TOYOTA AVENSIS 2005 Service Repair Manual

320VW±01
F45949
32±56
± BRAKEBRAKE ACTUATOR ASSY (W/ VSC)
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/ VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

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
± BRAKEBRAKE 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 surfaces.
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.

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)

320VY±01
F45949
± BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32±53
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/O VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

320W0±01
G23181
Union bolt
G23224
F45701
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
± BRAKEREAR BRAKE
32±47
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface.
3. REMOVE DISC BRAKE CYLINDER ASSY REAR LH
(a) Remove the union bolt and gasket from the brake cylinder
assy rear LH, then disconnect the flexible hose from the
disc brake cylinder assy rear LH.
(b) Hold the rear disc brake cylinder slide pin and remove the
2 bolts.
4. REMOVE REAR DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit rear.
(b) Remove the 2 rear disc brake pad support plates No.1
and 2 rear disc brake pad support plates No.2 from the
rear disc brake cylinder mounting LH.
5. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Remove the rear disc brake cylinder slide pin (No.1) and
rear disc brake cylinder slide pin (No.2) from the disc
brake cylinder mounting LH.
(b) Remove the rear disc brake cylinder slide bush from the
bottom side of the rear disc brake cylinder slide pin (No.2).

F45439
Front Disc Brake Cylinder Mounting
Bush Dust Boot
F45704
F42270
G23222
G23223
32±48
± BRAKEREAR 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.

G23182
F45707
F41555
Matchmarks
± BRAKEREAR BRAKE
32±49
AVENSIS REPAIR MANUAL (RM1018E)
11. REMOVE REAR DISC BRAKE BLEEDER PLUG
(a) Remove the bleeder plug cap and rear disc brake bleeder plug from the disc brake cylinder assy raer
LH.
12. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the cylinder bore and piston for rust or scoring.
13. INSPECT REAR DISC BRAKE PAD KIT
(a) Using a ruler, measure the disc brake pad lining thick-
ness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 2.0 mm (0.079 in.)
(b) Inspect the 2 rear disc brake pad support plates No.1 and
2 rear disc brake pad support plates No.2. Make sure that
they have sufficient rebound, no deformation cracks or
wear, and have had all rust, dirt and foreign particles
cleaned off.
14. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the rear disc thickness.
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 9.0 mm (0.354 in.)
15. REMOVE PARKING BRAKE SHOE ADJUSTING HOLE PLUG
16. REMOVE REAR DISC
(a) Place matchmarks on the rear disc and the axle hub.
(b) Remove the rear disc.
17. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
Select the installation position where the rear disc has the mini-
mum runout.
18. INSTALL PARKING BRAKE SHOE ADJUSTING HOLE PLUG

F45708
F45750Lithium soap base glycol grease
Cylinder Boot
Piston
G23231Cylinder Boot
Piston
F45704
32±50
±
BRAKE REAR 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)

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
±
BRAKE REAR 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)

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)