Brake RM808U

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BR-47

BRAKE - ABS ACTUATOR

ABS ACTUATOR
BR0LL-05

COMPONENTS

15 (155, 11)

13 (130, 9)

Holder

ABS Actuator

Holder 15 (155, 11)

Cushion
Cushion

19 (195, 14)

Actuator Bracket
Air Cleaner Assembly
19 (195, 14)

N·m (kgf·cm, ft·lbf) : Specified torque


F09731

 3.0 (31, 27 in.·lbf)

ECU

Spring Plate

Actuator

N·m (kgf·cm, ft·lbf) : Specified torque


 Non-reusable part
W03328

2001 AVALON (RM808U)

Author: Date: 1446


BR-49
BRAKE - ABS ACTUATOR
BR0LN-03

DISASSEMBLY
1. DISCONNECT CONNECTOR
2. REMOVE ECU
(a) Using a T20 torx wrench, loosen the 6 screws.
Torque: 3.0 N·m (31 kgf·cm, 27 in.·lbf)
NOTICE:
At the time of reassembly, tighten the screws according to
the order shown on the left.
W03326
(b) Remove the ECU and spring plate from the actuator.
NOTICE:
Protect the actuator in order to prevent sealing surface
from getting dirty and causing damage on the valve body.
If the dirt and the like are stuck to the sealing surface, use
plastic tools or soft objects to remove the dirt. Do not use
chemical solvents.

2001 AVALON (RM808U)

Author: Date: 1448


BR-51
BRAKE - ABS ACTUATOR
BR0LP-04

INSTALLATION
Installation is in the reverse order of removal (See page BR-48 ).
HINT:
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
 Check for fluid leaks.

2001 AVALON (RM808U)

Author: Date: 1450


BR-50
BRAKE - ABS ACTUATOR
BR0LO-01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-49 ).

2001 AVALON (RM808U)

Author: Date: 1449


BR-48
BRAKE - ABS ACTUATOR
BR154-01

2 REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
1
2. DISCONNECT CONNECTOR
Pull out the release bar, and disconnect the connector.

F09732

3. DISCONNECT BRAKE LINES


Using SST, disconnect the 6 brake lines from the ABS actuator.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

F09733

4. REMOVE ABS ACTUATOR ASSEMBLY


Remove the 3 bolts and ABS actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
5. REMOVE ABS ACTUATOR
(a) Remove the 2 nuts and ABS actuator.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Remove the 2 holders and 3 cushions from the ABS ac-
tuator.
F09734

2001 AVALON (RM808U)

Author: Date: 1447


BR-53
BRAKE - ABS & VSC ACTUATOR
BR156-01

COMPONENTS

15 (155, 11)

15 (155, 11)
Air Cleaner Assembly
ABS & VSC Actuator Assembly
19 (195, 14)

19 (195, 14)

Holder
13 (130, 9)

ABS & VSC Actuator

Holder

13 (130, 9)
Cushion

Cushion

Actuator Bracket

N·m (kgf·cm, ft·lbf) : Specified torque


F09735

2001 AVALON (RM808U)

Author: Date: 1452


BR-55
BRAKE - ABS & VSC ACTUATOR
BR158-01

INSTALLATION
Installation is in the reverse order of removal (See page BR-54 ).
HINT:
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
 Check for fluid leaks.

2001 AVALON (RM808U)

Author: Date: 1454


BR-52
BRAKE - ABS & VSC ACTUATOR

TOYOTA Hand-held Tester ABS & VSC ACTUATOR BR155-01

ON-VEHICLE INSPECTION
1. CONNECT TOYOTA HAND-HELD TESTER:
(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the TOYOTA hand-
held tester.
DLC3 D07259
Please refer to the TOYOTA hand-held tester operator’s
manual for further details.
2. INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor opera-
tion 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 depressed.
(d) With the motor relay ON, check that the pedal does not
pulsate.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of 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 the solenoid which is not 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 solenoid ON for more than 10 seconds contin-
uously. When operating it continuously, set the interval of
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 re-
turns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds con-
tinuously. When operating it continuously, set the interval
of more than 20 seconds.
(e) Turn the motor relay OFF and release the brake pedal.
4. INSPECT OTHER WHEEL OPERATION
As in the same procedure, check the solenoids of other wheels.
HINT:
Left front wheel: SFLH, SFLR
Right rear wheel: SRRH, SRRR
Left rear wheel: SRLH, SRLR
5. CLEAR DTC (See page DI-252 )
2001 AVALON (RM808U)

Author: Date: 1451


BR-54
BRAKE - ABS & VSC ACTUATOR
BR157-01

REMOVAL
1. REMOVE AIR CLEANER ASSEMBLY
2. DISCONNECT ABS & VSC ACTUATOR CONNECTOR

3. DISCONNECT BRAKE LINES


Using SST, disconnect the 6 brake lines from the ABS & VSC
actuator.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

F09736

4. REMOVE ABS & VSC ACTUATOR ASSEMBLY


Remove the 3 bolts and ABS & VSC actuator assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)
5. REMOVE ABS & VSC ACTUATOR
(a) Remove the 2 nuts and ABS & VSC actuator from the
bracket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(b) Remove the 2 holders and 3 cushions from the ABS &
F09737 VSC actuator.

2001 AVALON (RM808U)

Author: Date: 1453


BR-22
BRAKE - BRAKE BOOSTER ASSEMBLY
BR0KX-04

COMPONENTS
Air Cleaner with Air Cleaner Hose
Return Spring
Pin
Vacuum Hose
Wave Washer
Master Cylinder
15 (155, 11)

Clip
2-way Clevise
Level Warning Switch 12 (260, 19)
13 (130, 9)
Connetor
 Gasket
13 (130, 9) Brake Booster Assembly

w/ VSC: 19 (195, 14)


15 (155, 11) 13 (130, 9)
19 (195, 14)

Precharge Pump Assembly

Lower LH Instrument
Panel Insert

Lower No. 1 Instrument


Panel

No. 2 Heater to Register Duct

N·m (kgf·cm, ft·lbf) : Specified torque


 Non-reusable part F09719

2001 AVALON (RM808U)

Author: Date: 1421


BR-24
BRAKE - BRAKE BOOSTER ASSEMBLY
BR152-01

INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)
(d) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.

2. ADJUST LENGTH OF BOOSTER PUSH ROD


Master (a) Set the SST on the master cylinder, and lower the pin until
Cylinder its tip slightly touches the piston.
SST 09737-0001 1
SST

F05420

(b) Turn the SST upside down, and set it on the booster.
SST
SST 09737-0001 1
(c) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)

F05422

(d) Using SST, adjust the booster push rod length until the
push rod lightly touches the pin head.
SST 09737-00020
3. w/ VSC:
INSTALL PRECHARGE PUMP ASSEMBLY (See page
BR-58 )
4. INSTALL MASTER CYLINDER (See page BR-20 )
SST 5. CONNECT VACUUM HOSE TO BRAKE BOOSTER
F05421 6. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4 )
7. CHECK FOR LEAKS
8. CHECK AND ADJUST BRAKE PEDAL (See page
BR-6 )
9. INSTALL NO. 2 HEATER TO REGISTER DUCT, LOWER
LH INSTRUMENT PANEL INSERT AND LOWER NO. 1
INSTRUMENT PANEL (See page BO-87 )
10. DO OPERATIONAL CHECK (See page BR-21 )

2001 AVALON (RM808U)

Author: Date: 1423


BR-21
BRAKE - BRAKE BOOSTER ASSEMBLY

BRAKE BOOSTER ASSEMBLY BR0KW-04

ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
BR2237
goes down slightly, operation is normal.

2. AIR TIGHTNESS CHECK


GOOD NO GOOD
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
3rd stop the engine with the pedal depressed.
2nd If there is no change in the pedal reverse travel after holding the
1st
BR2238 pedal for 30 seconds, the booster is air tight.

2001 AVALON (RM808U)

Author: Date: 1420


BR-23
BRAKE - BRAKE BOOSTER ASSEMBLY
BR0KY-05

REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15 )
3. w/ VSC:
REMOVE PRECHARGE PUMP ASSEMBLY (See page
BR-57 )
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH INSTRUMENT PANEL INSERT AND NO. 2
HEATER TO REGISTER DUCT (See page BO-87 )

6. REMOVE BRAKE BOOSTER ASSEMBLY


(a) Remove the pedal return spring.
(b) Remove the clip and clevis pin.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster and gasket.

F06431

2001 AVALON (RM808U)

Author: Date: 1422


BR-13
BRAKE - BRAKE MASTER CYLINDER

BRAKE MASTER CYLINDER


BR0KQ-04

COMPONENTS

Air Cleaner Cover with


Air Cleaner Hose
w/ VSC:

3-way

Master Cylinder

Level Warning Switch Connetor

15 (155, 11)

2-way

13 (130, 9)

13 (130, 9)

Brake Booster
15 (155, 11)

N·m (kgf·cm, ft·lbf) : Specified torque


F09712

2001 AVALON (RM808U)

Author: Date: 1412


BR-14
BRAKE - BRAKE MASTER CYLINDER

w/o VSC:

Cap

Strainer

Reservoir Set Screw Reservoir


1.7 (17.5, 15.2 in.·lbf) Snap Ring

 O-Ring
Grommet

Grommet

No. 1 Piston and Spring


Cylinder Body
No. 2 Piston and Spring

 Gasket
Stopper Bolt
10 (100, 7)

w/ VSC:
Cap

Strainer

Reservoir Set Screw Reservoir


1.7 (17.5, 15.2 in.·lbf)

Snap Ring

 O-Ring
Straight Pin

Grommet

Grommet

No. 1 Piston and Spring

No. 2 Piston and Spring

Cylinder Body
N·m (kgf·cm, ft·lbf) : Specified torque
 Non-reusable part
Lithium soap base giycol grease F09748

2001 AVALON (RM808U)

Author: Date: 1413


BR-16
BRAKE - BRAKE MASTER CYLINDER
BR0KS-03

DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N·m (17.5 kgf·cm, 15.2 in.·lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. w/o VSC:
PLACE CYLINDER IN VISE

4. w/o VSC:
Soft Jows
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)

F09715

5. w/o VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
Soft Jows straight out, not at an angle.
F09716 NOTICE:
 If pulled out and install at an angle, there is a possibil-
ity that the cylinder bore could be damaged.
 At the time of reassembly, be careful not to damage
the rubber lips on the pistons.

(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).
A

R12236

2001 AVALON (RM808U)

Author: Date: 1415


BR-17
BRAKE - BRAKE MASTER CYLINDER

6. w/ VSC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the
straight pin by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 piston and springs by hand, pulling straight
out, not at an angle.
F09717 NOTICE:
 If pulled out and installed at an angle, there is a possi-
bly that the cylinder bore could be damaged.

 At the time of reassembly, be careful not to damage


the rubber lips on the pistons.
HINT:
Insert the No. 2 piston with the groove positioning horizontally.

F09718

2001 AVALON (RM808U)

Author: Date: 1416


BR-18
BRAKE - BRAKE MASTER CYLINDER
BR0KT-01

INSPECTION
HINT:
Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE
If necessary, clean or replace the cylinder.

2001 AVALON (RM808U)

Author: Date: 1417


BR-20
BRAKE - BRAKE MASTER CYLINDER
BR0KV-05

INSTALLATION
Installation is in the reverse order of removal (See page BR-15 ).
HINT:
 Before installation, adjust length of brake booster push rod (See page BR-24 ).
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ), and
check for leaks.
 Check and adjust brake pedal (See page BR-6 ).

2001 AVALON (RM808U)

Author: Date: 1419


BR-19
BRAKE - BRAKE MASTER CYLINDER
BR0KU-01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See-page BR-16 ).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR-13 ).

2001 AVALON (RM808U)

Author: Date: 1418


BR-15
BRAKE - BRAKE MASTER CYLINDER
BR0KR-02

REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
4. w/ VSC:
DISCONNECT RESERVOIR HOSE

5. DISCONNECT BRAKE LINES


(a) w/o VSC:
Using SST, disconnect the 4 brake lines from the master
cylinder and 2-way.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)
(b) w/ VSC:
Using SST, disconnect the 5 brake lines from the master
SST F09713 cylinder and 3-way.
SST 09023-00100
Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

6. REMOVE MASTER CYLINDER


Remove the 2 mounting nuts, and pull out the 2 or 3-way, mas-
ter cylinder and gasket.
Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

F09714

2001 AVALON (RM808U)

Author: Date: 1414


BR-4
BRAKE - BRAKE FLUID

BRAKE FLUID BR14Z-01

BLEEDING
HINT:
If any work is done on the brake system or if air in the brake lines
is suspected, bleed the air from the system.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.

1. FILL BRAKE RESERVOIR WITH BRAKE FLUID


Check the fluid level in the reservoir after bleeding each wheel.
Add fluid, if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3

F09707

2. BLEED MASTER CYLINDER


HINT:
If the master cylinder has been disassembled or if the reservoir
becomes empty, bleed the air from the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
(b) Slowly depress the brake pedal and hold it.

F09708

(c) Block off the outlet plugs with your fingers, and release
the brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.

F09709

3. CONNECT VINYL TUBE TO BRAKE CALIPER BLEED-


ER PLUG
Insert other end of the tube in a half-full container of brake fluid.
NOTICE:
Bleed air of the rear brake first. If front brake is bled first,
rear brake air cannot be bled.
4. BLEED BRAKE LINE
(a) Slowly depress the brake pedal several times.
R00699

2001 AVALON (RM808U)

Author: Date: 1403


BR-5
BRAKE - BRAKE FLUID

(b) While an assistant depresses the pedal, loosen the


bleeder plug until fluid starts to run out. Then tighten the
bleeder plug.
(c) Repeat this procedure until there are no more air bubbles
in the fluid.
Bleeder plug tightening torque:
8.3 N·m (85 kgf·cm, 74 in.·lbf)
5. REPEAT PROCEDURE FOR EACH WHEEL

6. w/ VSC:
SST BLEED PRECHARGE PUMP
CAUTION:
When repairing the brake master cylinder or precharge
pump, bleed the precharge pump of the air.
(a) Install the SST to the reservoir.
SST 09992-00242, 09992-00350
(b) Using SST, apply pressure to the reservoir.
F10182 Pressure: 98.1 kpa (1.0 kgf/cm2, 14.2 psi)
(c) Disconnect the precharge pump connector.
1 2
(d) Connect ML+ (2) terminal to the battery positive (+) and
ML- (1) terminal to the battery negative (-), and activate
the precharge pump about 20 seconds.
(e) Remove the SST from the reservoir.
(f) Connect the vinyl tube to the front brake caliper RH, and
(-) (+) loosen the bleeder plug.
(g) Activate the precharge pump again until there are no
more air bubbles in the fluid.
F07901 Bleeder plug tightening torque:
8.3 N·m (85 kgf·cm, 74 in.·lbf)
(h) Connect the precharge pump connector.
7. CHECK FLUID LEVEL IN RESERVOIR
Check the fluid level and add fluid if necessary.
Fluid: SAE J1703 or FMVSS No. 116 DOT3

2001 AVALON (RM808U)

Author: Date: 1404


BR-8
BRAKE - BRAKE PEDAL
BR150-01

COMPONENTS

Lower No. 1 Instrument Panel

Brake Pedal Assembly

13 (130, 9)

Lower LH Panel Insert

13 (130, 9)

Stop Light Switch

Brake Pedal Bracket

Cruise Control ECU 5.0 (51, 44 in.·lbf)

Collar  Bushing
Cushion Plate
 Bushing
Clevis Pin
39 (400, 29)

Clip
Wave Washer
Return Spring

N·m (kgf·cm, ft·lbf) : Specified torque Pedal Pad


 Non-reusable part
Lithium soap base glycol grease Brake Pedal
F09720

2001 AVALON (RM808U)

Author: Date: 1407


BR-6
BRAKE - BRAKE PEDAL

BRAKE PEDAL
Stop Light Switch BR0KI-04

ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
153.3 - 163.3 mm (6.035 - 6.429 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Push Rod (a) Remove the lower No. 1 instrument panel and lower LH
instrument panel insert (See page BO-87 ).
(b) Disconnect the connector from the stop light switch.
(c) Loosen the stop light switch lock nut and remove the stop
light switch.
(d) Loosen the push rod lock nut.
(e) Adjust the pedal height by turning the pedal push rod.
Pedal Height
(f) Tighten the push rod lock nut.
Torque: 25 N·m (260 kgf·cm, 19 ft·lbf)
(g) Install the stop light switch.
R00954
(h) Connect the connector to the stop light switch.
(i) Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn
the stop light switch to lock the nut in the position where
the stop light goes off.
(j) After installation, push the brake pedal in 5 - 15 mm (0.20
- 0.59 in.), check that stop light lights up.
(k) After adjusting the pedal height, check the pedal freeplay.
(l) Install the lower LH instrument panel insert and lower No.
1 instrument panel (See page BO-87 ).

3. CHECK PEDAL FREEPLAY


(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
Pedal Freeplay (b) Push in the pedal by hand until the beginning of the resis-
tance is felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
R00935 Stop light switch clearance:
0.5 - 2.4 mm (0.020 - 0.094 in.)
HINT:
The freeplay to the 1st resistance is due to the play between the
clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 in.)
at the pedal.

2001 AVALON (RM808U)

Author: Date: 1405


BR-7
BRAKE - BRAKE PEDAL

4. CHECK PEDAL RESERVE DISTANCE


Pedal Reserve Distance
Release the parking brake.
With the engine running, depress the pedal and measure the
pedal reserve distance, as shown.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf): More than 75 mm (3.0 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.
R00934

2001 AVALON (RM808U)

Author: Date: 1406


BR-1
BRAKE - BRAKE SYSTEM

BRAKE SYSTEM
BR0MH-01

PRECAUTION
 Care must be taken to replace each part properly as it could affect the performance of the brake
system and result in a driving hazard. Replace the parts with parts of the same part number or
equivalent.
 It is very important to keep parts and the area clean when repairing the brake system.
 If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.

2001 AVALON (RM808U)

Author: Date: 1400


BR-28
BRAKE - FRONT BRAKE CALIPER

FRONT BRAKE CALIPER


BR0L2-04

COMPONENTS
107 (1,090, 79)
Caliper
Torque Plate 29 (300, 22)

34 (350, 25)
Disc

Bleeder Plug
8.3 (85, 74 in.·lbf)
29 (300, 22)

 Gasket
Sliding Pin
 Sliding Bushing
Piston
 Dust Boot

Set Ring

Piston Seal
Boot

Sliding Pin Pad Support Plate


 Dust Boot

Pad Wear Indicator Plate


Anti-squeal Shim
Inner Pad
Outer Pad
Inner Anti-squeal Shim
Inner Anti-squeal Shim Anti-squeal Shim

N·m (kgf·cm, ft·lbf) : Specified torque


 Non-reusable part
Lithium soap base glycol grease
Disc brake grease
F06986

2001 AVALON (RM808U)

Author: Date: 1427


BR-30
BRAKE - FRONT BRAKE CALIPER
BR0L4-04

DISASSEMBLY
1. REMOVE SET RING AND CYLINDER BOOT
Using a screwdriver, remove the set ring and cylinder boot from
the caliper.

R00121

2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
the caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
R00122

3. REMOVE PISTON SEAL


Using a screwdriver, remove the piston seals from the cylinder.

R00123

4. REMOVE SLIDING PINS AND DUST BOOTS


(a) Remove the 2 sliding pins from the torque plate.
NOTICE:
At the time of reassembly, insert the sliding pin with sliding
bushing into the top side.
(b) Using a screwdriver and hammer, tap out the 2 dust
boots.
HINT:
R02877 At the time of reaseembly, use a 24 mm socket wrench and tap
in 2 new dust boots into the torque plate.
NOTICE:
At the time of reassembly, confirm that the metal plate por-
tion of the dust boot fits snugly in the torque plate.

2001 AVALON (RM808U)

Author: Date: 1429


BR-31
BRAKE - FRONT BRAKE CALIPER
BR0L5-04

INSPECTION
1. MEASURE PAD LINING THICKNESS
Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 1.0 mm (0.039 in.)
Replace the pad if the pad’s thickness is at the minimum thick-
ness or less, or if the pad has severe, uneven wear.

F06988

2. MEASURE DISC THICKNESS


Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
Replace the disc if the disc’s thickness is at the minimum thick-
ness or less. Replace the disc or grind it on a lathe if it is badly
scored or worn unevenly.

F06395

3. MEASURE DISC RUNOUT


Using a dial indicator, measure the disc runout 10 mm (0.39 in.)
from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
If the disc’s runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA-9 ). If the bearing play and axle hub runout are
not abnormal, adjusting the disc runout or grind it on a ”On-Car”
F06396 brake lathe.

4. IF NECESSARY, ADJUST DISC RUNOUT


(a) Remove the mounting bolts and torque plate from the
knuckle.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5
of a turn round from its original position on the hub. Install
and torque the hub nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
Remeasure the disc runout. Make a note of the runout
F06397 and the disc’s position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.05 mm (0.0020 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.05 mm (0.0020 in.), replace the disc and repeat
step 3.
(f) Install the torque plate and torque the mounting bolts.
Torque: 107 N·m (1,090 kgf·cm, 79 ft·lbf)

2001 AVALON (RM808U)

Author: Date: 1430


BR-33
BRAKE - FRONT BRAKE CALIPER
BR0L7-04

INSTALLATION
Installation is in the reverse order of removal (See page BR-29 ).
HINT:
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
 Check for fluid leaks.

2001 AVALON (RM808U)

Author: Date: 1432


BR-32
BRAKE - FRONT BRAKE CALIPER
BR0L6-01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-30 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR-28 ).

2001 AVALON (RM808U)

Author: Date: 1431


BR-29
BRAKE - FRONT BRAKE CALIPER
BR0L3-04

REMOVAL
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
R02840
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, install the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 2 PAD SUPPORT PLATES

2001 AVALON (RM808U)

Author: Date: 1428


BR-25
BRAKE - FRONT BRAKE PAD

FRONT BRAKE PAD


BR0L0-04

COMPONENTS

34 (350, 25)

Anti-squeal Shim

Inner Anti-squeal Shim

Pad Wear Indicator Plate

Outer Pad

Pad Support Plate

Inner Pad

N·m (kgf·cm, ft·lbf) : Specified torque


Disc brake grease
F06983

2001 AVALON (RM808U)

Author: Date: 1424


BR-26
BRAKE - FRONT BRAKE PAD
BR0L1-04

REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if it is not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the bolt and flexible hose from the shock absorb-
F06984
er bracket.
(b) Remove the bottom side installation bolt.
(c) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL
SHIMS
5. REMOVE PAD WEAR INDICATOR PLATE
6. REMOVE 2 PAD SUPPORT PLATES
NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
7. CHECK DISC THICKNESS AND RUNOUT (See page
BR-31 )
8. INSTALL 2 PAD SUPPORT PLATES

9. INSTALL NEW PADS


NOTICE:
When replacing worn pads, the anti-squeal shims and
wear indicator plates must be replaced together with the
pads.
(a) Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to both sides of the inner anti-
squeal shims (See page BR-25 ).
F06985 (c) Install the 2 anti-squeal shims on each pad.
(d) Install inner pad with the pad wear indicator plate facing
upward.
(e) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.

2001 AVALON (RM808U)

Author: Date: 1425


BR-27
BRAKE - FRONT BRAKE PAD

10. INSTALL CALIPER


(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
R02981 (d) Hold the sliding pin and torque the installation bolt.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
(e) Install the flexible hose and bolt to the shock absorber
bracket.
Torque: 29 N·m (300 kgf·cm, 21 ft·lbf)
11. INSTALL FRONT WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
12. DEPRESS BRAKE PEDAL SEVERAL TIMES
13. CHECK THAT FLUID LEVEL IS AT MAX LINE

2001 AVALON (RM808U)

Author: Date: 1426


BR-59
BRAKE - FRONT SPEED SENSOR

FRONT SPEED SENSOR


BR0LU-02

COMPONENTS

Sensor Rotor

8.0 (82, 71 in.·lbf)

5.4 (55, 48 in.·lbf)

Front Speed Sensor

N·m (kgf·cm, ft·lbf) : Specified torque


F09738

2001 AVALON (RM808U)

Author: Date: 1458


BR-61
BRAKE - FRONT SPEED SENSOR
BR0LW-03

INSTALLATION
Installation is in the reverse order of removal (See page BR-60 ).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 )

2001 AVALON (RM808U)

Author: Date: 1460


BR-60
BRAKE - FRONT SPEED SENSOR
BR0LV-03

REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the fender liner.
(b) Disconnect the speed sensor connector.

R00327

2. REMOVE SPEED SENSOR


(a) Remove the 2 clamp bolts holding the sensor harness to
the body and shock absorber.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(b) Remove the bolt and speed sensor from the steering
knuckle.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)

F09739

2001 AVALON (RM808U)

Author: Date: 1459


BR-43
BRAKE - PARKING BRAKE

PARKING BRAKE
BR0LG-03

COMPONENTS

Adjuster

Guide Plate

Spring
Shoe Strut
47 (475, 34)
Shoe Return Spring
Pin
Shim
 C-washer
Parking Brake 47 (475, 34)
Lever
Cap
Pin
Adjuster Shoe Hold-down Spring
Front Shoe Rear Disc Brake
Rear Shoe Assembly

Tension Spring
Cap

Plug
N·m (kgf·cm, ft·lbf) : Specified torque
 Non-reusable part Disc
High temperature grease
F09730

2001 AVALON (RM808U)

Author: Date: 1442


BR-44
BRAKE - PARKING BRAKE
BR0LH-03

DISASSEMBLY
1. REMOVE REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. REMOVE REAR DISC BRAKE ASSEMBLY
(a) Remove the 2 mounting bolts and remove the disc brake
assembly.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)
(b) Suspend the disc brake securely. Ensure that the hose is
W04053
not stretched.

3. REMOVE DISC
Release the parking brake pedal, and remove the disc.
HINT:
If the disc cannot be removed easily, turn the shoe adjuster until
the wheel turns freely.

R00309

4. REMOVE SHOE RETURN SPRINGS


Using needle-nose pliers, remove the 2 shoe return springs.
5. REMOVE FRONT SHOE, ADJUSTER AND TENSION
SPRING
(a) Disconnect the tension spring from the front shoe.
(b) Slide out the front shoe and remove the shoe adjuster.
(c) Remove the shoe strut with the spring.
(d) Remove the shoe hold-down spring, 2 caps and pin.
BR3948

6. REMOVE REAR SHOE


(a) Slide out the rear shoe and remove the tension spring.
(b) Remove the shoe hold-down spring, 2 caps and pin.
(c) Using needle-nose pliers, disconnect the parking brake
cable from the parking brake shoe lever.

R00310

2001 AVALON (RM808U)

Author: Date: 1443


BR-45
BRAKE - PARKING BRAKE
BR0LI-03

INSPECTION
1. INSPECT DISASSEMBLED PARTS
Inspect the disassembled parts for wear, rust or damage.
2. MEASURE BRAKE SHOE LINING THICKNESS
Using a ruler, measure the thickness of the shoe lining.
Standard thickness: 2.0 mm (0.079 in.)
Minimum thickness: 1.0 mm (0.039 in.)
If the lining thickness is at the minimum thickness or less, or if
R00311
there is severe, uneven wear, replace the brake shoe.

3. MEASURE DISC INSIDE DIAMETER


Using a brake drum gauge or equivalent, measure the inside di-
ameter of the disc.
Standard inside diameter: 170 mm (6.69 in.)
Maximum inside diameter: 171 mm (6.73 in.)
Replace the disc if the inside diameter is at the maximum value
or more. Replace the disc or grind it with a lathe if the disc is
scored or worn unevenly.
F06409

4. INSPECT PARKING BRAKE LINING AND DISC FOR


PROPER CONTACT
Apply chalk to the inside surface of the disc, then grind down
the brake shoe lining to fit. If the contact between the disc and
the brake shoe lining is improper, repair it using a brake shoe
grinder or replace the brake shoe assembly.

BR0828

Shim 5. MEASURE CLEARANCE BETWEEN PARKING


BRAKE SHOE AND LEVER
Using a feeler gauge, measure the clearance.
Standard clearance: Less than 0.35 mm (0.0138 in.)
If the clearance is not within the specification, replace the shim
with one of the correct size.
Shim Thickness Shim Thickness
0.3 mm (0.012 in.) 0.9 mm (0.035 in.)
Clearance R00343
0.6 mm (0.024 in.) -

6. IF NECESSARY, REPLACE SHIM


(a) Using a screwdriver, remove the C-washer and shim.
(b) Install the correct size shim with a new C-washer.
(c) Remeasure the clearance.

R00313

2001 AVALON (RM808U)

Author: Date: 1444


BR-46
BRAKE - PARKING BRAKE
BR0LJ-03

REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page BR-44 ).
NOTICE:
Apply high temperature grease to the parts indicated by the
arrows (See page BR-43 ).
1. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug.

(c) Turn the adjuster and expand the shoes until the disc
locks.
Contract (d) Return the adjuster 8 notches.
(e) Install the hole plug.
2. SETTLING PARKING BRAKE SHOES AND DISC
(a) Depress the parking brake pedal with 147 N (15 kgf, 33
lbf).
Expand (b) Drive the vehicle at about 50 km/h (31 mph) on a safe, lev-
BR0823 el and dry road.
(c) Drive the vehicle for about 400 meters (0.25 mile) in this
condition.
(d) Repeat this procedure 2 or 3 times.
3. RECHECK AND ADJUST PARKING BRAKE PEDAL
TRAVEL (See page BR-9 )

2001 AVALON (RM808U)

Author: Date: 1445


BR-10
BRAKE - PARKING BRAKE PEDAL
BR0KK-03

COMPONENTS

No. 2 Heater to Register Duct

Lower LH Panel Insert

Lower No. 1 Instrument Panel

61 (620, 45)

Parking Brake Pedal Assembly

Parking Brake Switch

Clip
61 (620, 45)

Cushion

Pedal Pad 61 (620, 45)

Parking Brake Cable

N·m (kgf·cm, ft·lbf) : Specified torque


F09711

2001 AVALON (RM808U)

Author: Date: 1409


BR-12
BRAKE - PARKING BRAKE PEDAL
BR0KM-03

INSTALLATION
Installation is in the reverse order of removal (See page BR-1 1).
AFTER INSTALLATION, ADJUST PARKING BRAKE PEDAL TRAVEL (See page BR-6 )

2001 AVALON (RM808U)

Author: Date: 1411


BR-9
BRAKE - PARKING BRAKE PEDAL

PARKING BRAKE PEDAL BR0KJ-02

ON-VEHICLE INSPECTION
1. CHECK PARKING BRAKE PEDAL TRAVEL
Slowly depress the parking brake pedal all the way, and count
the number of clicks.
Parking brake pedal travel at 294 N (30 kgf, 66 lbf):
3 - 6 clicks
R00254
If incorrect, adjust the parking brake.

Adjusting Hexagon
2. IF NECESSARY, ADJUST PARKING BRAKE PEDAL
TRAVEL
HINT:
Before adjusting the parking brake, make sure that the rear
brake shoe clearance has been adjusted.
For shoe clearance adjustment, see step 1 on page BR-46 .
(a) Floor shift:
Remove the console box.
Lock Nut No. 4 Cable (b) Column shift:
F09710

Remove the hole cover.


(c) Confirm that the parking brake pedal is released.
(d) Hold the screw end of No. 4 cable not to rotate.
(e) Loosen the lock nut.

(f) Hold the parking brake cable and turn the adjusting hexa-
gon until the pedal travel is correct.
NOTICE:
To prevent the parking brake cable from twisting, always
Red Paint keep the red-painted surface up.
(g) Holding the adjusting hexagon, tighten the lock nut.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
(h) Floor shift:
W03176 Install the console box.
(i) Column shift:
Install the hole cover.

2001 AVALON (RM808U)

Author: Date: 1408


BR-1 1
BRAKE - PARKING BRAKE PEDAL
BR151-01

REMOVAL
1. REMOVE LOWER NO. 1 INSTRUMENT PANEL, LOW-
ER LH PANEL INSERT AND NO. 2 HEATER TO REG-
ISTER DUCT (See page BO-87 )
2. RELEASE PARKING BRAKE PEDAL

3. REMOVE PARKING BRAKE PEDAL ASSEMBLY


(a) Disconnect the parking brake switch connector.
(b) Remove the clip, and disconnect the parking brake cable.

F09746

(c) Remove the 3 nuts and parking brake pedal assembly.


Torque: 61 N·m (620 kgf·cm, 45 ft·lbf)
(d) Remove the parking brake switch and cushion from the
parking brake pedal assembly.

F09747

2001 AVALON (RM808U)

Author: Date: 1410


BR-56
BRAKE - PRECHARGE PUMP

PRECHARGE PUMP
BR159-01

COMPONENTS
Air Cleaner Cover With Air Cleaner Hose
Level Warning Switch Connector

Master Cylinder
19 (195, 14)

3-way

15 (155, 11)

13 (130, 9)

19 (195, 14)
Precharge Pump Assembly

15 (155, 11)
Master Cylinder Pressrue Sensor
81 (830, 60)

Spacer
 O-Ring
Precharge Pump

20 (200, 15)
Cushion

Holder
Precharge Pump Bracket

Collar
Cushion
Washer
8.0 (82, 71in.·lbf)
13 (130, 9)

N·m (kgf·cm, ft·lbf) : Specified torque


 Non-reusable part F09741

2001 AVALON (RM808U)

Author: Date: 1455


BR-58
BRAKE - PRECHARGE PUMP
BR15B-01

INSTALLATION
Installation is in the reverse order of removal (See page BR-57 ).
HINT:
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
 Check for fluid leaks.

2001 AVALON (RM808U)

Author: Date: 1457


BR-57
BRAKE - PRECHARGE PUMP
BR15A-01

REMOVAL
1. REMOVE AIR CLEANER CASE WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR-15 )
3. DISCONNECT PRECHARGE PUMP CONNECTOR

4. REMOVE PRECHARGE PUMP ASSEMBLY


(a) Remove the 3 bolts and precharge pump assembly.
Torque: 19 N·m (195 kgf·cm, 14 ft·lbf)

F09742

(b) Using SST, disconnect the 2 brake lines from the prechar-
ge pump.
SST 09751-3601 1
Torque:
10 mm nut: 15 N·m (155 kgf·cm, 11 ft·lbf)
12 mm nut: 20 N·m (200 kgf·cm, 15 ft·lbf)

SST
F09743

5. REMOVE PRECHARGE PUMP


(a) Remove the 2 nuts, 2 bolts and precharge pump from the
pump bracket.
Torque:
Nut: 13 N·m (130 kgf·cm, 9 ft·lbf)
Bolt: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
(b) Remove the 2 holders, 2 collars, 2 washers and 4 cush-
ions.
F09744

6. REMOVE MASTER CYLINDER PRESSURE SENSOR


(a) Place the precharge pump in a vise with a cloth shown in
the illustration on the left.
(b) Using 30 mm deeper socket wrench, and remove the
master cylinder pressure sensor, O-ring and spacer.
Torque: 81 N·m (830 kgf·cm, 60 ft·lbf)

F09745

2001 AVALON (RM808U)

Author: Date: 1456


BR-37
BRAKE - REAR BRAKE CALIPER

REAR BRAKE CALIPER


BR0LA-03

COMPONENTS

Disc

 Gasket

34 (350, 25)
29 (300, 22)
Plug
Flexble Hose Bleeder Plug
8.3 (85, 74 in.·lbf)
 Gasket
Brake Caliper
34 (350, 25)

Inner Anti-squeal Shim


47 (475, 34)  Dust Boot
Piston Seal
Pad Support Plate
Anti-squeal Shim  Sliding Bushing

Piston
47 (475, 34)
Boot

Inner Pad Outer Pad


Set Ring

Pad Support Plate Torque Plate


Anti-squeal Shim

N·m (kgf·cm, ft·lbf) : Specified torque


 Non-reusable part Inner Anti-squeal Shim
Lithium soap bass glycol grease
Disc brake grease
F09724

2001 AVALON (RM808U)

Author: Date: 1436


BR-39
BRAKE - REAR BRAKE CALIPER
BR153-01

DISASSEMBLY
1. REMOVE CYLINDER BOOT SET RING AND CYL-
INDER BOOT
Using a screwdriver, remove the cylinder boot set ring and cylin-
der boot from the cylinder.

F09726

2. REMOVE PISTON
(a) Place a piece of cloth or similar, between the piston and
caliper.
(b) Use compressed air to remove the piston from the cylin-
der.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
F09727

3. REMOVE PISTON SEAL


Using a screwdriver, remove the piston seal from the cylinder.
4. REMOVE 2 DUST BOOTS

F09728

2001 AVALON (RM808U)

Author: Date: 1438


BR-40
BRAKE - REAR BRAKE CALIPER
BR0LD-03

INSPECTION
1. MEASURE PAD LINING THICKNESS (See page
BR-31 )
Standard thickness: 10.0 mm (0.394 in.)
Minimum thickness: 1.0 mm (0.039 in.)
2. MEASURE DISC THICKNESS
(See step 2 on page BR-31 )
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 10.5 mm (0.413 in.)
3. MEASURE DISC RUNOUT
(See step 3 on page BR-31 )
Maximum disc runout: 0.15 mm (0.0059 in.)
If the disc’s runout is at the maximum value or greater, check the
bearing play in the axial direction and check the axle hub runout
(See page SA-45 ). If the bearing play and axle hub runout are
not abnormal, adjusting the disc runout or grind it on a ”On-Car”
brake lathe.
4. IF NECESSARY, ADJUST DISC RUNOUT
(a) Remove the 2 bolts and torque plate.
(b) Remove the hub nuts and the disc. Reinstall the disc 1/5
of a turn round from its original position on the hub. Install
and torque the hub nuts.
Torque: 103 N·m (1050 kgf·cm, 76 ft·lbf)
Remeasure the disc runout. Make a note of the runout
and the disc’s position on the hub.
(c) Repeat (b) until the disc has been installed on the 3 re-
maining hub positions.
(d) If the minimum runout recorded in (b) and (c) is less than
0.15 mm (0.0059 in.), install the disc in that position.
(e) If the minimum runout recorded in (b) and (c) is greater
than 0.15 mm (0.0059 in.), replace the disc and repeat
step 3.

(f) Install the torque plate and torque the mounting bolts.
Torque: 47 N·m (475 kgf·cm, 34 ft·lbf)

F09729

2001 AVALON (RM808U)

Author: Date: 1439


BR-42
BRAKE - REAR BRAKE CALIPER
BR0LF-03

INSTALLATION
Installation is in the reverse order of removal (See page BR-38 ).
HINT:
 After installation, fill the brake reservoir with brake fluid, bleed brake system (See page BR-4 ).
 Check for fluid leaks.

2001 AVALON (RM808U)

Author: Date: 1441


BR-41
BRAKE - REAR BRAKE CALIPER
BR0LE-01

REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR-39 ).
NOTICE:
Apply lithium soap base glycol grease to the parts indicated by the arrows (See page BR-37 ).

2001 AVALON (RM808U)

Author: Date: 1440


BR-38
BRAKE - REAR BRAKE CALIPER
BR0LB-02

REMOVAL
1. REMOVE REAR WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
F09725
Torque: 29 N·m (300 kgf·cm, 22 ft·lbf)
HINT:
At the time of installation, insert the flexible hose lock securely
in the lock hole in the caliper.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) Remove the 2 installation bolts.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
NOTICE:
At the time of installation, insert the sliding pin with sliding
bushing into the bottom side.
(b) Remove the caliper from the torque plate.
4. REMOVE 2 BRAKE PADS WITH ANTI- SQUEAL
SHIMS
5. REMOVE 4 PAD SUPPORT PLATES
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or disc.

2001 AVALON (RM808U)

Author: Date: 1437


BR-34
BRAKE - REAR BRAKE PAD

REAR BRAKE PAD


BR0L8-03

COMPONENTS

34 (350, 35)

Anti-squeal Shim

Inner Anti-squeal Shim

Pad Support Plate

Outer Pad
Inner Pad

Pad Support Plate

Inner Anti-squeal Shim

Anti-squeal Shim

N·m (kgf·cm, ft·lbf) : Specified torque


Disc brake grease F09721

2001 AVALON (RM808U)

Author: Date: 1433


BR-35
BRAKE - REAR BRAKE PAD
BR0L9-03

REPLACEMENT
1. REMOVE REAR WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad’s thickness through the caliper inspection hole
and replace pads if not within specification.
Minimum thickness: 1.0 mm (0.039 in.)

F09722

3. LIFT UP CALIPER
(a) Remove the bottom side installation bolt.
(b) Lift up and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. REMOVE 2 BRAKE PADS WITH 4 ANTI- SQUEAL
SHIMS
5. REMOVE 4 PAD SUPPORT PLATES
F09723 NOTICE:
The support plates can be used again provided that they
have sufficient rebound, no deformation, cracks or wear,
and have had all rust, dirt and foreign particles cleaned off.
6. CHECK DISC THICKNESS AND RUNOUT
(See page BR-40 )
7. INSTALL PAD SUPPORT PLATES
Install the 4 pad support plates.
8. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti-squeal shims must be
replaced together with the pads.
(a) Apply disc brake grease to both side of the inner
anti-squeal shims (See page BR-37 ).
(b) Install the 2 anti-squeal shims on each pad.
(c) Install 2 pads with the pad wear indicator plates facing
downward.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.

9. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.

R10387

2001 AVALON (RM808U)

Author: Date: 1434


BR-36
BRAKE - REAR BRAKE PAD

(c) Install the caliper.


(d) Install the installation bolt.
Torque: 34 N·m (350 kgf·cm, 25 ft·lbf)
10. INSTALL REAR WHEEL
Torque: 103 N·m (1,050 kgf·cm, 76 ft·lbf)
11. DEPRESS BRAKE PEDAL SEVERAL TIMES
12. CHECK THAT FLUID LEVEL IS AT MAX LINE

F09723

2001 AVALON (RM808U)

Author: Date: 1435


BR-62
BRAKE - REAR SPEED SENSOR

REAR SPEED SENSOR


BR0LX-03

COMPONENTS

5.4 (55 48 in.·lbf)

Rear Speed Sensor

8.0 (82, 71 in.·lbf)

N·m (kgf·cm, ft·lbf) : Specified torque


F09740

2001 AVALON (RM808U)

Author: Date: 1461


BR-64
BRAKE - REAR SPEED SENSOR
BR0LZ-04

INSTALLATION
Installation is in the reverse order of removal (See page BR-63 ).
AFTER INSTALLATION, CHECK SPEED SENSOR SIGNAL (See page DI-252 or DI-212 )

2001 AVALON (RM808U)

Author: Date: 1463


BR-63
BRAKE - REAR SPEED SENSOR
BR0LY-03

REMOVAL
1. DISCONNECT SPEED SENSOR CONNECTOR
(a) Remove the seat cushion and seatback.
(b) Disconnect the speed sensor connector, and pull out the
sensor wire harness with the grommet.

R00330

2. REMOVE SPEED SENSOR


(a) Remove the bolt and speed sensor from the axle carrier.
Torque: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
(b) Remove the 2 clamp bolts holding the sensor wire har-
ness to the body and shock absorber.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

R00331

2001 AVALON (RM808U)

Author: Date: 1462


BR-2
BRAKE - TROUBLESHOOTING

TROUBLESHOOTING
BR0KG-05

PROBLEM SYMPTOMS TABLE


Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
Symptom Suspect Area See page
5. Fluid leaks for brake system DI-249
DI-346
6. Air in brake system BR-4
Lower pedal or spongy pedal 7. Piston seals (Worn or damaged) BR-28
BR-37
8. Master cylinder (Faulty) BR-13
9. Booster push rod (Out of adjustment) BR-24
1. Brake pedal freeplay (Minimal) BR-6
2. Parking brake pedal travel (Out of adjustment) BR-9
3. Parking brake wire (Sticking) -
4. Rear brake shoe clearance (Out of adjustment) BR-46
5. Pad (Cracked or distorted) BR-25
BR-34
6. Piston (Stuck) BR-28
Brake drag
BR-37
7. Piston (Frozen) BR-28
BR-37
8. Tension or return spring (Faulty) BR-43
9. Booster push rod (Out of adjustment) BR-24
10.Vacuum leaks for booster system BR-22
11.Master cylinder (Faulty) BR-13
1. Piston (Stuck) BR-28
BR-37
2. Pad (Oily) BR-25
BR-34
3. Piston (Frozen) BR-28
Brake pull
BR-37
4. Disc (Scored) BR-28
BR-37
5. Pad (Cracked or distorted) BR-25
BR-34
1. Fluid leaks for brake system DI-249
DI-346
2. Air in brake system BR-4
3. Piston (Stuck) BR-28
BR-37
4. Pad (Cracked or distorted) BR-25
BR-34
Hard pedal but brake inefficient 5. Pad (Oily) BR-25
BR-34
6. Pad (Glazed) BR-25
BR-34
7. Disc (Scored) BR-28
BR-37
8. Booster push rod (Out of adjustment) BR-24
9. Vacuum leaks for booster system BR-22

2001 AVALON (RM808U)

Author: Date: 1401


BR-3
BRAKE - TROUBLESHOOTING

Symptom Suspect Area See page


1. Pad (Cracked or distorted) BR-25
BR-34
2. Installation bolt (Loosen) BR-28
BR-37
3. Disc (Scored) BR-28
BR-37
4. Pad support plate (Loosen) BR-25
BR-34
5. Sliding pin (Worn) BR-28
Noise from brake
BR-37
6. Pad (Dirty) BR-25
BR-34
7. Pad (Glazed) BR-25
BR-34
8. Tension or return spring (Faulty) BR-43
9. Anti-squeal shim (Damage) BR-25
BR-34
10.Hold-down spring (Damage) BR-43

2001 AVALON (RM808U)

Author: Date: 1402

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