TOYOTA AVENSIS 2003 Service Repair Manual

\b
F44709
F42661
C80704
F44822
SST
\bF44705
SST
33±16
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
11. APPLY HIGH TEMPERATURE GREASE
(a) Apply the high temperature grease to the shoe attached surface of backing plate.
12. INSTALL PARKING BRAKE SHOE LEVER LH
(a) Using needle±nose pliers, connect the parking brake cable assy No.3 to the parking brake shoe lever LH.
13. INSTALL PARKING BRAKE SHOE KIT
(a) Apply the high temperature grease to the contact part of the parking brake shoe and parking brake shoe lever.
(b) Using SST, install the parking brake shoe LH No.2 with the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010
(c) Using SST, install the parking brake shoe LH No.1 with the parking brake shoe hold±down compression spring
and parking brake shoe hold±down spring pin.
SST 09718±00010
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C80705

G22380
C80706
G22379
±
PARKING BRAKE PARKING BRAKE ASSY
33±17
AVENSIS REPAIR MANUAL (RM1018E)
14. INSTALL PARKING BRAKE SHOE ADJUSTING
SCREW SET
(a) Apply the high temperature grease to the adjusting bolt
and support piece.
(b) Install the parking brake shoe adjusting screw set LH.
(c) Using needle±nose pliers, install the tension spring.
15. INSTALL PARKING BRAKE ADJUSTER KIT
(a) Apply the high temperature grease to the contact part of the shoe strut and tension spring.
(b) Install the parking brake shoe strut LH.
(c) Using needle±nose pliers, install the upper side 2 tension springs.
HINT:
Install the 2 tension spring securely to the grooves of the shoe
strut.
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F44823
RH
LH
Front Front
F44708
Expand
Contract
33±18
±
PARKING BRAKE PARKING BRAKE ASSY
AVENSIS REPAIR MANUAL (RM1018E)
16. CHECK PARKING BRAKE INSTALLATION
(a) Check that each part is installed properly.
NOTICE:
There should be no oil or grease on the friction surface of the shoe lin\
ing and disc.
17. INSTALL REAR DISC 18. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug, and turn the adjuster and expandthe shoes until the disc locks.
(c) Contract the shoe adjuster until the disc can rotate smoothly.
Standard : Return 8 notches
(d) Check that there is no brake drag.
(e) Install the hole plug.
19. CONNECT REAR DISC BRAKE CALIPER ASSY LH
(a) Install the rear disc brake caliper with the 2 bolts. Torque: 47 N
m (475 kgf
cm, 34 ft
lbf)
20. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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±
PARKING BRAKE PARKING BRAKE ASSY
33±19
AVENSIS REPAIR MANUAL (RM1018E)
21. SETTLING PARKING BRAKE SHOES AND DISC
(a) Drive the vehicle at about 50km/h (31 mph) on a safe,level and dry roa\
d.
(b) With the parking brake release button pushed in, pull on the lever with 98 N\
(10kgf, 19.8 lbf) of force.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this condition.
(d) Repeat this procedure 2 or 3 times.
22.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
23.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
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3306A±03
F44814
Parking Brake Lever Sub±assy
Parking Brake Switch Connector Lock Nut
5.0 (51, 44 in.

lbf)
Adjusting Nut
Parking Brake Cable Assy No.1 Equalizer
Front Floor Heat
Insulator No.1 Front Floor Heat
Insulator No.2
Exhaust Pipe Assy Front Exhaust Pipe Support
Exhaust Pipe Support
N
m (kgf
cm, ft
lbf)
: Specified torque Front Floor Panel Brace
Gasoline Engine Type: Gasoline Engine Type:
5.5 (56, 49 in.

lbf)
5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
13 (127, 9)
43 (440, 32)
A/T Transaxle type:
Console Panel Sub±Assy Upper
M/T Transaxle type:
Console Panel Sub±Assy Upper Floor Shift Shift
Lever Knob
Sub±Assy
Console Box Assy RR
Console Panel Sub±Assy Lower
43 (440, 32)
A/T Transaxle
M/T Transaxle
M/T Transaxle
43 (440, 32)30 (302, 21)
33±6
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE CABLE ASSY NO.1
COMPONENTS
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3306B±03
F44815
F44816
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
33±7
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE SHIFT LEVER KNOB SUB±ASSY (M/T TRANSAXLE)
(See page 41±11)
2.REMOVE CONSOLE PANEL SUB±ASSY UPPER (See page 71±11)
3.REMOVE CONSOLE PANEL SUB±ASSY LOWER (See page 71±11)
4.REMOVE CONSOLE BOX ASSY RR (See page 71±11)
5.REMOVE PARKING BRAKE LEVER SUB±ASSY (See page 33±4)
6. REMOVE EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
7. REMOVE FRONT FLOOR HEAT INSULATOR NO.1(GASOLINE ENGINE TYPE)
(a) Remove the 3 nuts and front floor insulator No.1.
8. REMOVE FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE)
(a) Remove the 2 nuts and front floor insulator No.2.
9. REMOVE PARKING BRAKE CABLE ASSY NO.1
(a) Disconnect the parking brake cable assy No.1 from the equalizer and remove the parking brake cable assy No.1.
10. INSTALL PARKING BRAKE CABLE ASSY NO.1
(a) Connect the parking brake cable assy No.1 to the equalizer and install the park\
ing brake cable assy No.1.
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F44816
F44815
33±8
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.1
AVENSIS REPAIR MANUAL (RM1018E)
11. INSTALL FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE)
(a) Install the front floor insulator No.2 with the 2 nuts.
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
12. .INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(a) Install the front floor insulator No.1 with the 3 nuts. Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
13. INSTALL EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
14.INSTALL PARKING BRAKE LEVER SUB±ASSY (See page 33±4)
15.INSPECT PARKING BRAKE LEVER TRAVEL (See page 33±2)
16.ADJUST PARKING BRAKE LEVER TRAVEL (See page 33±2)
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3306C±05
F44817
Parking Brake Cable Assy No.2Parking Brake Cable Assy No.3
Equalizer
Front Floor Heat
Insulator No.1 Front Floor Heat Insulator No.2 Fuel Tank Protector No.1
Exhaust Pipe Support Cable
Retainer
N

m (kgf
cm, ft
lbf) : Specified torque Front Floor Panel Brace
Gasoline Engine Type:
Gasoline Engine Type:
5.5 (56, 49 in.

lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
43 (440, 32)
5.5 (56, 49 in.
lbf)
Parking Brake Cable No.2 Clamp
Parking Brake Cable
No.2 Clamp
5.0 (51, 44 in.
lbf)
43 (440, 32)30 (302, 21)
Exhaust Pipe Assy Front
Exhaust Pipe Support
43 (440, 32)
5.5 (56, 49 in.
lbf)
5.5 (56, 49 in.
lbf)
5.0 (51, 44 in.
lbf)
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
33±9
AVENSIS REPAIR MANUAL (RM1018E)
PARKING BRAKE CABLE ASSY NO.3
COMPONENTS
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330C7±01
F44818
33±10
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
HINT:
For parking brake cable assy No.2, perform the same procedure to the RH sid\
e.
1. REMOVE REAR WHEEL
2.DISCONNECT REAR DISC BRAKE CALIPER ASSY LH (See page 30±31)
3.REMOVE REAR DISC(See page 33±14)
4.REMOVE PARKING BRAKE ADJUSTER KIT (See page 33±14)
5.REMOVE PARKING BRAKE SHOE ADJUSTING SCREW SET(See page 33±14)
6.REMOVE PARKING BRAKE SHOE KIT (See page 33±14) SST 09718±00010
7. DISCONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Using needle±nose pliers, and disconnect the parkingbrake cable assy No.3 from the backing plate.
8. REMOVE EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
9. REMOVE FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE)
(See page 33±7)
10. REMOVE FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE) (See page 33±7)
11. REMOVE PARKING BRAKE CABLE ASSY NO.3
(a) Remove the 3 nuts and fuel tank protector No.1 (When re-placing parking brake cable assy No.2).
(b) Remove the 4 bolts and cable retainer from the body.
(c) Disconnect the parking brake cable assy No.3 from the equalizer, and remove the parking brake cable assy No.3.
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F44819
F44820
±
PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3
33±11
AVENSIS REPAIR MANUAL (RM1018E)
12. INSTALL PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the equaliz-
er.
(b) Install the parking brake cable assy No.3 with the 4 bolts. Torque: 5.0 N
m (55 kgf
cm, 48 in.
lbf)
(c) Install the fuel tank protector No.1 and 3 nuts (When re- placing parking brake cable assy No.2).
Torque: 5.5 N
m (56 kgf
cm, 49 in.
lbf)
13. INSTALL FRONT FLOOR HEAT INSULATOR NO.2 (GASOLINE ENGINE TYPE) (See page 33±7)
14. INSTALL FRONT FLOOR HEAT INSULATOR NO.1 (GASOLINE ENGINE TYPE) (See page 33±7)
15. INSTALL EXHAUST PIPE ASSY FRONT 1ZZ±FE/3ZZ±FE ENGINE TYPE: See page 15±2
1AZ±FE/1AZ±FSE ENGINE TYPE: See page 15±7
16. CONNECT PARKING BRAKE CABLE ASSY NO.3
(a) Connect the parking brake cable assy No.3 to the backingplate.
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