TOYOTA AVENSIS 2003 Service Repair Manual

F05383
Air
Hose Side Vacuum Pump Side
Air
F08981
F08982
New O±Ring
F08970
±
BRAKE VACUUM PUMP ASSY (1CD±FTV)
32±37
AVENSIS REPAIR MANUAL (RM1018E)
10. INSPECT CHECK VALVE SUB±ASSY
(a) Check that air flows from the hose side to the pump side.
(b) Check that air does not flow from the pump side to the
hose side.
NOTICE:
Block off the 4 holes on the side surface of the check valve
when checking.
If necessary, replace the check valve.
11. INSTALL VACUUM PUMP COUPLING
(a) Place the vacuum pump coupling to the rotor shaft.
(b) Install a new snap ring to the rotor shaft.
12. INSTALL VACUUM PUMP ROTOR SUB±ASSY
(a) Coat the rotor with engine oil, and install it to the rotor shaft. 13. INSTALL VACUUM PUMP BLADE A
(a) Apply the engine oil to the rotor, and install the rotor in the
housing.
(b) Apply the engine oil to the 5 new blades.
(c) Install the 5 blades with the round end facing outward.
NOTICE:
Install so that the blade attaches on the housing.
(d) Coat 2 new O±rings with engine oil, and install them on the housing.
(e) Using soft jaws on the vise, place the vacuum pump on the vise, as shown in the illustration.
NOTICE:
Only place the vacuum pump assy, never hold the in±low
of the housing with a vise.
(f) Place the end cover, and temporarily install the 3 bolts.
(g) Using a pin punch and hammer, drive in the 2 straight pins.
NOTICE:
Install so that the blade and end cover of the eccentric ring
does not interfere with each other.
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F08969
F08984
New Gasket
F08985
New Gasket
New Gasket
F45364
32±38
±
BRAKE VACUUM PUMP ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
(h) Using soft jaws on the vise, hold the vacuum pump in the vise.
NOTICE:
Do not tighten the vise to tightly.
(i) Tighten the 3 bolts.
Torque: 7.8 N
m (80 kgf
cm, 69 in.
lbf)
14. INSTALL CHECK VALVE SUB±ASSY
(a) Install the check valve sub±assy and a new gasket. Torque: 74 N
m (750 kgf
cm, 54 ft
lbf)
15. INSTALL VACUUM PUMP UNION
(a) Install the vacuum pump union and 2 new gaskets with the union bolt.
Torque: 14 N
m (140 kgf
cm, 10 ft
lbf)
HINT:
Align and insert the pin of the union into the matching hole of
the casing.
16. INSPECT VACUUM PUMP ASSY
(a) Turn the gear counterclockwise direction by hand when
seeing from the vacuum pump gear direction and check
for any abnormality such as dragging or torque fluctua-
tion.
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G24250
Vacuum HoseNew O±Ring
Oil Hose
F45366
Vacuum Gauge
±
BRAKE VACUUM PUMP ASSY (1CD±FTV)
32±39
AVENSIS REPAIR MANUAL (RM1018E)
17. INSTALL VACUUM PUMP ASSY
(a) Coat 2 new O±rings with engine oil, and install them to the
vacuum pump assy.
(b) Install the vacuum pump assy aligning the coupling with the slit of the camshaft.
(c) Install the 2 bolts. Torque: 21 N
m (214 kgf
cm, 15 ft
lbf)
(d) Connect 2 vacuum hoses and oil hose.
18. INSPECT CHECK VACUUM PUMP OPERATION
(a) Slide the clip, then disconnect the vacuum hose from vac- uum pump assy.
(b) Connect the hose of the vacuum gauge to the vacuum pump assy.
(c) Block off another hose of the vacuum gauge with the hose clamp No.2.
(d) Start the engine and warm it up for more than 2 minutes.
(e) With the engine idle, check the negative pressure of the vacuum pump assy.
Standard: More than 650 mmHg (86.7 kPa).
(f) Remove the vacuum gauge from the vacuum pump assy.
(g) Connect the vacuum hose with the clip to the vacuum pump assy.
19. INSTALL AIR CLEANER CAP SUB±ASSY
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320GM±02
G23169
G23170
G23171
G23170
±
BRAKE YAWRATE SENSOR
32±63
AVENSIS REPAIR MANUAL (RM1018E)
YAWRATE SENSOR
REPLACEMENT
NOTICE:

Don't use the dropped or damaged yawrate sensor.

Free from the foreing matters between yawrate sensor braket and body.

Make sure the sensor direction.
1.REMOVE FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
2. REMOVE YAWRATE SENSOR BRACKET
(a) Remove the bolt and upper part of the yawrate sensorbracket.
3. REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector from the yaw- rate sensor.
(b) Remove the 2 bolts and the yawrate sensor with the yaw- rate sensor bracket from the body.
(c) Remove the 2 nuts and yawrate sensor from the yawrate sensor bracket.
4. INSTALL YAWRATE SENSOR
(a) Install the 2 nuts and yawrate sensor to the yawrate sen- sor bracket.
Torque: 6 N
m (61 ft
lbf, 53 in.
lbf)
(b) Install the 2 bolts and the yawrate sensor with the yawrate sensor bracket to the body.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
(c) Connect the yawrate sensor connector to the yawrate sensor.
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G23169
32±64
±
BRAKE YAWRATE SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL YAWRATE SENSOR BRACKET
(a) Install the bolt and upper part og the yawrate sensor bracket.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
6.INSTALL FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
7.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05±756)
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320GM±02
G23169
G23170
G23171
G23170
±
BRAKE YAWRATE SENSOR
32±63
AVENSIS REPAIR MANUAL (RM1018E)
YAWRATE SENSOR
REPLACEMENT
NOTICE:

Don't use the dropped or damaged yawrate sensor.

Free from the foreing matters between yawrate sensor braket and body.

Make sure the sensor direction.
1.REMOVE FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
2. REMOVE YAWRATE SENSOR BRACKET
(a) Remove the bolt and upper part of the yawrate sensorbracket.
3. REMOVE YAWRATE SENSOR
(a) Disconnect the yawrate sensor connector from the yaw- rate sensor.
(b) Remove the 2 bolts and the yawrate sensor with the yaw- rate sensor bracket from the body.
(c) Remove the 2 nuts and yawrate sensor from the yawrate sensor bracket.
4. INSTALL YAWRATE SENSOR
(a) Install the 2 nuts and yawrate sensor to the yawrate sen- sor bracket.
Torque: 6 N
m (61 ft
lbf, 53 in.
lbf)
(b) Install the 2 bolts and the yawrate sensor with the yawrate sensor bracket to the body.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
(c) Connect the yawrate sensor connector to the yawrate sensor.
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G23169
32±64
±
BRAKE YAWRATE SENSOR
AVENSIS REPAIR MANUAL (RM1018E)
5. INSTALL YAWRATE SENSOR BRACKET
(a) Install the bolt and upper part og the yawrate sensor bracket.
Torque: 21 N
m (214 ft
lbf, 15 ft
lbf)
6.INSTALL FRONT SEAT ASSEMBLY LH (See page 72±11 or 72±16)
7.PERFORM YAWRATE SENSOR ZERO POINT CALIBRATION (See page 05±756)
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3306E±05
Parking Brake
Shoe Hold±Down
Compression Spring
Parking Brake Shoe
Adjusting Screw SetParking Brake
Shoe Strut LH
F44821
Parking Brake
Shoe Lever LHParking Brake
Shoe Assy LH No.2
Parking Brake
Shoe Assy LH No.1
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Spring Pin
Parking Brake Shoe
Hold±Down Compression Spring
Tension Spring
Tension Spring
Tension Spring
Rear Disc
Rear Disc Brake
Caliper Assy LH
47(475, 34)
N
m (kgf
cm, ft
lbf) : Specified torque
High temperature grease
±
PARKING BRAKE PARKING BRAKE ASSY
33±13
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE ASSY
COMPONENTS
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330C8±01
F45710
Contract
F06409
G22379

G22380
33±14
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by the same procedures as those of the LH side.
1. REMOVE REAR WHEEL
2.DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (See page 30±31) 3. REMOVE REAR DISC
(a) Release the parking brake, and remove the rear disc.
HINT:

Put matchmarks on the disc and the axle hub.

If the disc cannot be removed easily, turn the shoe adjust-
er until the wheel turns freely.
4. INSPECT BRAKE DISC INSIDE DIAMETER
(a) Using a brake drum gauge or equivalent, measure the in- side diameter of the disc.
Standard inside diameter: 173 mm (6.81 in.)
Maximum inside diameter: 174 mm (6.85 in.)
5. REMOVE PARKING BRAKE ADJUSTER KIT
(a) Using needle±nose pliers, remove the shoe upper side 2 tension springs.
(b) Remove the parking brake shoe strut LH.
6. REMOVE PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Using needle±nose pliers, remove the anchor side ten- sion spring.
(b) Remove the shoe adjusting screw set.
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F45077
SST
F44822
SST
R00311
BR0828
F42661
±
PARKING BRAKE PARKING BRAKE ASSY
33±15
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE PARKING BRAKE SHOE KIT
(a) Using SST, remove the parking brake shoe hold±down
compression spring, parking brake shoe hold±down
spring pin and parking brake shoe assy LH No.1.
SST 09718±00010
(b) Using SST, remove the parking brake shoe hold±down compression spring and parking brake shoe hold±down
spring pin.
SST 09718±00010
(c) Disconnect the parking brake shoe assy LH No.2 from the parking brake shoe lever LH, and remove the parking
brake shoe LH No.2.
8. INSPECT PARKING B RAKE SHOE LINING
THICKNESS
(a) Using a ruler, measure the thickness of the shoe lining. Standard thickness: 3.5 mm (0.138 in.)
Minimum thickness: 1.0 mm (0.039 in.)
9. INSPECT BRAKE DISC AND PARKING BRAKE SHOE LINING FOR PROPER CONTACT
(a) Apply chalk to the inside surface of the disc, then grind down the brake shoe lining to fit.
If the contact between the brake disc and the shoe lining is im-
proper, repair it using a brake shoe grinder or replace the brake
shoe assembly.
10. REMOVE PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, disconnect the parking brake cable assy No.3 and remove the parking brake shoe lever
LH.
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