Manual Frenos Corolla
Manual Frenos Corolla
Manual Frenos Corolla
BRAKE
BRAKE SYSTEM
BRAKE SYSTEM
320I701
PRECAUTION
Care must be taken to replace each part properly, because it could affect the performance of
the brake system and result in a driving hazard. Replace the parts with the parts which have
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
introduction section.
Author:
Date:
1292
322
BRAKE
BRAKE SYSTEM
320I802
Suspect Area
See page
6. Piston (Stuck)
7. Piston (Frozen)
8. Tension or return spring (Faulty)
9. Booster push rod (Out of adjustment)
10.Vacuum leaks for booster system
11.Master cylinder (Faulty)
1. Piston (Stuck)
326
332
337
3310
3231
3225
3231
3225
3231
3225
3231
3231
3213
3218
3213
3225
3231
3225
3231
3225
3231
3225
3225
3231
324
3225
3231
3231
3213
3213
3. Piston (Frozen)
4. Disc (Scored)
5. Pad or lining (Cracked or distorted)
Author:
Date:
1293
323
BRAKE
BRAKE SYSTEM
2.
3.
4.
5.
6.
324
3225
3231
3225
3231
3231
3225
3231
3225
3231
3225
3213
3218
3225
3231
3225
3225
3225
3225
3225
3231
3225
3231
3231
3225
3231
Author:
Date:
1294
324
BRAKE
BRAKE FLUID
BRAKE FLUID
320I901
BLEEDING
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
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.
1.
C80823
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 0902300100
(b) Slowly depress the brake pedal and hold it.
C80824
(c)
(d)
Block off the outer holes with your fingers, and release the
brake pedal.
Repeat (b) and (c) 3 or 4 times.
F42863
3.
(a)
(b)
(c)
(d)
C80826
Author:
Date:
1295
325
BRAKE
BRAKE FLUID
(e)
4.
(a)
C80823
Author:
Date:
1296
326
BRAKE
ADJUSTMENT
Push Rod
Pedal Height
F40001
1.
(a)
Author:
Date:
1297
327
BRAKE
3.
(a)
Author:
Date:
1298
328
BRAKE
COMPONENTS
Brake Pedal
Support Subassy
Bush
Bush
12.7 (130, 9)
F42828
Author:
Date:
1299
329
BRAKE
REPLACEMENT
1.
2.
(a)
(c)
F42280
F42862
4.
(a)
(b)
5.
(a)
(b)
6.
(a)
7.
(a)
8.
(a)
9.
(a)
(b)
Author:
Date:
1300
3210
BRAKE
10.
(a)
(b)
F42862
(c)
F42280
11.
(a)
(b)
12.
13.
14.
15.
Author:
Date:
1301
3211
BRAKE
COMPONENTS
w/ ABS: No.1 Way
Vacuum Check
Valve Bracket
No.1 Way
12.5 (127, 9)
M/T:
Clip
M/T:
Clutch Reservoir
Tube No.1
Author:
Date:
1302
3212
BRAKE
A/T:
Master Cylinder
Reservoir Subassy
Cap
Strainer
Master Cylinder
Reservoir Subassy
Grommet
ORing
Grommet
Master Cylinder
Gasket
Piston Stopper Bolt
10 (102, 7)
Snap Ring
C86272
Author:
Date:
1303
3213
BRAKE
OVERHAUL
1.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
2.
REMOVE AIR CLEANER CAP SUBASSY
3.
REMOVE BRAKE MASTER CYLINDER SUBASSY
(a) Disconnect the brake fluid level switch connector from
master cylinder reservoir subassy.
(b) M/T:
Slide the clip and disconnect the clutch reservoir tube
No.1 from master cylinder reservoir subassy.
SST
(c)
(d)
F42809
w/o ABS:
w/ ABS:
F42810
Author:
Date:
1304
3214
BRAKE
(e)
Remove the 2 nuts, and pull out the master cylinder, No.1
way and vacuum check valve bracket.
F42811
4.
(a)
(b)
(c)
Push in the piston and remove the snap ring with snap
ring pliers.
F40004
(d)
Push in the piston and remove the piston stopper bolt and
gasket.
(e) Remove the No.1 piston subassy by hand, pulling
straight out not at an angle.
NOTICE:
If being pulled out at an angle, the piston may damage the
cylinder bore.
C69097
(f)
(A)
R12236
Author:
Date:
1305
3215
BRAKE
6.
(a)
Push in the piston and install a new gasket and a new piston stopper bolt.
Torque: 10 Nm (102 kgfcm, 7 ftlbf)
(e)
Push in the piston and install the snap ring with snap ring
pliers.
Apply the lithium soap base glycol grease to a new O
ring, and install the Oring to the master cylinder.
C69097
(f)
F40004
8.
(a)
(b)
(a)
(b)
C94955
F42864
Author:
Date:
1306
3216
BRAKE
(c)
SST
HINT:
SST
F42815
(d)
HINT:
When adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.
SST
F42816
10.
(a)
(b)
F42811
w/o ABS:
w/ ABS:
F42810
Author:
Date:
1307
3217
BRAKE
(c)
(d)
(e)
SST
11.
12.
13.
14.
15.
16.
F42809
Author:
Date:
1308
3218
BRAKE
ONVEHICLE INSPECTION
GOOD
1st
2nd
1.
(a)
NO GOOD
3rd
BR2238
HINT:
If the pedal goes down farthest at the 1st time, but gradually
rises after the 2nd or 3rd time, the booster is airtight.
(2) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed.
HINT:
If there is no change in the pedal reserve distance after holding
the pedal for 30 seconds, the booster is airtight.
(b)
BR2237
Ventilation
No Ventilation
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
(a) Check vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3)
(4)
F40007
Author:
Date:
1309
3219
BRAKE
COMPONENTS
Clevis Pin
Wave Washer
12.7 (130, 9)
w/ Cruse control:
Cruise Control Actuator
Gasket
Clip
43 (438, 32)
Brake Tube
Clamp
Clevis
Vacuum Hose
43 (438, 32)
w/ ABS:
No.1 Way
Clip
Level
Warning Switch
Connector
15.2 (155, 11)
Grommet
26 (265, 19)
Vacuum Check
Valve Bracket
Brake Master
Cylinder Subassy
12.5 (127, 9)
M/T:
Clip
M/T:
Clutch Reservoir
Tube No.1
No.1 Way
15.2 (155, 11)
Air Cleaner
Cap Subassy
Brake Tube
Air Cleaner
Element
Author:
Date:
1310
3220
BRAKE
REPLACEMENT
1.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
2.
REMOVE AIR CLEANER CAP SUBASSY
3.
REMOVE AIR CLEANER CASE SUBASSY
(a) Remove the air cleaner element, then remove the 3 bolts and air cleaner case subassy.
4.
REMOVE BRAKE MASTER CYLINDER SUBASSY (See page 3213)
5.
DISCONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS
(a) Loosen the push rod clevis lock nut.
(b) Remove the clip, clevis pin and wave washer.
6.
(a)
F42813
7.
8.
(a)
(b)
F40019
Author:
Date:
1311
3221
BRAKE
w/o ABS:
(c)
(d)
(e)
9.
(a)
(b)
w/ ABS:
F42814
F42862
F42862
Author:
Date:
1312
3222
BRAKE
w/o ABS:
(c)
(d)
(e)
w/ ABS:
F42814
F40019
10.
11.
(a)
F42813
12.
(a)
(b)
13.
Author:
Date:
1313
3223
BRAKE
14.
(a)
15.
16.
17.
18.
19.
20.
21.
22.
23.
Author:
Date:
1314
3224
BRAKE
FRONT BRAKE
FRONT BRAKE
320II01
COMPONENTS
Union Bolt
29 (296, 21)
Front Disc
Front Disc Brake
Cylinder Sliding Pin
Gasket
Flexible Hose
Front Disc
Brake Cylinder
Sliding Pin
Bush Dust Boot
Pad Wear
Indicator Plate
Antisqueal
Shim No.2
Bleeder Plug
8.3 (85, 74 in.lbf)
Cylinder Boot
34.3 (350, 25)
Piston Seal
Set Ring
F42829
Author:
Date:
1315
3225
BRAKE
FRONT BRAKE
320IJ01
OVERHAUL
HINT:
Overhaul the RH side by the same procedure as the LH side.
1.
REMOVE FRONT WHEEL
2.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
3.
(a)
HINT:
Gasket has 2 types: 2piece type and 1piece type.
C86274
(b)
C86275
4.
(a)
(b)
5.
(a)
6.
(a)
7.
(a)
F41561
Author:
Date:
1316
3226
BRAKE
FRONT BRAKE
8.
(a)
(b)
9.
(a)
C68791
R09298
10.
(a)
C64095
11.
(a)
12.
(a)
13.
(a)
14.
(a)
R02951
Author:
Date:
1317
3227
BRAKE
15.
(a)
FRONT BRAKE
16.
(a)
F42895
Matchmarks
F41543
19.
(a)
Author:
Date:
1318
3228
BRAKE
23.
(a)
F42832
FRONT BRAKE
HINT:
Install the boot securely to the grooves of the cylinder and piston.
(b) Using a screwdriver, install the set ring.
NOTICE:
Do not damage the cylinder boot.
24. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Place front disc brake cylinder mounting in vise.
(b) Apply the lithium soap base glycol grease to seal surface
of 2 new bush dust boots.
(c) Using a socket wrench (19 mm) and hammer, drive the 2
bush dust boots to the disc brake cylinder mounting.
C68792
25.
(a)
26.
(a)
(b)
27.
(a)
Antisqueal
Shim No.2
Antisqueal
Shim No.1
Disc Brake
Pad Kit
F42831
29.
(a)
C86275
Author:
Date:
1319
3229
BRAKE
(b)
FRONT BRAKE
Install a new gasket and flexible hose with the union bolt.
Torque: 29 Nm (296 kgfcm, 21 ftlbf)
HINT:
C86274
30.
31.
32.
33.
34.
35.
Author:
Date:
1320
3230
BRAKE
REAR BRAKE
REAR BRAKE
320IK01
COMPONENTS
Bleeder Plug
15.2 (155, 11)
Hole Plug
Pin
Cylinder
Dust Boot
10 (102, 7)
Cylinder Cup
Piston
Compression Spring
Rear Wheel Brake
Cylinder Assy
CWasher
Parking Brake Shoe
Lever Subassy
Cup
Front Brake Shoe
Shoe Holddown
Spring
Rear Brake Automatic
Adjust Lever LH
Tension Spring
Tension Spring
Cup
F42669
Author:
Date:
1321
3231
BRAKE
REAR BRAKE
320IL01
OVERHAUL
HINT:
Overhaul the RH side by the same procedures with LH side.
1.
REMOVE REAR WHEEL
2.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
3.
(a)
Contract
F42837
HINT:
If the brake drum cannot be removed easily, do the following
steps.
(b) Remove the hole plug and insert a screwdriver through
the hole in the backing plate, and hold the automatic adjusting lever away from the adjuster.
(c) Using a another screwdriver, reduce the brake shoe adjuster by turning the adjusting wheel.
4.
(a)
5.
F06408
(a)
(b)
F42670
Author:
Date:
1322
3232
BRAKE
REAR BRAKE
6.
(a)
(b)
F42671
SST
(c)
F42672
7.
8.
(a)
(b)
SST
F42673
(c)
F42688
Author:
Date:
1323
3233
BRAKE
9.
(a)
REAR BRAKE
F42689
10.
F42690
11.
12.
(a)
(b)
F42691
13.
(a)
(b)
(c)
(d)
14.
(a)
Author:
Date:
1324
3234
BRAKE
15.
(a)
(b)
(c)
(d)
F42692
16.
(a)
(b)
(e)
REAR BRAKE
F42693
17.
(a)
18.
F42893
(a)
F42694
19.
(a)
F42688
Author:
Date:
1325
3235
BRAKE
REAR BRAKE
(b)
Using SST, install the rear brake shoe, pin, shoe hold
down spring and cup.
SST 0971800010
20.
(a)
(b)
21.
(a)
(b)
Using SST, install the front brake shoe, pin, shoe hold
down spring and cup.
SST 0971800010
(c)
Using a needlenose pliers, install the anchor side tension spring to each shoe.
INSTALL REAR BRAKE AUTOMATIC ADJUST LEVER
LH
Install the rear brake automatic adjust lever LH to the rear
brake shoe.
SST
F42673
F42695
F42674
SST
F42672
22.
(a)
F42671
Author:
Date:
1326
3236
BRAKE
(b)
F42670
REAR BRAKE
LH:
RH:
Front
Front
F42675
24.
(b)
Remove the hole plug, and turn the adjuster and expand
the shoe until the drum locks.
Expand
F42838
Author:
Date:
1327
3237
BRAKE
(c)
(d)
REAR BRAKE
Contract
F42837
26.
27.
28.
29.
30.
31.
32.
33.
Author:
Date:
1328
3238
BRAKE
ONVEHICLE INSPECTION
1.
(a)
(b)
SST
SST
C86277
2.
RAISE MASTER CYLINDER PRESSURE AND CHECK REAR WHEEL CYLINDER PRESSURE
Master cylinder pressure
kgf/cm2,
1,138 psi)
HINT:
When inspecting the fluid pressure, inspect the left front and right rear together, and the right front and left
rear together.
If the rear wheel cylinder pressure is imprper, replace the proportioning valve assy.
3.
REMOVE LSPV GAUGE (SST)
(a) Remove the LSPV gauge (SST).
SST 0970929018
(b) Install the bleeder plugs.
Torque: 8.3 Nm (85 kgfcm, 74 in.lbf)
4.
BLEED MASTER CYLINDER (See page 324)
SST 0902300100
5.
BLEED BRAKE LINE (See page 324)
6.
CHECK FOR LEAKS
Author:
Date:
1329
3239
BRAKE
REPLACEMENT
1.
(a)
(b)
2.
(a)
(b)
F42835
F42836
F42836
F42835
3.
4.
5.
6.
Author:
Date:
1330
3240
BRAKE
ONVEHICLE INSPECTION
1.
CONNECT HANDHELD TESTER:
(a) Connect the handheld tester to the DLC3.
(b) Start the engine and run it at idle.
(c) Select the ACTIVE TEST mode on the handheld tester.
HINT:
Please refer to the handheld tester operators manual for further details.
2.
INSPECT ACTUATOR MOTOR OPERATION
(a) With the motor relay ON, check the actuator motor operation noise.
(b) Turn the motor relay to 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 continuously. When operating it continuously,
set the interval more than 20 seconds.
(e) Turn the motor relay to 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 to ON simultaneously, and check that the pedal cannot be depressed.
NOTICE:
Do not keep solenoid ON for more than 10 seconds continuously. When operating it continuously,
set the interval more than 20 seconds.
(c) Turn the SFRH and SFRR solenoid to OFF simultaneously, and check that the pedal can be depressed.
(d) Turn the motor relay to ON, and check that the pedal returns.
NOTICE:
Do not keep motor relay ON for more than 5 seconds continuously. When operating it continuously,
set the interval more than 20 seconds.
(e) Turn the motor relay to OFF and release the brake pedal.
4.
INSPECT OTHER WHEEL OPERATION
(a) As 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
Author:
Date:
1331
3241
BRAKE
REPLACEMENT
1.
DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it comes into contact with any painted surface.
2.
REMOVE FRONT WHEEL RH
3.
REMOVE FRONT FENDER LINER RH
4.
REMOVE BRAKE ACTUATOR WITH BRACKET
(a) Turn the latch of the actuator connector to disconnect the
connector.
(b)
(c)
F42822
To Master Cylinder
To Master
Cylinder
To Front Left
To Rear Right
To Front Right
To Rear Left
F42823
Author:
Date:
1332
3242
BRAKE
(d)
F42824
5.
(a)
6.
(a)
F42824
Author:
Date:
1333
3243
BRAKE
To Master Cylinder
To Master
Cylinder
(b)
To Front Left
(c)
Using SST, connect the 6 brake tubes to the correct position of brake actuator, as shown in the illustration.
SST 0902300100
Torque: 15.2 Nm (155 kgfcm, 11 ftlbf)
Connect the brake actuator connector.
To Rear Right
To Front Right
To Rear Left
F42823
8.
9.
10.
11.
12.
13.
14.
15.
Author:
Date:
1334
3244
BRAKE
REPLACEMENT
HINT:
Replace the RH side by the same procedure as the LH side.
1.
REMOVE FRONT WHEEL
2.
REMOVE FRONT FENDER LINER LH
3.
(a)
(b)
F42599
(c)
F40024
C80815
4.
(a)
C80815
Author:
Date:
1335
3245
BRAKE
(b)
(c)
(d)
F40024
F42599
5.
6.
7.
Author:
Date:
1336
3246
BRAKE
REPLACEMENT
HINT:
Replace the RH side by the same procedure as the LH side.
1.
REMOVE REAR WHEEL
2.
REMOVE REAR BRAKE DRUM SUBASSY (See page 3231)
3.
(a)
F12503
4.
REMOVE REAR AXLE HUB & BEARING ASSY LH (See page 3024)
5.
REMOVE SKID CONTROL SENSOR
(a) Mount the rear axle hub in a soft jaw vise.
NOTICE:
Replace the axle hub assembly if it is dropped or a strong
shock is given to it.
(b) Using a pin punch and hammer, drive out the 2 pins and
remove the 2 attachments from SST.
(c) Using SST and 2 bolts (Diameter: 12 mm, pitch: 1.5 mm),
remove the skid control sensor from the rear axle hub.
SST 0952000031 (0952000040), 0952100020,
0995000020
NOTICE:
If a damage is inflicted to the sensor rotor, replace the
axle hub assembly.
Do not scratch the contacting surface of axle hub and
speed sensor.
SST
Bolt
Bolt
SST
F08657
Author:
Date:
1337
3247
BRAKE
6.
(a)
F07318
(c)
SST
Using SST and press, install the new speed sensor to the
axle hub.
SST 0921476011
F08658
7.
INSTALL REAR AXLE HUB & BEARING ASSY LH (See page 3024)
8.
(a)
F12503
9.
10.
11.
12.
Author:
Date:
1338