2001 TOYOTA AVALON Service Repair Manual

BR0KM-03
BR-12
- BRAKEPARKING BRAKE PEDAL
1411 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-1 1).
AFTER INSTALLATION, ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR-6)

R00254
BR0KJ-02
F09710No. 4 CableLock Nut
Adjusting Hexagon
W03176
Red Paint
- BRAKEPARKING BRAKE PEDAL
BR-9
1408 Author
: Date
:
2001 AVALON (RM808U)
PARKING BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE PEDAL TRAVEL
Slowly depress the parking brake pedal all the way, and count
the number of clicks.
Parking brake pedal travel at 294 N (30 kgf, 66 lbf):
3 - 6 clicks
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL
TRAVEL
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 1 on page BR-46.
(a) Floor shift:
Remove the console box.
(b) Column shift:
Remove the hole cover.
(c) Confirm that the parking brake pedal is released.
(d) Hold the screw end of No. 4 cable not to rotate.
(e) Loosen the lock nut.
(f) Hold the parking brake cable and turn the adjusting hexa-
gon until the pedal travel is correct.
NOTICE:
To prevent the parking brake cable from twisting, always
keep the red-painted surface up.
(g) Holding the adjusting hexagon, tighten the lock nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(h) Floor shift:
Install the console box.
(i) Column shift:
Install the hole cover.

BR151-01
F09746
F09747
- BRAKEPARKING BRAKE PEDAL
BR-1 1
1410 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH PANEL INSERT AND NO. 2 HEATER TO REG-
ISTER DUCT (See page BO-87)
2. RELEASE PARKING BRAKE PEDAL
3. REMOVE PARKING BRAKE PEDAL ASSEMBLY
(a) Disconnect the parking brake switch connector.
(b) Remove the clip, and disconnect the parking brake cable.
(c) Remove the 3 nuts and parking brake pedal assembly.
Torque: 61 N´m (620 kgf´cm, 45 ft´lbf)
(d) Remove the parking brake switch and cushion from the
parking brake pedal assembly.

BR159-01
F09741
Air Cleaner Cover With Air Cleaner Hose
Level Warning Switch Connector
Master Cylinder
Precharge Pump Precharge Pump Assembly
Master Cylinder Pressrue Sensor
3-way
Precharge Pump Bracket
N´m (kgf´cm, ft´lbf) : Specified torque

Non-reusable partCushion
15 (155, 11)
Holder
13 (130, 9)
19 (195, 14)
19 (195, 14)
13 (130, 9)8.0 (82, 71in.´lbf)
Washer CushionCollar
20 (200, 15)
15 (155, 11)
O-Ring

Spacer
81 (830, 60)
BR-56
- BRAKEPRECHARGE PUMP
1455 Author
: Date
:
2001 AVALON (RM808U)
PRECHARGE PUMP
COMPONENTS

BR15B-01
BR-58
- BRAKEPRECHARGE PUMP
1457 Author
: Date
:
2001 AVALON (RM808U)
INSTALLATION
Installation is in the reverse order of removal (See page BR-57).
HINT:

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

Check for fluid leaks.

BR15A-01
F09742
F09743
SST
F09744
F09745
- BRAKEPRECHARGE PUMP
BR-57
1456 Author
: Date
:
2001 AVALON (RM808U)
REMOVAL
1. REMOVE AIR CLEANER CASE WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15)
3. DISCONNECT PRECHARGE PUMP CONNECTOR
4. REMOVE PRECHARGE PUMP ASSEMBLY
(a) Remove the 3 bolts and precharge pump assembly.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
(b) Using SST, disconnect the 2 brake lines from the prechar-
ge pump.
SST 09751-3601 1
Torque:
10 mm nut: 15 N´m (155 kgf´cm, 11 ft´lbf)
12 mm nut: 20 N´m (200 kgf´cm, 15 ft´lbf)
5. REMOVE PRECHARGE PUMP
(a) Remove the 2 nuts, 2 bolts and precharge pump from the
pump bracket.
Torque:
Nut: 13 N´m (130 kgf´cm, 9 ft´lbf)
Bolt: 8.0 N´m (82 kgf´cm, 71 in.´lbf)
(b) Remove the 2 holders, 2 collars, 2 washers and 4 cush-
ions.
6. REMOVE MASTER CYLINDER PRESSURE SENSOR
(a) Place the precharge pump in a vise with a cloth shown in
the illustration on the left.
(b) Using 30 mm deeper socket wrench, and remove the
master cylinder pressure sensor, O-ring and spacer.
Torque: 81 N´m (830 kgf´cm, 60 ft´lbf)

BR0LA-03
F09724
Brake Caliper
Torque Plate Piston Seal
Set Ring Piston
Dust Boot
Pad Support Plate
Sliding Bushing
Inner Pad
Anti-squeal Shim
N´m (kgf´cm, ft´lbf): Specified torque

Non-reusable part
Lithium soap bass glycol grease
Disc brake grease
Bleeder Plug
29 (300, 22)
8.3 (85, 74 in.´lbf)
47 (475, 34)
Inner Anti-squeal Shim Anti-squeal Shim
Plug
47 (475, 34)
Boot
Pad Support Plate
Outer Pad
Inner Anti-squeal Shim
34 (350, 25)
34 (350, 25)
Flexble Hose
Disc
Gasket


Gasket


- BRAKEREAR BRAKE CALIPER
BR-37
1436 Author
: Date
:
2001 AVALON (RM808U)
REAR BRAKE CALIPER
COMPONENTS

BR153-01
F09726
F09727
F09728
- BRAKEREAR BRAKE CALIPER
BR-39
1438 Author
: Date
:
2001 AVALON (RM808U)
DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the cylinder.
2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
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 seal from the cylinder.
4. REMOVE 2 DUST BOOTS