Camry Repair Manual
BRAKE SYSTEM –BRAKE SYSTEM BR–1 PRECAUTIONS 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and re- sult in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. Parking brake out of adjustment Binding parking brake wire Booster push rod out of adjustment Tension or return spring faulty Brake line restricted Lining cracked or distorted Pad cracked or distorted Wheel cylinder or caliper piston sticking Adjuster broken Master cylinder faulty Brake shoes distorted, linings worn or glazed Brake pads distorted, worn or glazed Drum or disc out of round Tension or return spring faulty Wheel cylinder faulty Brake cylinder faulty Piston frozen in brake cylinder Brake pad sticking Replace brake shoes Replace pads Repair leak Repair or replace master cylinder Bleed brake system Repair wheel cylinder Repair cylinder Repair brake cylinder Repair or replace adjuster Air in brake system Wheel cylinder faulty Brake cylinder faulty Piston seals worn or damaged Rear brake automatic adjuster faulty Adjust parking brake Repair as necessary Adjust push rod Replace spring Repair as necessary Replace shoe Replace pad Repair as necessary Replace pads Replace drum or disc Replace spring Repair wheel cylinder Repair cylinder Repair cylinder Replace pads Inflate tires to proper pressure Check for cause. Replace shoes or pads Replace brake shoes Linings worn Brake pads worn Leak in brake system Master cylinder faulty BR–18, 34 BR–18, 26 34 BR–26, 42 BR–26 BR–18, 34 BR–18, 34 BR–18, 34 Replace adjuster Repair or replace master cylinder TROUBLESHOOTING BR–7 BR–26 BR–18, 34 BR–18, 34 BR–26, 42 BR–18,34 BR–18, 26 34 Oil or grease on shoes or pads Tires improperly inflated BR–18, 26 34 BR–26, 42 Low or spongy pedal BR–26 BR–18, 34 BR–1 6 BR–26, 42 Possible cause Brakes drag Brakes pull Remedy Problem Page BR–8 BR–9 BR–9 –BRAKE SYSTEM Precautions BR–2 PRECAUTIONS 1. Care must be taken to replace each part properly as it could affect the performance of the brake system and re- sult in a driving hazard. Replace the parts with parts of the same part number or equivalent. 2. It is very important to keep parts and the area clean when repairing the brake system. Parking brake out of adjustment Binding parking brake wire Booster push rod out of adjustment Tension or return spring faulty Brake line restricted Lining cracked or distorted Pad cracked or distorted Wheel cylinder or caliper piston sticking Adjuster broken Master cylinder faulty Brake shoes distorted, linings worn or glazed Brake pads distorted, worn or glazed Drum or disc out of round Tension or return spring faulty Wheel cylinder faulty Brake cylinder faulty Piston frozen in brake cylinder Brake pad sticking Replace brake shoes Replace pads Repair leak Repair or replace master cylinder Bleed brake system Repair wheel cylinder Repair cylinder Repair brake cylinder Repair or replace adjuster Air in brake system Wheel cylinder faulty Brake cylinder faulty Piston seals worn or damaged Rear brake automatic adjuster faulty Adjust parking brake Repair as necessary Adjust push rod Replace spring Repair as necessary Replace shoe Replace pad Repair as necessary Replace pads Replace drum or disc Replace spring Repair wheel cylinder Repair cylinder Repair cylinder Replace pads Inflate tires to proper pressure Check for cause. Replace shoes or pads Replace brake shoes Linings worn Brake pads worn Leak in brake system Master cylinder faulty BR–18, 34 BR–18, 26 34 BR–26, 42 BR–26 BR–18, 34 BR–18, 34 BR–18, 34 Replace adjuster Repair or replace master cylinder TROUBLESHOOTING BR–7 BR–26 BR–18, 34 BR–18, 34 BR–26, 42 BR–18,34 BR–18, 26 34 Oil or grease on shoes or pads Tires improperly inflated BR–18, 26 34 BR–26, 42 Low or spongy pedal BR–26 BR–18, 34 BR–16 BR–26, 42 Possible cause Brakes drag Brakes pull Remedy Problem Page BR–8 BR–9 BR–9 –BRAKE SYSTEM Troubleshooting BR–2 (Drum brake) Brake shoes binding at backing plate ledges Backing plate ledges worn Loose or missing shoe hold–down spring Loose set bolt at backing plate (Disc brake) Loose or missing pad support plate Loose installation bolt Wear on slide bushing Brake shoes distorted, linings worn or glazed, drums worn Brake pads distorted, worn or glazed Piston frozen in brake cylinder Brake booster faulty Vacuum leaks Brake line restricted Caliper to wheel or rotor interference Dust cover to rotor or backing plate to drum interference Other brake system components faulty Replace and lubricate ledges Replace shoe hold–down spring Tighten Replace pads Repair cylinder Repair booster Repair as necessary Repair as necessary Replace pad support plate Tighten Replace slide bushing Replace or refinish drums or rotors if heavily scored Replace as required TROUBLESHOOTING (Cont’d) Check for cause. Replace shoes or pads Replace brake shoes Repair or replace as necessary Repair as necessary Tires rubbing against chassis and/or body Snapping or clicking noise when brakes are applied Scraping or grinding noise when brakes are applied Oil or grease on shoes or pads Hard pedal but brakes inefficient Worn brake linings or pads BR–18,34 BR–18, 34 BR–18, 34 BR–18,34 BR–18,34 BR–15 BR–18,26 34 BR–26, BR–18, 26 34 BR–18, 34 Correct or replace BR– 18, 26 34 Possible cause BR–26 BR–26 Lubricate Problem Remedy BR–26 Page BR–26 –BRAKE SYSTEM Troubleshooting BR–3 Maladjustment of brake pedal or booster push rod Poor return of brake booster or master cylinder or wheel cylinder (Disc brake) Rusted or stuck piston Improper positioning of pad in caliper Rotor rubbing against caliper housing Improper installation of disc brake pad support plate Pad wear and pad wear indicator making contact with the rotor (Drum brake) Weak, damaged or incorrect shoe hold–down springs Grooved backing plate ledges Bent or warped backing plate causing interference with drum Improper machining of drum causing interference with backing plate or shoe Other brake system components: Loose or extra parts in brakes Rear drum adjustment too tight causing lining to glaze Worn, damaged or insufficiently lubricated wheel bearings Brake drums and linings, rotors and pads worn or scored Dirty, greased, contaminated or glazed linings or pads Improper linings or pads using Maladjustment of brake pedal or booster push rod (Disc brake) Missing or damaged brake pad anti–squeal shim Pad wear and pad wear indicator making contact with the rotor Burred or rusted calipers (Drum brake) Weak damaged or incorrect shoe hold–down springs, loose or damaged shoe hold–down spring pins and springs and grooved backing plate ledges Squeaking, squealing groaning or chattering noise when brakes are applied Note: Brake friction materials inherently generate noise and heat in order to dissipate eniergy. As a result, occasional squeal is normal and is aggravated by severe environmental conditions such as cold,’ heat, wetness, snow, salt, mud, etc. This occasional squeal is not a functional problem and does not indicate any loss of brake effectiveness Inspect, repair or replace Clean or replace Inspect for correct usage or replace Inspect and adjust Inspect and lubricate as necessary Repair or replace Repair or replace Repair or replace Replace Replace Repair or replace Repair or replace Replace drum TROUBLESHOOTING (Cont’d) Replace Replace Clean or deburr Inspect and adjust Inspect, repair or replace Squealing and squeaking noise when brakes are not applied BR–26, 42 BR–26, 42 BR–26, 42 BR–26, 42 BR–18,34 BR–18, 34 BR–18, 34 BR–18, 34 Inspect, repair or replace as necessary BR–18, 34 BR–18, 34 BR–18, 34 BR–18, 26, 34 BR–18, 26 34 –Inspect, repair or replace BR–9,15 26 Possible cause BR– 18, 34 BR–6,16 . Page Remedy BR–6, 16 Problem BR–26 –BRAKE SYSTEM Troubleshooting BR–4 Maladjustment of brake pedal or booster push rod worn, damaged or dry wheel bearings (Disc brake) Loose or missing anti–rattle spring or pad support plate or rimping on outer pad Failure of shim Wear on slide bushing Loose installation bolt Poor return of piston (Drum brake) Loose or extra parts Inspect , replace if necessary Inspect , replace if necessary Inspect , tighten if necessary Inspect , repair or replace Tighten to correct torque Replace if stud holes are elongated Inspect and adjust Stones or foreign material trapped inside wheel covers Loose wheel nuts TROUBLESHOOTING (Cont’d) Groaning, clicking or rattling noise when brakes are not applied Inspect and lubricate or replace BR–21, 37 BR–21, 37 BR–21, 37 BR–21, 37 Inspect, repair or replace Remove foreign material Inspect and repair Possible cause BR–21, 37 BR–26, 42 BR–6,16 Problem Remedy Page –BRAKE SYSTEM Troubleshooting BR–5 CHECKS AND ADJUSTMENTS CHECK AND ADJUSTMENT OF BRAKE PEDAL 1. CHECK THAT PEDAL HEIGHT IS CORRECT Pedal height from asphalt sheet: 177.5 – 187.5 mm (6.988 – 7.382 in.) If incorrect, adjust the pedal height. 2. IF NECESSARY, ADJUST PEDAL HEIGHT (a) If necessary, remove the instrument lower finish pan- el and air duct. (b) Loosen the stop light switch lock nut. (e) Sufficiently loosen the stop light switch. (d) Loosen the push rod lock nut. (e) Adjust the pedal height by turning the pedal push rod. (f) Return the stop light switch until it lightly contacts the pedal stopper. (g) Tighten the two lock nuts. (h) Check that the stop lights light when the brake pedal depressed. (i) After adjusting the pedal height, check and adjust the pedal freeplay. 3. CHECK THAT PEDAL FREEPLAY IS CORRECT (a) Stop the engine and depress the brake pedal sever- al times until there is no more vacuum left in the booster. (b) Push in the pedal until the beginning of resistance is felt. Measure the distance, as shown. Pedal freeplay: 3 –6 mm (0.12 – 0.24 in.) HINT: The freeplay to the first resistance is due to the play between the clevis and pin. And it is 1 3 mm (0.04– 0.12 in.) on the pedal. 4. IF NECESSARY, ADJUST PEDAL FREEPLAY (a) If incorrect, adjust the pedal freeplay by turning the pedal push rod. (b) Start the engine and confirm that pedal freepiay ex- ists. (e) After adjusting the pedal freeplay, check the pedal height. (d) Install the air duct and instrument lower finish panel. –BRAKE SYSTEM Checks and Adjustments BR–6 OPERATIONAL TEST OF BRAKE BOOSTER HINT: If there is leakage or lack of vacuum, repair before testing. If available, use a brake booster tester to check the booster operating condition. 1. OPERATING CHECK (a) Depress the brake pedal several times with the en- gine stopped, and check that is no change in the ped- al reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. 2. AIR TIGHTNESS CHECK (a) Start the engine and stop it after one or two minutes. Depress the brake pedal several times slowly. If the pedal goes down furtherest the first time, but gradual- ly rises after the second or third time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop it with the pedal depressed. If there is no change in pedal reserve travel after holding the pedal for thirty seconds, the booster is air tight. BLEEDING OF BRAKE SYSTEM HINT: If any work is done on the brake system or if air is sus- pected in the brake lines, bleed the system of air. 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. If necessary, add brake fluid. 5. CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT Release the parking brake. With engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 50 kg (110.2 1b): More than 85 mm, (3.35 in.) If incorrect, troubleshoot the brake system. 2. BLEED MASTER CYLINDER HINT: If the master cylinder was disassembled or if the res- ervoir becomes empty, bleed the air from the master cylin- der. (a) Disconnect the brake tubes from the master cylinder. (b) Depress the brake pedal and hold it. –BRAKE SYSTEM Checks and Adjustments BR–7 CHECK AND ADJUSTMENT OF PARKING BRAKE 1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT Pull the parking brake lever all the way up, and count the num- ber of clicks. Parking brake levertravel at 20 kg (44.1 Ib, 196 N): 5 – 8 clicks If incorrect, adjust the parking brake. 2. IF NECESSARY, ADJUST PARKING BRAKE LEVER TRAVEL HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. For shoe clearance adjustment, see steps 8 and 9 on page BR–32 or step 8 on page 48. (a) Remove the console box. (b) Loosen the lock nut and turn the adjusting nut until the lever travel is correct. (e) Tighten the lock nut. Torque: 55 kg–cm (48 in.–Ib, 5.4 N–m) (d) Install the console box. 3. BEGIN BLEEDING AIR FROM BRAKE OR WHEEL CYLINDER WITH LONGEST HYDRAULIC LINE (a) Connect the vinyl tube to the brake or wheel cylinder bleeder plug, and insert the other end of tube in a halffull container of brake fluid. (b) Slowly pump the brake pedal several times. (c) While having an assistant press on the pedal, loosen the bleeder plug until fluid starts to runout. Then close the bleeder plug. (d) Repeat (b) and (c) until there are no more air bubbles in the fluid. (e) Tighten the bleeder plug. Bleeder plug tightening torque: 85 kg–cm (74 in.–!b, 8.3 N–m) 4. REPEAT PROCEDURE FOR EACH WHEEL (c) Block off the outer holes with your fingers, and re- lease the brake pedal. (d) Repeat (b) and (c) three or four times. –BRAKE SYSTEM Checks and Adjustments BR–8 1. DISCONNECT LEVEL WARNING SWITCH CONNECTOR 2. TAKE OUT FLUID WITH SYRINGE NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. 3. DISCONNECT BRAKE TUBES Using SST, disconnect brake tubes from the master cylinder. SST 09751–36011 4. REMOVE MASTER CYLINDER (a) Remove the three nuts and 3–way union. (b) Remove the clamp. (c) Remove the master cylinder from the brake booster and remove the gasket. MASTER CYLINDER REMOVAL OF MASTER CYLINDER –BRAKE SYSTEM Master Cylinder BR–9 [...]... BR–6) BR–15 BRAKE SYSTEM – Brake Booster BRAKE BOOSTER REMOVAL OF BRAKE BOOSTER 1 2 3 4 5 REMOVE MASTER¿CYLINDER (See page BR–9) DISCONNECT VACUUM HOSE FROM BRAKE BOOSTER REMOVE PEDAL RETURN SPRING REMOVE CLIP AND CLEVIS PIN REMOVE BRAKE BOOSTER, GASKET AND CLEVIS (a) Remove the four nuts and clevis (b) Pull out the brake booster and gasket BR–16 BRAKE SYSTEM – Brake Booster INSTALLATION OF BRAKE BOOSTER... CLEARANCE BETWEEN BRAKE SHOES AND DRUM (a) Remove the brake drum (b) Measure the brake drum inside diameter and diameter of the brake shoes Check that the difference between the diameters is the correct shoe clearance Shoe clearance: 0.6 mm (0.024 in.) If incorrect, check the parking brake system 10 INSTALL BRAKE DRUM 11 INSTALL REAR WHEEL 12 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM... BR–34 BRAKE SYSTEM – Rear Brake REAR BRAKE Disc Brake COMPONENTS REPLACEMENT OF BRAKE PADS HINT: If a squealing noise occurs from the brakes while driving, check the pad wear indicator If there are traces of the indicator contacting the rotor disc, the brake pad should be replaced 1 REMOVE REAR WHEEL Remove the wheel and temporarily fasten the rotor disc with the hub nuts BR–35 BRAKE SYSTEM – Rear Brake. .. RETURN SPRING INSTALL INSTRUMENT LOWER FINISH PANEL BR–17 BRAKE SYSTEM – Brake Booster 6 INSTALL MASTER CYLINDER (See page BR–14) 7 CONNECT VACUUM HOSE TO BRAKE BOOSTER 8 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–7) 9 CHECK FOR FLUID LEAKAGE 10 CHECK AND ADJUST BRAKE PEDAL (See page BR–6) Check and adjust the brake pedal, then tighten the clevis lock nut Torque: 260... 11 PERFORM OPERATIONAL CHECK (See page BR–7) BR–18 BRAKE SYSTEM – Front Brake FRONT BRAKE COMPONENTS REPLACEMENT OF BRAKE PADS HINT: If a squealing noise occurs from the front brakes while driving, check the pad wear indicator If there are traces of the indicator contacting the rotor disc, the brake pad should be replaced BR–19 BRAKE SYSTEM – Front Brake 1 REMOVE FRONT WHEEL Remove the wheel and temporarily... the brake shoes HINT: If any of the brake shoes have to be replaced, replace all of the rear shoes in order to maintain even braking 3 MEASURE BRAKE DRUM INSIDE DIAMETER 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 to the maximum inside diameter BR–29 BRAKE SYSTEM – Rear Brake 4 INSPECT REAR BRAKE. .. parking brake lever of the rear shoe back and forth, as shown Check that the adjuster turns If the adjuster does not turn, check for incorrect installation of the rear brakes (b) Adjust the adjuster length to the shortest possible amount (c) Align the adjusting hole on the brake drum and largest hole on the axle carrier, install the brake drum BR–33 BRAKE SYSTEM – Rear Brake (d) Pull the parking brake. .. on the brake booster with three nuts Torque: 130 kg–cm (9 ft–Ib, 13 N¿ m) 5 CONNECT BRAKE TUBES Using SST, connect the brake tubes to the master cylinder Torque the union nuts SST 09751–36011 Torque: 155 kg–cm (11 ft–ib, 15 N – m) 6 7 8 9 CONNECT LEVEL WARNING SWITCH CONNECTOR FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See page BR–7) CHECK FOR FLUID LEAKAGE CHECK AND ADJUST BRAKE. .. page BR–7) CHECK FOR LEAKS BR–26 BRAKE SYSTEM – Rear Brake REAR BRAKE Drum Brake COMPONENTS REMOVAL OF REAR BRAKE 1 2 3 INSPECT SHOE LINING THICKNESS Remove the inspection hole plug, and check the shoe lining the thickness through the hole If less than minimum, replace the shoes Minimum thickness: 1.0 mm (0.039 in.) REMOVE REAR WHEEL REMOVE BRAKE DRUM HINT: If the brake drum cannot be removed easily,... groove BR–25 BRAKE SYSTEM – Front Brake INSTALLATION OF CYLINDER (See page BR–18) 1 INSTALL PADS (See Steps 7 and 8 on page BR–20) 2 INSTALL CYLINDER (See step 9 on page BR–20) 3 INSTALL FLEXIBLE HOSE TO BRAKE CYLINDER Set the flexible hose and new gaskets in position and install the union bolt Torque: 310 kg–em(22 ft–Ib, 30 N¿nn) 4 5 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See . pin head. BRAKE SYSTEM Brake Booster BR–16 6. INSTALL MASTER CYLINDER (See page BR–14) 7. CONNECT VACUUM HOSE TO BRAKE BOOSTER 8. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED BRAKE SYSTEM (See. frozen in brake cylinder Brake pad sticking Replace brake shoes Replace pads Repair leak Repair or replace master cylinder Bleed brake system Repair wheel cylinder Repair cylinder Repair brake cylinder Repair. spongy pedal BR–26 BR–18, 34 BR–16 BR–26, 42 Possible cause Brakes drag Brakes pull Remedy Problem Page BR–8 BR–9 BR–9 BRAKE SYSTEM Troubleshooting BR–2 (Drum brake) Brake shoes binding at backing plate ledges Backing