brake fluid TOYOTA AVENSIS 2003 Service Repair Manual

010B9±11
±
INTRODUCTION TERMS
01±37
AVENSIS REPAIR MANUAL (RM1018E)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
Approx.Approximately
ASSYAssembly
A/T, ATMAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CANController Area Network
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
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022KS±01
±
PREPARATION BRAKE
02±33
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
BRAKE ACTUATOR ASSY(W/O VSC)
09023±38400Union Nut Wrench 14mmBRAKE FLUID
BRAKE MASTER CYLINDER
SUB±ASSY
FRONT BRAKE
REAR BRAKE
BRAKE BOOSTER ASSY(LHD)
BRAKE BOOSTER ASSY(RHD)
BRAKE ACTUATOR ASSY(W/ VSC)
09214±76011Crankshaft Pulley ReplacerSKID CONTROL SENSOR
09520±00031Rear Axle Shaft PullerSKID CONTROL SENSOR
(09520±00040)ShockerSKID CONTROL SENSOR
09521±00020Drive Shaft Boot Clamping ToolSKID CONTROL SENSOR
09550±60010Differential Side Bearing
ReplacerFRONT BRAKE
(09710±06051)ReplacerREAR BRAKE
09950±00020Bearing RemoverSKID CONTROL SENSOR
Recomended Tools
09042±00010Torx Socket T30STEERING SENSOR
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02±34
±
PREPARATION BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
Equipment
Micrometer
Dial indicator w/ magnetic base
Brake drum gauge
Slide calipers
Torque wrench
Lubricant
ItemCapacityClassification
Brake fluid±SAE J1704 or FMVSS No. 116 DOT4
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022KZ±01
±
PREPARATION CLUTCH
02±43
AVENSIS REPAIR MANUAL (RM1018E)
CLUTCH
PREPARATION
SST
09023±00100Union Nut Wrench 10 mmCLUTCH ACCUMULATOR
ASSY(1CD±FTV)
CLUTCH RELEASE CYLINDER
ASSY(MTM)
CLUTCH MASTER CYLINDER
ASSY(MTM)
09301±00220Clutch Guide ToolCLUTCH UNIT(MTM)
09333±00013Universal Joint Bearing Remover
& ReplacerCLUTCH UNIT(MTM)
Recomended Tools
09040±00011Hexagon Wrench SetCLUTCH PEDAL SUB±ASSY(MTM)
Equipment
Torque wrench
Vernier calipers
Dial indicator with magnetic base
Vernier calipers
Lubricant
ItemCapacityClassification
Brake fluid±SAE J1704 or FMVSS No.116 DOT 4
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030KC±06
03±40
±
SERVICE SPECIFICATIONS DRIVE SHAFT / PROPELLER SHAFT / AXLE
AVENSIS REPAIR MANUAL (RM1018E)
TORQUE SPECIFICATION
Part TightenedN
mkgf
cmft
lbf
Front wheel set nut1031,05076
Rear wheel set nut1031,05076
Manual transaxle oil drain plug C50/C250:
E354/E357:39
49400
50029
36
Lower ball joint assy front x Suspension arm sub±assy lower No.18990866
Tie rod end sub±assy x Steering knuckle4950036
Flexible hose and speed sensor front x Shock absorber assy front1919414
Speed sensor front x Steering knuckle8.08271 in.
lbf
Front stabilizer link assy x Shock absorber assy front7475555
Front axle hub nut2162,200159
Disc brake dust cover front x Steering knuckle8.38573 in.
lbf
Lower ball joint assy front x Steering knuckle1031,05076
Front axle assy x Shock absorber assy front2202,243162
Front disc brake caliper assy x Steering knuckle1021,04075
Automatic transaxle fluid drain plug4950036
Drive shaft bearing case x Bearing bracket6465047
Rear axle hub & bearing assy x Rear axle carrier sub±assy5657141
Rear axle carrier sub±assy x Back plate assy1401,428103
Rear axle carrier sub±assy x Skid control sensor wire5.05144 in.
lbf
Rear disk brake caliper assy x Rear axle carrier sub±assy4747534
Rear axle carrier sub±assy x Upper control arm assy7475555
Rear axle carrier sub±assy x Lower control arm assy ball joint side:
member side:60
105612
1,07144
77
Rear axle carrier sub±assy x Rear suspension arm assy ball joint side: member side:105741,071 75577
55
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14±304
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
191. INSTALL AIR CLEANER ASSY Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
192. INSTALL ENGINE COVER NO.1
Torque: 8.0 N
m (82 kgf
cm, 71 in.
lbf)
193.BLEED CLUTCH PIPE LINE (See page 42±17)
194. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
195. ADD MANUAL TRANSAXLE OIL
196. ADD ENGINE OIL
197.ADD ENGINE COOLANT (See page 16±44)
198. CHECK CLUTCH FLUID LEAKAGE
199. CHECK FLUID LEVEL IN RESERVOIR
200. CHECK BRAKE FLUID LEAKAGE
201. CHECK FOR ENGINE OIL LEAKS
202.CHECK FOR FUEL LEAKS (See page 11±60)
203.CHECK FOR ENGINE COOLANT LEAKS (See page 16±44)
204. CHECK FOR EXHAUST GAS LEAKS
205.INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
206.INSPECT ENGINE IDLE SPEED (See page 14±266)
207.CHECK ABS SPEED SENSOR SIGNAL (See page 05±756)
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010BJ±01
±
INTRODUCTION TERMS (1ZZ±FE/3ZZ±FE)
01±7
1ZZ±FE,3ZZ±FE ENGINE REPAIR MANUAL
(RM923E)
TERMS (1ZZ±FE/3ZZ±FE)
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti±Lock Brake System
A/CAir Conditioner
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir±Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
ASSYAssembly
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
B+Battery Voltage
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi±Level
B/SBore±Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
CKDComplete Knock Down
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
CWCurb Weight
DCDirect Current
DEFDefogger
DFLDeflector
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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
±
BRAKE BRAKE 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 surface\
s.
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.
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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
±
BRAKEBRAKE 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)
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320VU±01
F45162
Vacuum HoseClipBrake Vacuum
Check Valve
Check Valve
Grommet Clevis Pin
Clip
Wave Washer
13 (130, 9)
Engine Room Relay Block
Way
Clutch Reservoir Tube M/T Transaxle:
Front Brake
Tube No.5
15 (155, 11) *1
29 (296, 21) *2
Brake Fluid Level
Switch Connector

Brake Booster Gasket
20 (204, 15)
20 (204, 15)
Brake Master
Cylinder Sub±assy

Brake Booster Assy
Brake Master
Cylinder clevis
15 (155, 11)
Fuel Filter Assy
Diesel Engine Type:
Heater Assy
w/ Cold Area:
Air Cleaner Assembly
With Hose
Clutch Tube M/T Transaxle:Gasoline Engine Type:
15 (155, 11)
*1
w/ ABS:
*2 w/ VSC:N
m (kgf
cm, ft
lbf) : Specified torque
5.4 (55, 48 in.
lbf)
Charcoal Canister
Assy
32±18
±
BRAKE BRAKE BOOSTER ASSY (LHD)
AVENSIS REPAIR MANUAL (RM1018E)
COMPONENTS
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