2001 TOYOTA AVALON Service Repair Manual

BR0KY-05
F06431
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-23
1422 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. w/ VSC:
REMOVE PRECHARGE PUMP ASSEMBLY (See page
BR-57)
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH INSTRUMENT PANEL INSERT AND NO. 2
HEATER TO REGISTER DUCT (See page BO-87)
6. REMOVE BRAKE BOOSTER ASSEMBLY
(a) Remove the pedal return spring.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster and gasket.

BR0KQ-04
F09712
3-way
2-wayMaster CylinderAir Cleaner Cover with
Air Cleaner Hose
Brake Booster
N´m (kgf´cm, ft´lbf) : Specified torquew/ VSC:
15 (155, 11)
13 (130, 9)
15 (155, 11)
13 (130, 9)
Level Warning Switch Connetor
- BRAKEBRAKE MASTER CYLINDER
BR-13
1412 Author
: Date
:
2001 AVALON (RM808U)
BRAKE MASTER CYLINDER
COMPONENTS

F09748
Cap
Strainer
Reservoir Reservoir Set Screw
Grommet
Cylinder Body

Gasket
Stopper BoltNo. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
Grommet w/o VSC:
Cap
Strainer
Reservoir
Grommet Reservoir Set Screw
Grommet
Cylinder Body Straight Pin

Non-reusable part
Lithium soap base giycol grease
w/ VSC:
1.7 (17.5, 15.2 in.´lbf)
10 (100, 7)
1.7 (17.5, 15.2 in.´lbf)
N´m (kgf´cm, ft´lbf) : Specified torque
O-Ring

O-Ring

No. 1 Piston and Spring
No. 2 Piston and SpringSnap Ring
BR-14
- BRAKEBRAKE MASTER CYLINDER
1413 Author
: Date
:
2001 AVALON (RM808U)

BR0KS-03
F09715
Soft Jows
F09716
Soft Jows
R12236
A BR-16
- BRAKEBRAKE MASTER CYLINDER
1415 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o VSC:
PLACE CYLINDER IN VISE
4. w/o VSC:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. w/o VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).

F09717
F09718
- BRAKEBRAKE MASTER CYLINDER
BR-17
1416 Author
: Date
:
2001 AVALON (RM808U)
6. w/ VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 piston and springs by hand, pulling straight
out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bly that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
HINT:
Insert the No. 2 piston with the groove positioning horizontally.

BR0KT-01
BR-18
- BRAKEBRAKE MASTER CYLINDER
1417 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

BR0KV-05
BR-20
- BRAKEBRAKE MASTER CYLINDER
1419 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-15).
HINT:

Before installation, adjust length of brake booster push rod (See page BR-24).

After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4), and
check for leaks.

Check and adjust brake pedal (See page BR-6).

BR0KU-01
- BRAKEBRAKE MASTER CYLINDER
BR-19
1418 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See-page BR-16).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR-13).