Toyota Camry

 XV30 (2002–2006) Service Manual

Brake
Brake booster assy

ON−VEHICLE INSPECTION

1. INSPECT BRAKE BOOSTER

1. Air tightness check.

1. Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly.

   HINT: If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is air tight.

2. Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed.

Inspect brake booster

HINT: If there is no change in the pedal reserve distance after holding the pedal for 30 seconds, the booster is air−tight.

2. Operating check.

1. Depress the brake pedal several times with the ignition switch OFF and check that there is no change in the pedal reserve distance.

2. Depress the brake pedal and start the engine.

   HINT: If the pedal goes down slightly, operation is normal.

2. INSPECT VACUUM CHECK VALVE

1. Check vacuum check valve.

1. Slide the clip and disconnect the vacuum hose.

2. Remove the vacuum check valve.

3. Check that there is ventilation from the booster to engine, and no ventilation from the engine to the booster.

4. If any fault is found, replace the vacuum check valve.

COMPONENTS

REPLACEMENT

HINT: COMPONENTS:

1. DRAIN BRAKE FLUID

NOTICE: Wash off the brake fluid immediately if it comes into contact with a painted surface.

2. REMOVE AIR CLEANER ASSY

3. REMOVE BRAKE MASTER CYLINDER SUB−ASSY

   SST 09023−00101

4. DISCONNECT VACUUM HOSE ASSY

1. Remove the bolt and separate the vacuum hose from the vacuum hose bracket.

2. Slide the clip and disconnect the vacuum hose from the brake booster.

Disconnect vacuum hose assy

5. REMOVE FRONT DOOR SCUFF PLATE LH

6. REMOVE COWL SIDE TRIM SUB−ASSY LH

7. REMOVE INSTRUMENT PANEL SUB−ASSY UPPER

8. REMOVE PUSH ROD PIN

1. Remove the clip and push rod pin.

9. REMOVE BRAKE MASTER CYLINDER PUSH ROD CLEVIS

1. Loosen the lock nut and remove the push rod clevis.

10. REMOVE FRONT BRAKE TUBE No.5

1. Using SST and remove the front brake tube No.5.

   SST 09023−00101

Remove front brake tube No.5

11. REMOVE BRAKE BOOSTER ASSY

1. Remove the 4 nuts.

2. Pull out the brake booster assy.

 Remove brake booster assy

12. REMOVE BRAKE BOOSTER GASKET

13. INSTALL BRAKE BOOSTER GASKET

1. Install a new brake booster gasket to the brake booster.

14. INSTALL BRAKE BOOSTER ASSY

1. Install the brake booster with the 4 nuts.

   Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

Install brake booster assy

15. INSTALL FRONT BRAKE TUBE No.5

1. Using SST and install the front brake tube No.5.

   Torque: 15 N·m (155 kgf·cm, 11 ft·lbf)

   SST 09023−00101

Install front brake tube No.5

16. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS

1. Install the push rod clevis and lock nut.

17. INSTALL PUSH ROD PIN

1. Install the push rod pin and clip.

   HINT: Apply the lithium soap base glycol grease to the part indicate by arrow.

18. INSTALL INSTRUMENT PANEL SUB−ASSY UPPER

19. INSTALL COWL SIDE TRIM SUB−ASSY LH

20.  INSTALL FRONT DOOR SCUFF PLATE LH

21.  INSTALL VACUUM HOSE ASSY

1. Install the vacuum hose and vacuum hose bracket to the body with a bolt.

   Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

2.  Connect the vacuum hose to the brake booster with the clip.

Install vacuum hose assy

22. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD

    SST 09737−00013, 09737−00020

23. INSTALL BRAKE MASTER CYLINDER SUB−ASSY

    SST 09023−00101

24. INSTALL AIR CLEANER ASSY

25. FILL RESERVOIR WITH BRAKE FLUID

26. BLEED MASTER CYLINDER

    SST 09023−00101

27. BLEED BRAKE LINE

28. CHECK FLUID LEVEL IN RESER

29. CHECK BRAKE FLUID LEAKAGE

30. CHECK AND ADJUST BRAKE PEDAL HEIGHT

Brake system

Brake pedal support assy

Accelerator & brake pedal assy

Brake system

Brake master cylinder sub-assy

Brake booster assy

Front brake

Brake fluid

Rear disc brake

Rear drum brake

Brake actuator assy (W/O VSC)

Brake actuator assy (W/ VSC)

Speed front LH

Skid control

Yawrate

Steering

Adjustable pedal switch

Adjustable pedal relay

Brake pedal support assy