Page 1105 of 2234

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
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Page 1106 of 2234
±
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
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Page 1107 of 2234
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 Piston Front Disc
30 (306, 22)
102 (1,040, 75)
30 (306, 22)
Bleeder Plug Cap
Front Disc Brake
Bleeder Plug
Non±reusable part
Nm (kgf cm, ftlbf) : 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
±
BRAKE FRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
FRONT BRAKE
COMPONENTS
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Page 1108 of 2234

320W1±01
F45421
Union Bolt
G23232
F45419
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
±
BRAKE FRONT 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).
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Page 1109 of 2234
F45420
Front Disc Brake Cylinder MountingBush Dust Boot
F45418
C64095
G23222
G23223
32±42
±
BRAKE FRONT 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.
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Page 1110 of 2234

G23179
F45705
F41543
Matchmarks
F45706
±
BRAKEFRONT BRAKE
32±43
AVENSIS REPAIR MANUAL (RM1018E)
11.REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a)Remove the bleeder plug cap and front disc brake bleeder plug from the disc b\
rake cylinder assy LH.
12.INSPECT BRAKE CYLINDER AND PISTON
(a)Check the cylinder bore and piston for rust or scoring.
13.INSPECT FRONT DISC BRAKE PAD KIT
(a)Using a ruler, measure the disc brake pad lining thick-ness.
Standard thickness: 12.5 mm (0.492 in.)
Minimum thickness: 2.0 mm (0.079 in.)
(b)Inspect the 2 front disc brake pad support plates No.2 and front disc brake pad support plates No.1.
Make sure that they have sufficient rebound, no deforma-
tion, cracks nor wear, and have had all rust, dirt and for-
eign particles cleaned off.
14.INSPECT DISC THICKNESS
(a)Using a micrometer, measure the front disc thickness.
Standard thickness: 26.0 mm (1.024 in.)
Minimum thickness: 24.0 mm (0.945 in.)
15.REMOVE FRONT DISC
(a)Place matchmarks on the front disc and the axle hub.
(b)Remove the front disc.
16.INSTALL FRONT DISC
(a)Aligning the matchmarks, install the front disc.
HINT:
Select the installation position where the disc has the minimum
runout.
17.INSPECT DISC RUNOUT
(a)Temporarily fasten the front disc together with the hub nuts.
Torque: 103 N m (1,050 kgfcm, 76 ftlbf)
(b)Using a dial indicator, measure the front disc runout 10 mm (0.39 in.) away from the outer edge of the front disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c)If the disc's runout is maximum value or greater, check the
bearing play in the axial direction and check for the axle
hub runout (See page 30±2). If the bearing play and axle
hub runout are normal, adjust the disc runout or grind it
on a ºOn±carº brake lathe.
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Page 1111 of 2234

G23226Lithium soap base glycol grease
Cylinder Boot
Piston
G23225
Cylinder Boot
Piston
F45418
F45420
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
32±44
±
BRAKE FRONT BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
18. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the disc brake c\
ylinder assy LH.
(b) Install the bleeder plug cap to the bleeder plug.
19. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the disc brake cylinder assy LH. 20. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front discbrake piston and a new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the piston to the disc brake cylinder assy LH.
NOTICE:
Do not install the piston forcibly in the disc brake cylinder.
21. INSTALL CYLINDER BOOT
(a) Using SST and a hammer, install the cylinder boot to the disc brake cylinder assy LH.
SST 09550±60010
NOTICE:
Do not damage the cylinder boot.
HINT:
Install the boot securely to the disc brake cylinder assy LH.
22. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting LH with the 2 bolts.
Torque: 102 N m (1,040 kgfcm, 75 ft lbf)
23. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Apply lithium soap base glycol grease to the sealing sur- face of 2 new front disc brake bush dust boots.
(b) Install the 2 front disc brake bush dust boots to the front disc brake cylinder mounting LH.
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Page 1112 of 2234

F45419
Cylinder Slide Pin
Lithium soap base glycol grease
F45421
Union Bolt
±
BRAKE FRONT BRAKE
32±45
AVENSIS REPAIR MANUAL (RM1018E)
24. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
KIT
(a) Apply lithium soap base glycol grease to the a new front
disc brake cylinder slide bush.
(b) Install the front disc brake cylinder slide bush to the bot- tom side of the front disc brake cylinder slide pin (No.2).
(c) Apply lithium soap base glycol grease to the sliding part
and the sealing surface of the 2 cylinder slide pins.
(d) Install the 2 front disc brake cylinder slide pins to the front disc brake cylinder mounting LH.
25. INSTALL FRONT DISC BRAKE PAD KIT
(a) Install the 2 front disc brake pad support plates (No.1) and 2 front disc bra\
ke pad support plates (No.2) to the front disc brake cylinder mounting LH.
(b) Install the disc brake pad kit front to the front disc brake cylinder mo\
unting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads an\
d the disc.
26. INSTALL DISC BRAKE CYLINDER ASSY LH
(a) Install the disc brake cylinder assy LH with the 2 bolts.Torque: 30 N m (306 kgf cm, 22 ftlbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N m (296 kgfcm, 21 ftlbf)
HINT:
Install the flexible hose lock securely in the lock hole in the disc
brake cylinder assy LH.
27.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
28.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
29.BLEED BRAKE LINE (See page 32±4)
30.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
31. CHECK BRAKE FLUID LEAKAGE
32. INSTALL FRONT WHEEL
Torque: 103 N m (1,050 kgfcm, 76 ft lbf)
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