2002 TOYOTA AVENSIS Rear brake

320VW±01
F45949
32±56
± BRAKEBRAKE ACTUATOR ASSY (W/ VSC)
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/ VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

320VY±01
F45949
± BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
32±53
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE ACTUATOR ASSY (W/O VSC)
ON±VEHICLE INSPECTION
1. CONNECT HAND±HELD TESTER:
(a) Connect the hand±held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand±held tester.
HINT:
Please refer to the hand±held tester operator's manual for fur-
ther details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay on, check the actuator motor operation noise.
(b) Turn the motor relay off.
(c) Depress the brake pedal and hold it for about 15 seconds. Check that the brake pedal cannot be de-
pressed.
(d) With the motor relay on, check that the pedal does not pulsate.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
3. INSPECT RIGHT FRONT WHEEL OPERATION
NOTICE:
Never turn on a solenoid in a manner described below.
(a) With the brake pedal depressed, perform the following operations.
(b) Turn the SFRH and SFRR solenoid on simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep a solenoids tvrned on for more than 5 seconds continuously. When operating it continu-
ously, set an interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid off simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay on, and check that the pedal returns.
NOTICE:
Do not keep a motor relay tvrned on for more than 5 seconds continuously. When operating it contin-
uously, set an interval more than 20 seconds.
(e) Turn the motor relay off and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
(a) Using the same procedure, check the solenoids of the other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR

320VZ±01
G24211
To Master Cylinder Front
G24212
To Master Cylinder Rear
To Front Wheel RH
To Rear Wheel LH
To Rear Wheel RH
To Front Wheel LH
G24213
32±54
± BRAKEBRAKE ACTUATOR ASSY (W/O VSC)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surfaces.
2. REMOVE FRONT WHEEL RH
3. REMOVE FRONT FENDER LINER RH
4. REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Release the latch of the brake actuator connector to dis-
connect the connector.
(b) Using SST, disconnect the brake tubes from the brake ac-
tuator.
SST 09023±00100
(c) Use tags or make a memo to identify the place to recon-
nect.
(d) Remove the nut, 2 bolts and brake actuator with bracket.

G24213
To Master Cylinder Front
G24212
To Master Cylinder Rear
To Front Wheel RH
To Rear Wheel LH
To Rear Wheel RH
To Front Wheel LH
±
BRAKE BRAKE ACTUATOR ASSY(W/O VSC)
32±55
AVENSIS REPAIR MANUAL (RM1018E)
5.REMOVE BRAKE ACTUATOR ASSY
(a)Remove the 2 nuts and brake actuator from the brake acutuator bracket.
6.REMOVE SKID CONTROL ECU
(a)Disconnect the connector from the skid control ECU.
(b)Using a torx driver (T20), remove the 4 screws and the skid control EC\
U from the brake actuator.
7.INSTALL SKID CONTROL ECU
(a)Install the skid control ECU and 4 screws with a torx driver (T20).
(b)Connect the connector to the skid control ECU.
8.INSTALL BRAKE ACTUATOR ASSY
(a)Install the brake actuator with the 2 nuts to the brake actuator bracket\
.
Torque: 7.0 N
m ( 71 kgf
cm, 62 in.
lbf)
9.INSTALL BRAKE ACTUATOR WITH BRACKET
(a)Install the brake actuator with bracket with the nut and 2 bolts.
Torque: 19 N
m (194 kgf
cm, 14 ft
lbf)
(b)Using SST, connect each brake line to the correct position of the brake actuator, as shown in the illustration.
SST09023±00100
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
(c)Connect the brake actuator connector.
10.INSTALL FRONT FENDER LINER RH
11.INSTALL FRONT WHEEL RH Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
12.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
13.BLEED MASTER CYLINDER (See page 32±4) SST 09023±00100
14.BLEED BRAKE LINE (See page 32±4)
15.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
16. CHECK BRAKE FLUID LEAKAGE
17.CHECK BRAKE ACTUATOR WITH HAND±HELD TESTER (See page 05±699)

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80802
C80806
32±26
± BRAKEBRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
(c) Use tags or make a memo to identify the place to recon-
nect.
(d) Using SST and a spanner, disconnect the brake tube from
the flexible hose of the front brake RH.
SST 09023±00100
(e) Remove the 2 bolts and disconnect the 2 brake tube
clamps.

F45361
F45362
F45367
F45363Vacuum tank
C81275
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±27
AVENSIS REPAIR MANUAL (RM1018E)
(f) Using SST, disconnect the 3 brake tubes from the ways.
SST 09023±00100
(g) Disconnect the brake tube from the clamp and remove
the brake tubes.
(h) Disconnect the 3 brake tubes from the clamp and remove
the brake tubes.
13. REMOVE BRAKE BOOSTER ASSY
(a) Gasoline engine type:
Remove the 2 bolts and separate the vacuum pipe from
the body.
(b) Diesel engine type:
Remove the 2 bolts and remove the vacuum tank from the
body.
(c) Disconnect the vacuum hose from the brake booster
assy.
(d) Remove the engine under cover.
(e) Remove the 2 nuts from the engine mounting bracket RH.
(f) Remove the bolt from the rear engine mounting bracket.
(g) Remove the bolt and nut from the front engine mounting
bracket.

C80805
C82119
C81275
C81274
F45367
± BRAKEBRAKE BOOSTER ASSY (RHD)
32±29
AVENSIS REPAIR MANUAL (RM1018E)
18. INSTALL BRAKE BOOSTER ASSY
(a) Install the clevis to the booster push rod.
(b) Install the brake booster assy with the 4 nuts.
Torque: 13 N
m (130 kgf
cm, 9 ft
lbf)
(c) Connect the vacuum hose to the check valve.
(d) Install the engine mounting bracket RH to the body with
the 3 bolts.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(e) Install the bolt to the rear engine mounting bracket.
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
(f) Install the bolt and nut to the front engine mounting brack-
et.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(g) Install the 2 nuts to the engine mounting bracket RH.
Torque: 52 N
m (530 kgf
cm, 39 ft
lbf)
(h) Install the engine under cover.
(i) Connect the vacuum hose to the brake booster assy.
(j) Gasoline engine type:
Install the vacuum pipe with 2 bolts to the body.
Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)

F45057
w/o VSC:
w/ VSC:
To Master
Cylinder Rear
To
Master
Cylinder
Front
To Rear Wheel
RH
To Front Wheel LH
To Front Wheel RH
To Rear Wheel
LH
A
To
Master
Cylinder
FrontTo Master
Cylinder
Rear
To Rear
Wheel RH
To Front Wheel LHTo Front Wheel RH
To Rear
Wheel LH
AA
AA
BB
C80806
±
BRAKE BRAKE BOOSTER ASSY (RHD)
32±31
AVENSIS REPAIR MANUAL (RM1018E)
(e) w/o VSC:
Using SST, connect the 6 brake tubes to the brake actua-
tor, as shown in the illustration.
SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
(f) w/ VSC: Using SST, connect the 6 brake tubes to the brake actua-
tor as shown in the illustration.
SST 09023±00100, 09023±38400
Torque:
A: 15 N
m (155 kgf
cm, 11 ft
lbf)
B: 29 N
m (296 kgf
cm, 21 ft
lbf)
(g) Install the brake tube clamps with the 2 bolts. Torque: 5.4 N
m (55 kgf
cm, 48 in.
lbf)
20. INSTALL FRONT WHEEL RH
21.INSTALL CYLINDER HEAD COVER SUB±ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
22.INSTALL IGNITION COIL ASSY (GASOLINE ENGINE TYPE) (See page 14±81)
23.INSTALL INJECTOR ASSY (DIESEL ENGINE TYPE) (See page 14±318)
24.INSTALL CYLINDER HEAD COVER SUB±ASSY (DIESEL ENGINE TYPE) (See page 14±318)
25.INSTALL TIMING BELT NO.2 COVER (DIESEL ENGINE TYPE) (See page 14±307)