2002 TOYOTA AVENSIS Repair Manual

320VT±01
G23220
G23175
F43108
Stop Lamp Switch Assy
Cushion
1.5 ± 2.5 mm (0.059 ± 0.098 in.)
±
BRAKE BRAKE PEDAL SUB±ASSY
32±9
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE COMBINATION METER ASSEMBLY (See page 71±21)
2. REMOVE BRAKE PEDAL SUPPORT SUB±ASSY
(a) Remove the bolt from the brake pedal support sub±assy.
(b) Disconnect the stop lamp switch connector.
(c) Remove the clip and clevis pin, and disconnect the brakemaster cylinder push rod clevis from the brake pedal sub±
assy.
(d) Remove the 4 nuts and brake pedal support sub±assy.
3. REMOVE BRAKE PEDAL SUB±ASSY
(a) Remove the brake pedal shaft and nut from the brake pedal support sub±\
assy.
(b) Remove the brake pedal sub±assy and 2 bushes.
4. REMOVE STOP LAMP SWITCH ASSY
(a) Turn the stop lamp switch assy counterclockwise and remove the stop lamp \
switch assy.
(b) Remove the stop lamp switch mounting adjuster from the brake pedal suppo\
rt sub±assy.
5. REMOVE BRAKE PEDAL PAD
(a) Remove the brake pedal pad from the brake pedal sub±assy.
6. INSTALL BRAKE PEDAL PAD
(a) Install the brake pedal pad to the brake pedal sub±assy. 7. INSTALL STOP LAMP SWITCH ASSY
(a) Install the stop lamp switch mounting adjuster to thebrake pedal support sub±assy.
(b) Install the stop lamp switch assy until the body hits the cushion.
NOTICE:
When inserting the stop lamp switch assy, support the ped-
al from behind so that the pedal is not pushed in.
(c) Make a quarter turn clockwise to install the stop lamp switch assy.
NOTICE:
The turning torque for installing the stop lamp switch assy. Torque: 1.5 N
m (15 kgf
cm, 13 in.
lbf) or less

G23175
G23220
32±10
±
BRAKE BRAKE PEDAL SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
8. INSTALL BRAKE PEDAL SUB±ASSY
(a) Apply lithium soap base glycol grease to the inside surface of 2 new bus\
hes.
(b) Install the brake pedal sub±assy and 2 bushes to the brake pedal supp\
ort sub±assy with the brake pedal shaft and nut.
Torque: 37 N
m (375 kgf
cm, 27 ft
lbf)
9. INSTALL BRAKE PEDAL SUPPORT SUB±ASSY
(a) Install the brake pedal support sub±assy with the 4 nuts. Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(b) Connect the stop lamp switch connector to the stop lamp switch assy.
(c) Apply lithium soap base glycol grease to the clevis pin.
(d) Install the clip and clevis pin, and connect the brake mas- ter cylinder push rod clevis with the clevis pin and clip.
(e) Install the bolt to the brake pedal support assy. Torque: 24 N
m (241 kgf
cm, 17 ft
lbf)
10.INSTALL COMBINATION METER ASSEMBLY (See page 71±21)
11.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
12.CHECK PEDAL FREE PLAY (See page 32±6)
13.CHECK PEDAL RESERVE DISTANCE (See page 32±6)

3201A±12
± BRAKEBRAKE SYSTEM
32±1
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE SYSTEM
PRECAUTION

Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the ones with parts having the same part number
or equivalent.

It is very important to keep the parts and the area clean when repairing the brake system.

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
INTRODUCTION.

3201B±12
32±2
±
BRAKE BRAKE SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers \
indicate the probability of the
problems in descending order. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Low pedal or spongy pedal
3. Fluid leaks in brake system
4. Air in brake system
5. Piston seals (Worn or damaged)
6. Brake master cylinder (faulty)
7. Brake booster push rod (Out of adjustment) ±
32±4
32±41
32±47
32±13
32±13
Brake drag
1. Brake pedal free play (Minimal)
2. Parking brake lever travel (Out of adjustment)
3. Parking brake wire (Sticking)
4. Disk brake pad (Cracked or distorted)
5. Piston (Stuck or Frozen)
6. Brake booster push rod (Out adjustment)
7. Vacuum leaks in brake booster system
8. Brake master cylinder (Faulty)32±6
33±2
33±2
32±41
32±47
32±41
32±47
32±13
32±17
32±21
32±13
Brake pull
1. Piston (Stuck or Frozen)
2. Pad or lining (Oily)
3. Disc (Scored)
4. Pad (Cracked or distorted) 32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
Hard pedal but brake inefficient
1. Fluid leaks in brake system
2. Air in brake system
3. Pad (Worn)
4. Pad (Cracked or distorted)
5. Pad (Oily)
6. Pad (Glazed)
7. Disc (Scored)
8. Booster push rod (Out of adjustment)
9. Vacuum leaks for booster system ±
32±4
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±13
32±17
32±21

±
BRAKE BRAKE SYSTEM
32±3
AVENSIS REPAIR MANUAL (RM1018E)
Noise from brakes
1. Pad (Cracked or distorted)
2. Installation bolt (Loose)
3. Disc (Scored)
4. Pad support plate (Loose)
5. Sliding pin (Worn)
6. Pad (dirty)
7. Pad(Glazed)32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47
32±41
32±47

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

320W1±01
F45421
Union Bolt
G23232
F45419
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
± BRAKEFRONT BRAKE
32±41
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE FRONT 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 LH
(a) Remove the union bolt and gasket from the disc brake cyl-
inder assy LH, then disconnect the flexible hose.
(b) Hold the front disc brake cylinder slide pin and remove the
2 bolts.
4. REMOVE FRONT DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit front from the front disc
brake cylinder mounting LH.
(b) Remove the 2 front disc brake pad support plates No.2
and 2 front disc brake pad support plates No.1.
5. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Remove the front disc brake cylinder slide pin (No.1) and
front disc brake cylinder slide pin (No.2) from the front disc
brake cylinder mounting LH.
(b) Remove the front disc brake cylinder slide bush from the
bottom side of the front disk brake cylinder slide pin
(No.2).

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.