Piston TOYOTA AVENSIS 2005 Service Owner's Manual

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)

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
± BRAKEREAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
REAR DISC BRAKE
COMPONENTS

F45420
Front Disc Brake Cylinder Mounting
Bush Dust Boot
F45418
C64095
G23222
G23223
32±42
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 front disc brake bush dust boots from the
front disc brake cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and front disc brake cylinder mount-
ing LH.
8. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug between the front disc brake piston and
the disc brake cylinder assy LH.
(b) Use compressed air to remove the front disc brake piston
from the disc brake cylinder assy 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.

G23179
F45705
F41543
Matchmarks
F45706
±
BRAKE FRONT BRAKE
32±43
AVENSIS REPAIR MANUAL (RM1018E)
11.REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a)Remove the bleeder plug cap and front disc brake bleeder plug from the disc b\
rake cylinder assy LH.
12.INSPECT BRAKE CYLINDER AND PISTON
(a)Check the cylinder bore and piston for rust or scoring.
13.INSPECT FRONT DISC BRAKE PAD KIT
(a)Using a ruler, measure the disc brake pad lining thick-ness.
Standard thickness: 12.5 mm (0.492 in.)
Minimum thickness: 2.0 mm (0.079 in.)
(b)Inspect the 2 front disc brake pad support plates No.2 and front disc brake pad support plates No.1.
Make sure that they have sufficient rebound, no deforma-
tion, cracks nor wear, and have had all rust, dirt and for-
eign particles cleaned off.
14.INSPECT DISC THICKNESS
(a)Using a micrometer, measure the front disc thickness.
Standard thickness: 26.0 mm (1.024 in.)
Minimum thickness: 24.0 mm (0.945 in.)
15.REMOVE FRONT DISC
(a)Place matchmarks on the front disc and the axle hub.
(b)Remove the front disc.
16.INSTALL FRONT DISC
(a)Aligning the matchmarks, install the front disc.
HINT:
Select the installation position where the disc has the minimum
runout.
17.INSPECT DISC RUNOUT
(a)Temporarily fasten the front disc together with the hub nuts.
Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
(b)Using a dial indicator, measure the front disc runout 10 mm (0.39 in.) away from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c)If the disc's 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.

G23226Lithium soap base glycol grease
Cylinder Boot
Piston
G23225
Cylinder Boot
Piston
F45418
F45420
Front Disc Brake Cylinder Mounting
Bush Dust Boot
Lithium soap base glycol grease
32±44
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
18. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake cylinder assy LH.
(b) Install the bleeder plug cap to the bleeder plug.
19. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy LH.
20. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc
brake piston and a new cylinder boot.
(b) Install the cylinder boot to the front 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.
21. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the
disc brake cylinder assy LH.
SST 09550±60010
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder assy LH.
22. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting LH with the
2 bolts.
Torque: 102 N
m (1,040 kgf
cm, 75 ft
lbf)
23. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to the sealing sur-
face of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front
disc brake cylinder mounting LH.

320GA±03
G23177
Disc Brake
Cylinder Assy LH
GasketFlexible Hose
Disc Brake
Pad Kit Front
Front Disc Brake
Pad Support Plate No.1
Front Disc Brake
Cylinder Slide Pin (No.2)
Front Disc Brake
Bush Dust Boot Front Disc Brake
Cylinder Slide Pin (No.1)
Front Disc Brake
Cylinder Slide Bush
Front Disc Brake
Cylinder Mounting LH

Cylinder Boot
Piston Seal
Front Disc
Brake PistonFront Disc
30 (306, 22)
102 (1,040, 75)
30 (306, 22)
Bleeder Plug CapFront Disc Brake
Bleeder Plug

Non±reusable part
N
m (kgf
cm, ft
lbf) : Specified torque
Lithium soap base glycol grease
29 (296, 21)
10 (102, 7)
Union bolt
Front Disc Brake
Pad Support Plate No.2
102 (1,040, 75)

Front Disc Brake
Bush Dust Boot
Bolt

Bolt




32±40
± BRAKEFRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BRAKE
COMPONENTS

C50017
D03553
B C
A
A
A
B B

C
C

C69150
D09179
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U241E)
40±49
AVENSIS REPAIR MANUAL (RM1018E)
(b) Install the spring and check ball body.
(c) Align the groove of the manual valve with the pin of the
lever.
(d) Install the valve body assy with the 17 bolts.
Torque: 11 N
m (112 kgf
cm, 8 ft
lbf)
NOTICE:
Push the valve body against the accumulator piston
spring and the check ball body to install it.
Tighten those bolts marked by
in the illustration
first temporarily because they are positioning bolts.
Bolt length:
Bolt A: 25 mm (0.984 in.)
Bolt B: 41 mm (1.614 in.)
Bolt C: 45 mm (1.771 in.)
8. INSTALL VALVE BODY OIL STRAINER ASSY
(a) Coat a new O±ring with ATF.
(b) Install the O±ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 11 N
m (112 kgf
cm, 8 ft
lbf)

D30632
D30633
Detent
Spring
Cover
D30634
D05901
D05902
± AUTOMATIC TRANSMISSION / TRANSTRANSMISSION VALVE BODY ASSY (U341E)
40±43
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE TRANSMISSION VALVE BODY ASSY
(a) Disconnect the 5 connectors.
(b) Remove the bolt and lock plate, and remove the ATF tem-
perature sensor.
(c) Remove the 2 bolts, cover and detent spring.
(d) Remove the 13 bolts and valve body.
NOTICE:
Be careful not to drop the check valve body, spring and ac-
cumulator piston.
(e) Remove the check ball body and spring.
(f) Remove the 2 apply gaskets.