.2) to the rear disc brake
cylinder mounting LH.
27.INSTALL REAR DISC BRAKE PAD KIT
(a)Install the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad\
support plate No.2 to the rear disc brake cylinder mounting LH.
(b)Install the disc brake pad kit rear to the disc brake cylinder mounting \
LH.
28.INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a)Install the disc brake cylinder assy rear 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 to the lock hole in the
disc brake cylinder assy rear LH.
29.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
30.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
31.BLEED BRAKE LINE (See page 32±4)
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
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4202X±03
D30055Lithium soap glycol grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
1CD±FTV Engine Type:
Bleeder PlugRelease Cylinder Body
Piston
Push Rod Boot
Bleeder Plug
Cap
8.4 (85, 74 in.

lbf)
Wire Harness Clamp Clutch Accumulator Assy
Spring
1AZ±FSE/1AZ±FE Engine Type:
15 (155, 11)
12 (120, 9)


12 (120, 9)
Release Cylinder Body
12 (120, 9)
Release Cylinder Body
Clutch Line Clamp
Clutch Line Bracket
15 (155, 11)
12 (122, 9)
5.0 (51, 44 in.

lbf)1ZZ±FE/3ZZ±FE Engine Type:
15 (155, 11)Clutch Line Clamp
14 (141, 10)
15 (155, 11)
12 (120, 9)
42±16
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH RELEASE CYLINDER ASSY (MTM)
COMPONENTS
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D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:
D26804
42±18
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE CLUTCH RELEASE CYLINDER ASSY (EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type:
Remove the 3 bolts, clutch release cylinder assy, and
clutch line bracket.
(b) 1AZ±FE/1AZ±FSE Engine Type: Remove the 3 bolts and clutch release cylinder assy.
6. REMOVE CLUTCH RELEASE CYLINDER ASSY (1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, remove the 2 bolts and clutch release cylinder assy.
7. REMOVE CLUTCH RELEASE CYLINDER KIT
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
(c) Remove the piston from the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder plug cap from the bleeder plug.
8. REMOVE RELEASE CYLINDER BLEEDER PLUG
9. INSTALL RELEASE CYLINDER BLEEDER PLUG Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
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CL0672
D26804
D30488
1ZZ±FE/3ZZ±FE Engine Type:
1AZ±FE/1AZ±FSE Engine Type:(1)
(1)
(1) (1)
(2)
(2)
±
CLUTCH CLUTCH RELEASE CYLINDER ASSY (MTM)
42±19
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTALL CLUTCH RELEASE CYLINDER KIT
(a) Install the bleeder plug cap to the bleeder plug.
(b) Install a new spring to the cylinder body.
(c) Coat the parts with lithium soap base glycol grease, as
shown in the illustration.
(d) Install the piston to the cylinder body.
NOTICE:
Be careful not to damage the inside of the cylinder body.
(e) Install the push rod to the cylinder body.
(f) Install the boot to the cylinder body.
11. INSTALL CLUTCH RELEASE CYLINDER ASSY (1CD±FTV ENGINE TYPE)
(a) Using a 12 mm deep socket wrench, install the clutch re- lease cylinder assy with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
12. INSTALL CLUTCH RELEASE CYLINDER ASSY (EXCEPT 1CD±FTV ENGINE TYPE)
(a) 1ZZ±FE/3ZZ±FE Engine Type: (1) Install the clutch release cylinder and clutch line
bracket with the 2 bolts.
Torque: 14 N
m (141 kgf
cm, 10 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
(b) 1AZ±FE/1AZ±FSE Engine Type:
(1) Install the clutch release cylinder with the 2 bolts.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(2) Install the flexible hose tube with the bolt.
Torque: 12 N
m (122 kgf
cm, 9 ft
lbf)
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4206H±01
D26321
1ZZ±FE/3ZZ±FE Engine Type:Flywheel Sub±assy Clutch Disc Assy
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease x6
Clutch Release
Bearing Assy Release Bearing
Hub Clip Clutch Release
Fork Sub±assy
Clutch Cover Assy Clutch Release Fork Boot
Release Fork Support
37 (375, 27)
19 (194, 14)
±
CLUTCH CLUTCH UNIT (MTM)
42±23
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH UNIT (MTM)
COMPONENTS
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D30056Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease
1AZ±FSE/1AZ±FE Engine Type:
Flywheel Sub±assy
Clutch Disc Assy Clutch Release
Fork Sub±assy
Clutch Cover Assy Release Bearing
Hub Clip
Clutch Release
Bearing Assy
Release Fork Support Clutch Release
Fork Boot
48 (480, 35)
19 (194, 14)
x6
42±24
±
CLUTCH CLUTCH UNIT (MTM)
AVENSIS REPAIR MANUAL (RM1018E)
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D30057
1CD±FTV Engine Type:
Flywheel Sub±assy Clutch Disc Assy
Clutch Release Fork Sub±assy
Clutch Cover Assy
Release Bearing
Hub Clip
Clutch Release
Bearing Assy
Release Fork Support Clutch Release
Fork Boot
37 (375, 27)
19 (194, 14)
x6
Release hub grease
N
m (kgf
cm, ft
lbf) : Specified torque

Non±reusable part
Clutch spline grease
±
CLUTCH CLUTCH UNIT (MTM)
42±25
AVENSIS REPAIR MANUAL (RM1018E)
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