TOYOTA SIENNA 2007 Service Repair Manual

BR–26BRAKE – FRONT BRAKE
BR
DISASSEMBLY
1. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake
cylinder mounting LH in the vise through aluminum
plates.
(b) Using a screwdriver and hammer, remove the 2
front disc brake bush dust boots from the front disc
brake cylinder mounting LH.
2. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and
cylinder boot.
3. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug, between the front disc brake
piston and the disc brake cylinder sub-assembly.
(b) Use compressed air to remove the front disc brake
piston from the disc brake cylinder sub-assembly.
CAUTION:
Do not place your fingers in front of the piston
when using compressed air.
NOTICE:
Do not spatter the brake fluid.
4. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from
the front disc brake cylinder sub-assembly.
NOTICE:
Do not damage the inner cylinder and cylinder
groove.
5. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the
front disc brake cylinder sub-assembly.
6. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
C068791
R009298
C097869
G023223

BRAKE – FRONT BRAKEBR–27
BR
7. REMOVE FRONT DISC
(a) Place matchmarks on the front disc and the axle
hub.
(b) Remove the front disc.
F041543E13

BR–28BRAKE – FRONT BRAKE
BR
INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the brake cylinder bore and front disc brake
piston for rust or scoring.
2. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Standard thickness:
12.0 mm (0.472 in.)
Minimum thickness:
1.0 mm (0.039 in.)
3. INSPECT FRONT DISC BRAKE PAD SUPPORT
PLATE
(a) Inspect the front disc brake pad support plate (No.
1) and front disc brake pad support plate (No. 2).
Make sure that they have sufficient rebound, no
deformation, cracks or wear, and have had all rust
and dirt cleaned off.
4. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness:
28.0 mm (1.102 in.)
Minimum thickness:
26.0 mm (1.024 in.)
REASSEMBLY
1. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
Select the installation position where the disc has
the minimum runout.
2. INSPECT DISC RUNOUT
(a) Temporarily fasten the disc with the hub nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Using a dial indicator, measure the disc runout 10
mm (0.39 in.) away from the outer edge of the disc.
Maximum disc runout:
0.05 mm (0.0020 in.)
(c) If the disc runout is the maximum value or greater,
check the bearing play in the axial direction and
check for the axle hub runout (See page AH-5). If
the bearing play and axle hub runout are normal,
adjust the disc runout or grind it on a "On-car" brake
lathe.
3. TEMPORARILY TIGHTEN FRONT DISC BRAKE
BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug
to the front disc brake cylinder sub-assembly.
R002951
F042895
F041543E13
C097900

BRAKE – FRONT BRAKEBR–29
BR
4. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
5. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new
piston seal.
(b) Install the piston seal to the front disc brake cylinder
sub-assembly.
6. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front
disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the front disc brake
piston.
(c) Install the front disc brake piston to the front disc
brake cylinder sub-assembly.
NOTICE:
Do not install the piston forcibly in the front disc
brake cylinder sub-assembly.
7. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the front disc brake
cylinder sub-assembly.
NOTICE:
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.
8. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake
cylinder mounting LH in the vise through aluminum
plates.
(b) Place front disc brake cylinder mounting LH in vise.
(c) Apply lithium soap base glycol grease to the sealing
surface of 2 new front disc brake bush dust boots.
(d) Using a socket wrench (19 mm) and hammer, drive
the 2 front disc brake bush dust boots to the front
disc brake cylinder mounting LH.
F045277E04
F042832E03
C068792

BRAKE – REAR DISC BRAKEBR–33
BR
INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the brake cylinder bore and rear disc brake
piston for rust or scoring.
2. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Standard thickness:
11.0mm (0.433 in.)
Minimum thickness:
1.0 mm (0.039 in.)
3. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Inspect the rear brake disc pad support plate (No. 1)
and rear brake disc pad support plate (No. 2). Make
sure that they have sufficient rebound, no
deformation, cracks or wear, and have had all rust
and dirt cleaned off.
4. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness:
12.0mm (0.472 in.)
Minimum thickness:
10.5 mm (0.413 in.)
REASSEMBLY
1. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
Select the installation position where the disc has
the minimum runout.
2. INSPECT DISC RUNOUT
(a) Temporarily fasten the disc with the hub nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Using a dial indicator, measure the disc runout 10
mm (0.39 in.) away from the outer edge of the disc.
Maximum disc runout:
0.10 mm (0.0039 in.)
(c) If the disc runout is the maximum value or greater,
check the bearing play in the axial direction and
check for the axle hub runout (See page AH-16). If
the bearing play and axle hub runout are normal,
adjust the disc runout or grind it on a "On-car" brake
lathe.
3. ADJUST PARKING BRAKE SHOE CLEARANCE
4. TEMPORARILY TIGHTEN REAR DISC BRAKE
BLEEDER PLUG
(a) Temporarily install the rear disc brake bleeder plug
to the disc brake cylinder assembly rear LH.
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
F045358
F041543
C065886

BR–34BRAKE – REAR DISC BRAKE
BR
6. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new
piston seal.
(b) Install the piston seal to the disc brake cylinder
assembly rear LH.
7. INSTALL REAR DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the rear
disc brake piston and new cylinder boot.
(b) Install the cylinder boot to the rear disc brake piston.
(c) Install the rear disc brake piston to the disc brake
cylinder assembly rear LH.
NOTICE:
Do not install the piston forcibly in the disc
brake cylinder.
8. INSTALL CYLINDER BOOT
(a) Install a new cylinder boot to the rear disc brake
cylinder sub-assembly.
NOTICE:
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.
9. INSTALL REAR DISC BRAKE BUSH DUST BOOT
(a) Install the 2 rear disc brake bush dust boot to the
disc brake cylinder mounting LH.
10. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the
sealing surface of the 2 rear disc brake cylinder
slide pins.
G024295
G024294

BR–30BRAKE – REAR DISC BRAKE
BR
BRAKE
BRAKE
REAR DISC BRAKE
COMPONENTS
C119328E03

BRAKE – REAR DISC BRAKEBR–31
BR
REMOVAL
HINT:
Remove the RH side by the same procedure as the LH side.
1. REMOVE REAR WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it attaches to
any painted surface.
3. SEPARATE REAR BRAKE TUBE NO.4
(a) Remove the clip and a disconnect, the rear brake
flexible hose.
(b) Using SST and spanner loosen the rear brake tube
No. 4.
SST 09023-00101
4. SEPARATE REAR LH FLEXIBLE HOSE
(a) Using SST, remove the rear brake flexible hose.
SST 09023-12701
5. REMOVE DISC BRAKE CYLINDER ASSEMBLY REAR
LH
(a) Hold the rear disc brake cylinder slide pin and
remove the 2 bolts.
(b) Remove the disc brake cylinder assembly rear LH
from the rear disc brake cylinder mounting LH.
6. REMOVE REAR DISC BRAKE CYLINDER SLIDE PIN
(a) Remove the 2 rear disc brake cylinder slide pins
from the rear disc brake cylinder mounting LH.
7. REMOVE REAR DISC BRAKE BUSH DUST BOOT
(a) Remove the 2 rear disc brake bush dust boots.
8. REMOVE DISC BRAKE PAD KIT REAR (PAD ONLY)
(a) Remove the disc brake pad kit rear.
9. REMOVE REAR DISC BRAKE ANTI SQUEAL SHIM
KIT
(a) Remove the anti squeal shim No. 1 and anti squeal
shim No. 2 from each pad.
C065884
C090476
C085507

BR–32BRAKE – REAR DISC BRAKE
BR
10. REMOVE REAR DISC BRAKE PAD SUPPORT PLATE
(a) Remove the rear disc brake pad support plate (No.
1) and rear disc brake pad support plate (No. 2)
from the rear disc brake cylinder mounting LH.
11. REMOVE REAR DISC BRAKE CYLINDER MOUNTING
LH
(a) Remove the bolts and rear disc brake cylinder
mounting LH.
DISASSEMBLY
1. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and
cylinder boot.
2. REMOVE REAR DISC BRAKE PISTON
(a) Place a shop rug, between the rear disc brake
piston and the disc brake cylinder.
(b) Use compressed air to remove the rear disc brake
piston from the disc brake cylinder.
CAUTION:
Do not place your fingers in front of the piston
when using compressed air.
NOTICE:
Do not spatter the brake fluid.
3. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from
the disc brake cylinder assembly rear LH.
NOTICE:
Do not damage the inner cylinder and cylinder
groove.
4. REMOVE REAR DISC BRAKE BLEEDER PLUG CAP
5. REMOVE REAR DISC BRAKE BLEEDER PLUG
(a) Remove the rear disc brake bleeder plug from the
disc brake cylinder assembly rear LH.
6. REMOVE REAR DISC
(a) Make matchmarks on the rear disc and the axle
hub.
(b) Remove the rear disc.
F012033
F012034
F012035
F041543E13

BRAKE – REAR DISC BRAKEBR–33
BR
INSPECTION
1. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the brake cylinder bore and rear disc brake
piston for rust or scoring.
2. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Standard thickness:
11.0mm (0.433 in.)
Minimum thickness:
1.0 mm (0.039 in.)
3. INSPECT REAR DISC BRAKE PAD SUPPORT PLATE
(a) Inspect the rear brake disc pad support plate (No. 1)
and rear brake disc pad support plate (No. 2). Make
sure that they have sufficient rebound, no
deformation, cracks or wear, and have had all rust
and dirt cleaned off.
4. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness:
12.0mm (0.472 in.)
Minimum thickness:
10.5 mm (0.413 in.)
REASSEMBLY
1. INSTALL REAR DISC
(a) Aligning the matchmarks, install the rear disc.
HINT:
Select the installation position where the disc has
the minimum runout.
2. INSPECT DISC RUNOUT
(a) Temporarily fasten the disc with the hub nuts.
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
(b) Using a dial indicator, measure the disc runout 10
mm (0.39 in.) away from the outer edge of the disc.
Maximum disc runout:
0.10 mm (0.0039 in.)
(c) If the disc runout is the maximum value or greater,
check the bearing play in the axial direction and
check for the axle hub runout (See page AH-16). If
the bearing play and axle hub runout are normal,
adjust the disc runout or grind it on a "On-car" brake
lathe.
3. ADJUST PARKING BRAKE SHOE CLEARANCE
4. TEMPORARILY TIGHTEN REAR DISC BRAKE
BLEEDER PLUG
(a) Temporarily install the rear disc brake bleeder plug
to the disc brake cylinder assembly rear LH.
5. INSTALL REAR DISC BRAKE BLEEDER PLUG CAP
F045358
F041543
C065886