Toyota Camry

 XV30 (2002–2006) Service Manual

Brake
Brake pedal support assy

COMPONENTS

OVERHAUL

1. REMOVE INSTRUMENT PANEL REINFORCEMENT

2. REMOVE BRAKE PEDAL RETURN SPRING

3. REMOVE PUSH ROD PIN

1. Remove the clip and push rod pin.

4. REMOVE BRAKE PEDAL SUPPORT ASSY

1. Disconnect the stop lamp switch connector.

2. Normal type: Remove the bolt, 4 nuts and brake pedal support assy.

3. Link type: Remove the 4 nuts and brake pedal support assy.

5. REMOVE STOP LAMP SWITCH ASSY

a Loosen the lock nut and remove the stop lamp switch.

6. REMOVE BRAKE PEDAL SUB−ASSY (NORMAL TYPE BRAKE PEDAL)

a Remove the nut, bolt and brake pedal sub−assy from brake pedal support sub−assy.

7. REMOVE BRAKE PEDAL PAD

8. REMOVE BRAKE PEDAL BUSH (NORMAL TYPE BRAKE PEDAL)

a Remove the 2 brake pedal bushes from brake pedal sub−assy.

9. REMOVE STOP LAMP SWITCH CUSHION

10. INSTALL STOP LAMP SWITCH CUSHION

11. INSTALL BRAKE PEDAL BUSH (NORMAL TYPE BRAKE PEDAL)

a Install the new 2 brake pedal bushes to brake pedal sub−assy.

HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows.

12.  INSTALL BRAKE PEDAL PAD

13. INSTALL BRAKE PEDAL SUB−ASSY (NORMAL TYPE BRAKE PEDAL)

a Install the brake pedal sub−assy with the bolt and nut.

Torque: 37 N·m (375 kgf·cm, 27 ft·lbf)

14. INSTALL STOP LAMP SWITCH ASSY

a Install the stop lamp switch with the lock nut.

Torque: 26 N·m (265 kgf·cm, 19 ft·lbf)

15. INSTALL BRAKE PEDAL SUPPORT ASSY

1. Normal type: Install the brake pedal support assy with the bolt and 4 nuts.

   Torque:
   Bolt: 20 N·m (204 kgf·cm, 15 ft·lbf) Nut: 13 N·m (130 kgf·cm, 9 ft·lbf)

2. Link type: Install the brake pedal support assy with the 4 nuts.

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

16. INSTALL PUSH ROD PIN

a Install the push rod pin and clip.

HINT: Apply the lithium soap base glycol grease to the parts indicates by arrows.

17. INSTALL BRAKE PEDAL RETURN SPRING

18. INSTALL INSTRUMENT PANEL REINFORCEMENT

19. CHECK AND ADJUST BRAKE PEDAL HEIGHT

20. CHECK PEDAL FREE PLAY

21. CHECK PEDAL RESERVE DISTANCE

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