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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 ftlbf)
(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 ftlbf)
B: 29 N m (296 kgf cm, 21 ftlbf)
(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)
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32±32
±
BRAKE BRAKE BOOSTER ASSY (RHD)
AVENSIS REPAIR MANUAL (RM1018E)
26. INSTALL ENGINE COVER NO.1
27.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (1AZ±FSE ENGINE TYPE) (See page 14±204)
28.INSTALL CLUTCH MASTER CYLINDER ASSY (M/T TRANSAXLE) (See page 42±13) SST 09023±00100
29.INSTALL BRAKE MASTER CYLINDER SUB±ASSY (See page 32±13)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
30.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
31.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100, 09023±00100
(b) w/ VSC: SST 09023±00100, 09023±00100
32.BLEED BRAKE LINE (See page 32±4)
33.CHECK AND ADJUST BRAKE PEDAL HEIGHT (See page 32±6)
34.CHECK PEDAL FREE PLAY (See page 32±6)
35.CHECK PEDAL RESERVE DISTANCE (See page 32±6)
36.BLEED CLUTCH PIPE LINE (M/T TRANSAXLE) (See page 42±13)
37.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (M/T TRANSAXLE) (See page 42±2)
38.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
39. CHECK BRAKE FLUID LEAKAGE
40. CHECK CLUTCH FLUID LEAKAGE (M/T TRANSAXLE)
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Page 1091 of 2234
3201C±08
G24222
G24223
G24224
32±4
±
BRAKE BRAKE FLUID
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE FLUID
BLEEDING
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surfaces.
HINT:
When working on the brake system or when air in the brake lines is suspected,\
bleed the air from the system. 1. FILL RESERVOIR WITH BRAKE FLUIDFluid: SAE J1704 or FMVSS No. 116 DOT4
2. BLEED MASTER CYLINDER
HINT:
After disassembling the master cylinder or when the reservoir
becomes empty, bleed the air out of the brake master cylinder.
(a) w/o VSC: Using SST, Disconnect the brake lines from the brake
master cylinder.
SST 09023±00100
(b) w/ VSC:
Using SST, Disconnect the brake lines from the brake
master cylinder.
SST 09023±38400
(c) Slowly depress and hold the brake pedal it.
(d) Cover off the outer holes with your fingers, and release the brake pedal.
(e) Repeat (b) and (c) 3 or 4 times.
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Page 1092 of 2234
F42258
G24222
±
BRAKE BRAKE FLUID
32±5
AVENSIS REPAIR MANUAL (RM1018E)
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal depressed.
(c) At the point when the fluid stops, coming out tighten the bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the brake line for each wheel.
Torque: 10 N m (102 kgf cm, 7 ft.lbf)
4. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid if necessary. Fluid: SAE J1704 or FMVSS No. 116 DOT4
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Page 1093 of 2234
320W5±01
G24285
LHD Steering Position Type:Charcoal Canister Assy
Brake Fluid Level
Switch Connector Clutch Reservoir
Tube M/T Transaxle:Brake Booster Assy
Clip
Way
20 (204, 15)
15 (155, 11)
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Brake Master
Cylinder Sub±assy
20 (204, 15)
Engin Room Relay Block
RHD Steering Position Type: Air Cleaner Cap Sub±assy
Brake Fluid Level
Switch Connector Brake Master
Cylinder Sub±assy
Clip
Accelerator Control
Cable Support
20 (204, 15)
*1
w/ ABS:*2 w/ VSC:Nm (kgf cm, ftlbf) : Specified torque
15 (155, 11)*1
29 (296, 21)*2
15 (155, 11)*1
29 (296, 21)*2
Clutch Reservoir
Tube M/T Transaxle:
Brake Booster Assy
5.4 (55, 48 in. lbf)
Fuel Filter Assy Diesel Engin Type:
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±11
AVENSIS REPAIR MANUAL (RM1018E)
BRAKE MASTER CYLINDER SUB±ASSY
COMPONENTS
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G24284
Cap
Strainer
Brake Master Cylinder Reservoir Sub±Assy
Brake Master Cylinder
Reservoir Grommet
Brake Master Cylinder
Straight Pin
Screw
Lithium soap base glycol grease
Non±reusable part
Nm (kgf cm, ftlbf) : Specified torque
Brake Master Cylinder
Reservoir Grommet
LHD Steering Position Type
RHD Steering Position Type
O±Ring
Retianer Washer
32±12
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
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320W6±01
G24218
G24217
F45393
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
32±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
NOTICE:
Do not adjust the brake booster push rod.
1. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it adheres to any painted surface\
.
2. REMOVE ENGINE ROOM RELAY BLOCK (LHD STEERING POSITION TYPE)
3. REMOVE AIR CLEANER CAP SUB±ASSY (LHD STEERING POSITION TYPE)
4. REMOVE CHARCOAL CANISTER ASSY (LHD STEERING POSITION TYPE)
5. REMOVE FUEL FILTER ASSY (LHD STEERING POSITION TYPE)
(a) Diesal engine type:
Remove the fuel filter assy with the 3 bolts.
6. REMOVE BRAKE MASTER CYLINDER SUB±ASSY(LHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle: Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC:
Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Using SST, disconnect the 2 brake lines from the way. SST 09023±00100
(f) Remove the 2 nuts, and pull out the way and brake master cylinder sub±assy.
(g) Remove the O±ring from the brake master cylinder sub±
assy.
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Page 1096 of 2234

G24225
F45394
F45395Lithium soap base glycol grease
Grommets
Retainer
Washer
32±14
±
BRAKE BRAKE MASTER CYLINDER SUB±ASSY
AVENSIS REPAIR MANUAL (RM1018E)
7. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (RHD STEERING POSITION TYPE)
(a) Disconnect the brake fluid level switch connector.
(b) M/T transaxle:
Slide the clip and disconnect the clutch reservoir tube.
(c) w/o VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±00100
(d) w/ VSC: Using SST, disconnect the 2 brake lines from the brake
master cylinder sub±assy.
SST 09023±38400
(e) Remove the 2 nuts and pull out the accelerator control cable support and brake master cylinder sub±assy.
(f) Remove the O±ring from the brake master cylinder sub± assy.
8. REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB±ASSY
(a) Using a screwdriver, remove the screw from the brake master cylinder.
(b) Remove the brake master cylinder reservoir sub±assy and 2 brake master cylinder reservoir grommets from the brake master cylinder.
(c) Remove the cap and strainer from the master cylinder reservoir. 9. INSTALL BRAKE MASTER CYLINDER RESERVOIRSUB±ASSY
(a) Apply lithium soap base grycol grease to the 2 brake mas- ter cylinder reservoir grommets.
(b) Install the retainer washer to the brake master cylinder.
(c) Install the 2 brake master cylinder reservoir grommets to the brake master cylinder.
(d) Using a screwdriver, install the brake master cylinder re-
sevoir sub±assy with the screw.
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