Page 2641 of 5135

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)
Page 2642 of 5135

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)
Page 2643 of 5135

400DA±02
D30339
Neutral
Basic Line
Groove
Neutral
Basic Line
GrooveU241E:
U341E: 40±8
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. INSPECT PARK/NEUTRAL POSITION SWITCH ASSY
(a) Apply the parking brake and turn the ignition switch ON.
(b) Depress the brake pedal and check that the engine starts only when the shift lever is set in N or P posi-
tion and it does not start in other position.
(c) Check that the back±up light is on and the reverse warning buzzer sounds only when the shift lever
is set in R position and these do not function in other position.
If a failure is found, check the park/neutral position switch for continuity.
2. ADJUST PARK/NEUTRAL POSITION SWITCH ASSY
(a) Loosen the 2 bolts of park/neutral position switch and set
the shift lever to the N position.
(b) Align the groove and neutral basic line.
(c) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(d) After adjustment, perform the inspection described in
step 1.
Page 2644 of 5135
4011W±01
D30337
U241E:
U341E:
C81535
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
40±3
AVENSIS REPAIR MANUAL (RM1018E)
PARK/NEUTRAL POSITION SWITCH ASSY (ATM)
REPLACEMENT
1. REMOVE ENGINE UNDER COVER LH
2. SEPARATE TRANSMISSION CONTROL CABLE ASSY
(a) Remove the nut from the control shaft lever.
(b) Separate the control cable from the control shaft lever.
(c) Remove the clip and separate the control cable from the
control cable bracket.
Page 2645 of 5135
D30338
U241E:
U341E:
C99454
D31059
D30919N 40±4
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
3. REMOVE PARK/NEUTRAL POSITION SWITCH ASSY
(a) Disconnect the park/neutral position switch connector.
(b) Remove the nut, washer and control shaft lever.
(c) Pry out the lock plate and remove the manual valve shaft
nut and lock plate.
(d) Remove the 2 bolts and pull out the park/neutral position
switch.
4. INSTALL PARK/NEUTRAL POSITION SWITCH ASSY
(a) U241E:
(1) Install the park/neutral position switch to the manual
valve shaft.
(2) Temporarily install the 2 bolts.
(3) Place a new lock plate and tighten the nut.
Torque: 6.9 Nm (70 kgfcm, 61 in.lbf)
(4) Temporarily install the control shaft lever.
(5) Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
(6) Remove the control shaft lever.
Page 2646 of 5135
C99456
GrooveNeutral
Basic Line
C99457
C99458
C62665
D31060
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
40±5
AVENSIS REPAIR MANUAL (RM1018E)
(7) Align the groove with the neutral basic line.
(8) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in.lbf)
(9) Using a screwdriver, stake the nut with the lock
plate.
(10) Install the control shaft lever, washer and nut.
Torque: 13 Nm (130 kgfcm, 9 ftlbf)
(11) Connect the park/neutral position switch connector.
(b) U341E:
(1) Install the park/neutral position switch to the manual
valve shaft.
(2) Temporarily install the 2 bolts.
(3) Place a new lock plate and tighten the nut.
Torque: 6.9 Nm (70 kgfcm, 61 in.lbf)
(4) Temporarily install the control shaft lever.
Page 2647 of 5135
C82031
N
G25654
Groove
Neutral
Basic Line
C62669
C82032
C81535
40±6
± AUTOMATIC TRANSMISSION / TRANSPARK/NEUTRAL POSITION SWITCH ASSY (ATM)
AVENSIS REPAIR MANUAL (RM1018E)
(5) Turn the lever counterclockwise until it stops, then
turn it clockwise 2 notches.
(6) Remove the control shaft lever.
(7) Align the groove with the Gneutral basic line.
(8) Hold the switch in position and tighten the 2 bolts.
Torque: 5.4 Nm (55 kgfcm, 48 in. lbf)
(9) Using a screwdriver, stake the nut with the lock
plate.
(10) Install the control shaft lever, washer and nut.
Torque: 13 Nm (130 kgfcm, 9 ftlbf)
(11) Connect the park/neutral position switch connector.
5. INSTALL TRANSMISSION CONTROL CABLE ASSY
(a) Install the control cable and clip to the control cable brack-
et.
Page 2648 of 5135
D30337
U241E:
U341E:
±
AUTOMATIC TRANSMISSION / TRANS PARK/NEUTRAL POSITION SWITCH ASSY(ATM)
40±7
AVENSIS REPAIR MANUAL (RM1018E)
(b)Temporarily install the control cable to the control shaft le-
ver with the nut.
6.ADJUST SHIFT LEVER POSITION (See page 40±69)
7.INSPECT SHIFT LEVER POSITION (See page 40±69)
8.INSPECT PARK/NEUTRAL POSITION SWITCH ASSY (See page 40±8)