2003 TOYOTA AVENSIS brake fluid

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 ft
lbf)
(b) Install a new gasket and flexible hose with the union bolt.
Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
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 kgf
cm, 76 ft
lbf)
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320W0±01
G23181
Union bolt
G23224
F45701
Cylinder Slide Pin
F45417
Cylinder Slide Bush
Cylinder Slide Pin (No.2)
±
BRAKE REAR BRAKE
32±47
AVENSIS REPAIR MANUAL (RM1018E)
OVERHAUL
HINT:
Overhaul the RH side by using the same procedures as those for the LH side.
1. REMOVE REAR 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 REAR LH
(a) Remove the union bolt and gasket from the brake cylinderassy rear LH, then disconnect the flexible hose from the
disc brake cylinder assy rear LH.
(b) Hold the rear disc brake cylinder slide pin and remove the 2 bolts.
4. REMOVE REAR DISC BRAKE PAD KIT
(a) Remove the disc brake pad kit rear.
(b) Remove the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad support plates No.2 from the
rear disc brake cylinder mounting LH.
5. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a) Remove the rear disc brake cylinder slide pin (No.1) and rear disc brake cylinder slide pin (No.2) from the disc
brake cylinder mounting LH.
(b) Remove the rear disc brake cylinder slide bush from the bottom side of the rear disc brake cylinder slide pin (No.2).
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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
F45704
F42270
G23222
G23223
32±48
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
6. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 rear disc brake bush dust boots from the rear disc brake cylinder mounting LH.
7. REMOVE REAR DISC BRAKE CYLINDER MOUNTING LH
(a) Remove the 2 bolts and rear disc brake cylinder mounting LH.
8. REMOVE REAR DISC BRAKE PISTON
(a) Place a shop rug between the rear disc brake piston and the disc brake cylinder assy rear LH.
(b) Use compressed air to remove the rear disc brake piston from the disc brake cylinder assy rear 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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F45439
Front Disc Brake Cylinder MountingBush Dust Boot
Lithium soap base glycol grease
F45701
Cylinder Slide Pin
Lithium soap base glycol grease
G23181
Union bolt
±
BRAKEREAR BRAKE
32±51
AVENSIS REPAIR MANUAL (RM1018E)
25.INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a)Apply lithium soap base glycol grease to the sealing sur-
face of 2 new bush dust boots.
(b)Install the 2 bush dust boots to the rear disc brake cylinder mounting LH.
26.INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN KIT
(a)Apply lithium soap base glycol grease to sealing surface of a new cylinder slide bush.
(b)Install the rear disc brake cylinder slide bush to the bottom side of the rear 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 rear disc brake cylinder
slide pins.
(d)Install the rear disc brake cylinder slide pin (No.1) and rear
disc brake cylinder slide pin (No.2) to the rear disc brake
cylinder mounting LH.
27.INSTALL REAR DISC BRAKE PAD KIT
(a)Install the 2 rear disc brake pad support plates No.1 and 2 rear disc brake pad\
support plate No.2 to the rear disc brake cylinder mounting LH.
(b)Install the disc brake pad kit rear to the disc brake cylinder mounting \
LH.
28.INSTALL DISC BRAKE CYLINDER ASSY REAR LH
(a)Install the disc brake cylinder assy rear LH with the 2 bolts.Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
(b)Install a new gasket and flexible hose with the union bolt. Torque: 29 N
m (296 kgf
cm, 21 ft
lbf)
HINT:
Install the flexible hose lock securely in to the lock hole in the
disc brake cylinder assy rear LH.
29.FILL RESERVOIR WITH BRAKE FLUID (See page 32±4)
30.BLEED MASTER CYLINDER (See page 32±4)
(a) w/o VSC: SST 09023±00100
(b) w/ VSC: SST 09023±38400
31.BLEED BRAKE LINE (See page 32±4)
32.CHECK FLUID LEVEL IN RESERVOIR (See page 32±4)
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32±52
±
BRAKE REAR BRAKE
AVENSIS REPAIR MANUAL (RM1018E)
33. CHECK BRAKE FLUID LEAKAGE
34. INSTALL REAR WHEEL Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
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4206G±01
D30813
(a)
(a) (b)(b)
(a)
(b)
D30813
(a)
(a) (b)(b)
(a)
(b)
D26852
SST(s)
42±22
±
CLUTCH CLUTCH ACCUMULATOR ASSY (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. REMOVE BATTERY
2.REMOVE AIR TUBE NO.1 (See page 14±286) 3. REMOVE CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), disconnect the flexible hose tube.SST 09023±00100
HINT:
Use a container to catch the fluid.
(b) Remove a bolt, 2 nuts and clutch accumulator assy.
4. INSTALL CLUTCH ACCUMULATOR ASSY
(a) Using SST(s), connect the 2 flexible hose tubes to the clutch accumulator assy.
SST 09023±00100
(b) Install the clutch accumulator assy with the 2 nuts and a
bolt.
Torque: 12 N
m (120 kgf
cm, 9 ft
lbf)
(c) Using SST(s), tighten the flexible hose tube. SST 09023±00100
Torque: 15 N
m (155 kgf
cm, 11 ft
lbf)
5.INSTALL AIR TUBE NO.1 (See page 14±286)
6. INSTALL BATTERY
7. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the brake fluid and bleed clutch syst\
em. Torque: 8.3 N
m (85 kgf
cm, 73 in.
lbf)
8. CHECK CLUTCH FLUID LEAKAGE
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4206E±01
D30068
D30069
SST(s)
D30782
RHD Steering Position Type:
LHD Steering Position Type:
±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±13
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1. DRAIN CLUTCH FLUID
2. REMOVE BRAKE MASTER CYLINDER SUB±ASSY (LHD STEERING POSITION TYPE)
(See page 32±13)
3.REMOVE BRAKE BOOSTER ASSY (LHD STEERING POSITION TYPE) (See page 32±19)
4. DISCONNECT CLUTCH RESERVOIR TUBE
(a) Loosen the clip and disconnect the clutch reservoir tubefrom the clutch master cylinder assy.
HINT:
Use a container to catch the fluid.
5. DISCONNECT CLUTCH MASTER CYLINDER TO FLEXIBLE HOSE TUBE
(a) Using SST(s), disconnect the flexible hose tube. SST 09023±00100
HINT:
Use a container to catch the fluid.
6. REMOVE CLUTCH MASTER CYLINDER PUSH ROD
CLEVIS W/HOLE PIN
(a) Remove the clip and hole pin.
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±
CLUTCH CLUTCH MASTER CYLINDER ASSY (MTM)
42±15
AVENSIS REPAIR MANUAL (RM1018E)
15. BLEED CLUTCH PIPE LINE
(a) Fill the brake reservoir tank with the clutch fluid and bleed clutch sys\
tem.
Torque: 8.4 N
m (85 kgf
cm, 73 in.
lbf)
16. CHECK AND ADJUST BRAKE PEDAL HEIGHT (LHD STEERING POSITION TYPE) (See page 32±6)
17.INSPECT AND ADJUST CLUTCH PEDAL SUB±ASSY (See page 42±2)
18. CHECK BRAKE FLUID LEAKAGE (LHD STEERING POSITION TYPE)
19. CHECK CLUTCH FLUID LEAKAGE
20. CHECK FLUID LEVEL IN RESERVOIR
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