2001 TOYOTA AVALON Service Repair Manual

BR0L4-04
R00121
R00122
R00123
R02877
BR-30
- BRAKEFRONT BRAKE CALIPER
1429 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot from
the caliper.
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
3. REMOVE PISTON SEAL
Using a screwdriver, remove the piston seals from the cylinder.
4. REMOVE SLIDING PINS AND DUST BOOTS
(a) Remove the 2 sliding pins from the torque plate.
NOTICE:
At the time of reassembly, insert the sliding pin with sliding
bushing into the top side.
(b) Using a screwdriver and hammer, tap out the 2 dust
boots.
HINT:
At the time of reaseembly, use a 24 mm socket wrench and tap
in 2 new dust boots into the torque plate.
NOTICE:
At the time of reassembly, confirm that the metal plate por-
tion of the dust boot fits snugly in the torque plate.

BR0L5-04
F06988
F06395
F06396
F06397
- BRAKEFRONT BRAKE CALIPER
BR-31
1430 Author
: Date
:
2001 AVALON (RM808U)
INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad's thickness is at the minimum thick-
ness or less, or if the pad has severe, uneven wear.
2. MEASURE DISC THICKNESS
Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
Replace the disc if the disc's thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.
3. MEASURE DISC RUNOUT
Using a dial indicator, measure the disc runout 10 mm (0.39 in.)
from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc's runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA-9). If the bearing play and axle hub runout are
not abnormal, adjusting the disc runout or grind it on a ºOn-Carº
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the mounting bolts and torque plate from the
knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5
of a turn round from its original position on the hub. Install
and torque the hub nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
Remeasure the disc runout. Make a note of the runout
and the disc's position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.05 mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.05 mm (0.0020 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and torque the mounting bolts.
Torque: 107 N´m (1,090 kgf´cm, 79 ft´lbf)

BR0L7-04
- BRAKEFRONT BRAKE CALIPER
BR-33
1432 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-29).
HINT:

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

Check for fluid leaks.

BR0L6-01
BR-32
- BRAKEFRONT BRAKE CALIPER
1431 Author
: Date
:
2001 AVALON (RM808U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-30).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-28).

BR0L3-04
R02840
- BRAKEFRONT BRAKE CALIPER
BR-29
1428 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
HINT:
At the time of installation, install the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 2 PAD SUPPORT PLATES

BR0L0-04
F06983
Anti-squeal Shim
Inner Anti-squeal Shim
Pad Wear Indicator Plate
Outer Pad
Pad Support Plate
Inner Pad
Disc brake grease
34 (350, 25)
N´m (kgf´cm, ft´lbf): Specified torque
- BRAKEFRONT BRAKE PAD
BR-25
1424 Author
: Date
:
2001 AVALON (RM808U)
FRONT BRAKE PAD
COMPONENTS

BR0L1-04
F06984
F06985
BR-26
- BRAKEFRONT BRAKE PAD
1425 Author
: Date
:
2001 AVALON (RM808U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if it is not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the bolt and flexible hose from the shock absorb-
er bracket.
(b) Remove the bottom side installation bolt.
(c) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL
SHIMS
5. REMOVE PAD WEAR INDICATOR PLATE
6. REMOVE 2 PAD SUPPORT PLATES
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
7. CHECK DISC THICKNESS AND RUNOUT (See page
BR-31)
8. INSTALL 2 PAD SUPPORT PLATES
9. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to both sides of the inner anti-
squeal shims (See page BR-25).
(c) Install the 2 anti-squeal shims on each pad.
(d) Install inner pad with the pad wear indicator plate facing
upward.
(e) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.

R02981
- BRAKEFRONT BRAKE PAD
BR-27
1426 Author
: Date
:
2001 AVALON (RM808U)
10. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) Hold the sliding pin and torque the installation bolt.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(e) Install the flexible hose and bolt to the shock absorber
bracket.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
11. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
12. DEPRESS BRAKE PEDAL SEVERAL TIMES
13. CHECK THAT FLUID LEVEL IS AT MAX LINE