Camry Repair Manual
BR0A9–01 –BRAKE BRAKE SYSTEM BR–1 2024AuthorĂ: DateĂ: BRAKE SYSTEM PRECAUTION 1. 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 having the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. 3. If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section. BR0AA–03 BR–2 –BRAKE TROUBLESHOOTING 2025AuthorĂ: DateĂ: TROUBLESHOOTING 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 CAUSE PAGE Low pedal or spongy pedal 1. Fluid leaks for brake system 2. Air in brake system 3. Piston seals (Worn or damaged) 4. Rear brake shoe clearance (Out of adjustment) 5. Master cylinder (Faulty) 6. Booster push rod (Out of adjustment) DI–536 BR–4 BR–24 BR–31 BR–39 BR–35 BR–9 BR–20 Brake drag 1. Brake pedal freeplay (Minimal) 2. Parking brake lever travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Rear brake shoe clearance (Out of adjustment) 5. Pad or lining (Cracked or distorted) 6. Piston (Stuck) 7. Piston (Frozen) 8. Anchor, return or tension spring (Faulty) 9. Booster push rod (Out of adjustment) 10.Vacuum leaks for booster system 11.Master cylinder (Faulty) BR–5 BR–8 BR–35 BR–21 BR–31 BR–36 BR–24 BR–31 BR–39 BR–24 BR–31 BR–39 BR–31 BR–45 BR–20 BR–18 BR–9 Brake pull 1. Piston (Stuck) 2. Pad or lining (Oily) 3. Piston (Frozen) 4. Disc (Scored) 5. Pad or lining (Cracked or distorted) BR–24 BR–31 BR–39 BR–21 BR–31 BR–36 BR–24 BR–31 BR–39 BR–24 BR–39 BR–21 BR–31 BR–36 –BRAKE TROUBLESHOOTING BR–3 2026AuthorĂ: DateĂ: Hard pedal but brake inefficient 1. Fluid leaks for brake system 2. Air in brake system 3. Pad or lining (Worn) 4. Pad or lining (Cracked or distorted) 5. Rear brake shoe clearance (Out of adjustment) 6. Pad or lining (Oily) 7. Pad or lining (Glazed) 8. Disc (Scored) 9. Booster push rod (Out of adjustment) 10.Vacuum leaks for booster system DI–536 BR–4 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–35 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–24 BR–39 BR–20 BR–18 Noise from brakes 1. Pad or lining (Cracked or distorted) 2. Installation bolt (Loose) 3. Disc (Scored) 4. Pad support plate (Loose) 5. Sliding pin (Worn) 6. Pad or lining (Dirty) 7. Pad or lining (Glazed) 8. Anchor, return or tension spring (Faulty) 9. Anti–squeal shim (Damaged) 10.Shoe hold–down spring (Damaged) BR–21 BR–31 BR–36 BR–24 BR–39 BR–24 BR–39 BR–21 BR–36 BR–24 BR–39 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–31 BR–45 BR–21 BR–36 BR–31 BR–45 F05595 F05596 BR0AB–03 F05597 R00252 BR–4 –BRAKE BRAKE FLUID 2027AuthorĂ: DateĂ: BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, 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: SAEJ1703 or FMVSS No.116 DOT 3 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 2 brake lines from the master cylinder. (b) Slowly depress the brake pedal and hold it. (c) Block off the outlet plugs with your fingers, and release the brake pedal. (d) Repeat (b) and (c) 3 or 4 times. 3. CONNECT VINYL TUBE TO BRAKE CALIPER OR WHEEL CYLINDER BLEEDER PLUG Insert the 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. (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. Torque: (Bleeder plug) 8.3 N·m (85 kgf·cm, 74 in.·lbf) 5. REPEAT PROCEDURE FOR EACH WHEEL R00954 Stop Light Switch Push Rod Pedal Height BR0YH–01 R00935 Pedal Freeplay –BRAKE BRAKE PEDAL BR–5 2028AuthorĂ: DateĂ: BRAKE PEDAL ON–VEHICLE INSPECTION 1. CHECK PEDAL HEIGHT Pedal height from asphalt sheet: 152.0 – 162.0 mm (5.984 – 6.378 in.) 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) Disconnect the connector from the stop light switch. (b) Loosen the stop light switch lock nut and remove the stop light switch. (c) Loosen the push rod lock nut. (d) Adjust the pedal height by turning the pedal push rod. (e) Tighten the push rod lock nut. Torque: 25 N·m (260 kgf·cm, 19 ft·lbf) (f) Install the stop light switch and turn it until it lightly con- tacts the pedal stopper. (g) Push in the brake pedal 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. (h) Connect the connector to the stop light switch. (i) After installation, push in the brake pedal 5–15 mm (0.20–0.59 in.), check that stop light lights up. (j) Connect the connector to the stop light switch. (k) After adjusting the pedal height, check the pedal freeplay. 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. (b) Push in the pedal by hand until the resistance begins to be felt, then measure the distance. Pedal freeplay: 1 – 6 mm (0.04 – 0.24 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. If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. Stop light switch clearance: 0.5 – 2.4 mm (0.020 – 0.094 in.) R00934 Pedal Reserve Distance BR–6 –BRAKE BRAKE PEDAL 2029AuthorĂ: DateĂ: 4. CHECK PEDAL RESERVE DISTANCE (a) Release the parking brake. (b) 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 70 mm (2.76 in.) If the reserve distance is incorrect, troubleshoot the brake sys- tem. BR0YI–01 F07004 Lower Panel Insert S Bushing Clip Clevis Pin No.1 Lower Panel Return Spring Cushion Plate Collar Brake Pedal Cowl Side Trim Front Opening Cover Brake Pedal Inside Scuff Plate M/T: Stop Light Switch Wave Washer Cruise Control ECU Lithium soap base glycol grease 13 (130, 9) 5.0 (51, 44 in.·lbf) 13 (130, 9) Pedal Pad Pedal Pad S Bushing A/T: 39 (400, 29) : Specified torqueN·m (kgf·cm, ft·lbf) S Non–reusable part Brake Pedal Bracket –BRAKE BRAKE PEDAL BR–7 2030AuthorĂ: DateĂ: COMPONENTS W03254 W03255 Lock Nut Adjusting Nut BR0AD–03 BR–8 –BRAKE PARKING BRAKE LEVER 2031AuthorĂ: DateĂ: PARKING BRAKE LEVER ON–VEHICLE INSPECTION 1. CHECK THAT PARKING BRAKE LEVER TRAVEL Pull the parking brake lever all the way up, and count the num- ber of clicks. Parking brake lever travel at 196 N (20 kgf, 44.1 lbf): 5 – 8 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE LEVER TRAVEL HINT: Before adjusting the parking brake lever travel, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see step 2 on page BR–35 or step 1 on page BR–48. (a) Remove the console box. (b) Loosen the lock nut and adjust the adjusting nut until the lever travel is correct. (c) Tighten the lock nut. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf) (d) Install the console box. BR0AE–02 Z19120 w/ ABS (& TRAC) 2–way 15 (155, 11) 13 (130, 9) Master Cylinder S Gasket Brake Booster N·m (kgf·cm, ft·lbf) : Specified torque S Non–reusable part w/o ABS 3–way W03569 N·m (kgf·cm, ft·lbf) : Specified torque Lithium soap base glycol grease Grommet Cylinder Body No. 2 Piston No. 1 Piston Spring Spring Cap Strainer Reservoir Grommet Straight Pin Reservoir Set Screw 1.7 (18, 16 in.·lbf) w/ TRAC –BRAKE BRAKE MASTER CYLINDER BR–9 2032AuthorĂ: DateĂ: BRAKE MASTER CYLINDER COMPONENTS Z19122 w/o ABS w/ ABS Cap Strainer Reservoir No. 2 Piston and Spring No. 1 Piston and Spring Cylinder Body Stopper Bolt S Gasket Reservoir Set Screw Grommet Snap Ring Grommet Cap Strainer Reservoir Reservoir Set Screw Cylinder Body S Gasket Stopper Bolt Grommet Grommet No. 1 Piston and Spring No. 2 Piston and Spring Snap Ring Lithium soap base glycol grease S Non–reusable part N·m (kgf·cm, ft·lbf) : Specified torque 1.7 (18, 16 in.·lbf) 10 (100, 7) 1.7 (18, 16 in.·lbf) 10 (100, 7) BR–10 –BRAKE BRAKE MASTER CYLINDER 2033AuthorĂ: DateĂ: [...]... BR–16) INSTALL AIR CLEANER COVER WITH AIR CLEANER HOSE CONNECT VACUUM HOSE TO BRAKE BOOSTER FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–4) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE PEDAL (See page BR–5) DO OPERATIONAL CHECK (See page BR–17) AuthorĂ: DateĂ: 2043 BR–21 BRAKE – FRONT BRAKE PAD FRONT BRAKE PAD BR0AO–03 COMPONENTS 5S–FE engine: 34 (350, 25) Anti–squeal Shim... AuthorĂ: DateĂ: 2038 BR–16 BRAKE – BRAKE MASTER CYLINDER BR0AJ–02 INSTALLATION Installation is in the reverse order of removal (See page BR–11) HINT: S Before installation, adjust length of the brake booster push rod (See page BR–20) S After installation, fill the brake reservoir with brake fluid, bleed the brake system and check for leaks (See page BR–4) S Check and adjust brake pedal (See page BR–5)... worn, the brake drum may be lathed to the maximum inside diameter F06408 4 INSPECT REAR BRAKE LINING AND DRUM FOR PROPER CONTACT If the contact between the brake lining and drum is improper, repair the lining with a brake shoe grinder, or replace the brake shoe assembly BR1543 AuthorĂ: DateĂ: 2057 BR–35 BRAKE – REAR DRUM BRAKE BR0AZ–02 INSTALLATION Installation is in the reverse order of removal (See page... HINT: S After installation, fill the brake reservoir with brake fluid, bleed the brake system (See page BR–4) S Check for leaks AuthorĂ: DateĂ: 2053 BR–31 BRAKE – REAR DRUM BRAKE REAR DRUM BRAKE BR0AW–03 COMPONENTS Bleeder Plug Plug Adjuster 8.3 (85, 74 in.·lbf) 10 (100, 7) Wheel Cylinder Spring Boot Inspection Hole Plug SCup SC–washer Parking Brake Lever Piston Automatic Adjusting Lever E–ring Pin Adjuster... DateĂ: 2054 BR–32 BRAKE – REAR DRUM BRAKE BR0AX–03 REMOVAL 1 INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining thickness through the hole If less than the minimum, replace the shoes Minimum thickness: 1.0 mm (0.039 in.) 2 REMOVE REAR WHEEL BR1532 3 (a) R00285 REMOVE BRAKE DRUM Release the parking brake lever and remove the brake drum HINT: If the brake drum cannot... HOSE FROM BRAKE BOOSTER REMOVE PEDAL RETURN SPRING REMOVE CLIP AND CLEVIS PIN 7 (a) (b) REMOVE BRAKE BOOSTER, GASKET AND CLEVIS Remove the 4 nuts and clevis Pull out the brake booster and gasket 2 3 4 F06431 AuthorĂ: DateĂ: 2042 BR–20 BRAKE – BRAKE BOOSTER ASSEMBLY BR0AN–03 INSTALLATION 1 (a) (b) (c) (d) (e) (f) 2 (a) (b) SST Gasket (c) F03521 SST (d) (e) 3 4 5 R11347 6 7 8 9 10 INSTALL BRAKE BOOSTER... W01679 (c) (d) Align the adjusting hole on the brake drum and the largest hole on the axle carrier, install the brake drum Pull the parking brake lever all the way up until a clicking sound can no longer be heard BR1553 4 CHECK CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the drum (b) Measure the brake drum inside diameter and diameter between the brake shoes Check that the difference between the... adjust brake pedal (See page BR–5) AuthorĂ: DateĂ: 2039 BR–17 BRAKE – BRAKE BOOSTER ASSEMBLY BRAKE BOOSTER ASSEMBLY BR0AK–03 ON–VEHICLE INSPECTION 1 (a) (b) BR2237 GOOD NO GOOD 3rd 1st 2nd BR2238 OPERATING CHECK Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance Depress the brake pedal and start the engine If the pedal goes down slightly,... shoes HINT: If any of the brake shoes have to be replaced, replace all of the rear brake shoes in order to maintain even braking BR0AY–03 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using brake drum gauge or equivalent, measure the inside diameter of the drum Standard inside diameter: 228.6 mm (9.000 in.) Maximum inside diameter: 230.6 mm (9.079 in.) If the drum is scored or worn, the brake drum may be lathed... BR–29 BRAKE – FRONT BRAKE CALIPER BR0AU–01 REASSEMBLY Reassembly is in the reverse order of disassembly (See page BR–27) NOTICE: Apply lithium soap base glycol grease to the parts indicated by arrows (See page BR–24) AuthorĂ: DateĂ: 2052 BR–30 BRAKE – FRONT BRAKE CALIPER BR0AV–02 INSTALLATION Installation is in the reverse order of removal (See page BR–26) HINT: S After installation, fill the brake . part Brake Pedal Bracket BRAKE BRAKE PEDAL BR–7 2030AuthorĂ: DateĂ: COMPONENTS W03254 W03255 Lock Nut Adjusting Nut BR0AD–03 BR–8 BRAKE PARKING BRAKE LEVER 2031AuthorĂ: DateĂ: PARKING BRAKE. (Damaged) BR–21 BR–31 BR–36 BR–24 BR–39 BR–24 BR–39 BR–21 BR–36 BR–24 BR–39 BR–21 BR–31 BR–36 BR–21 BR–31 BR–36 BR–31 BR–45 BR–21 BR–36 BR–31 BR–45 F05595 F05596 BR0AB–03 F05597 R00252 BR–4 BRAKE BRAKE FLUID 2027AuthorĂ: DateĂ: BRAKE FLUID BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the air from. adjustment) DI–536 BR–4 BR–24 BR–31 BR–39 BR–35 BR–9 BR–20 Brake drag 1. Brake pedal freeplay (Minimal) 2. Parking brake lever travel (Out of adjustment) 3. Parking brake wire (Sticking) 4. Rear brake shoe clearance (Out of