lock LEXUS SC400 1991 Service Repair Manual

PARKING BRAKE CHECK AND
ADJUSTMENT
BR03R±04
1. CHECK THAT PARKING BRAKE LEVER TRAVEL IS
CORRECT
Pull the parking brake lever all the way up, and count the
number of clicks.
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf):
5±8 clicks
If incorrect, adjust the parking brake.
2. IF NECESSARY, ADJUST PARKING BRAKE HINT: Before adjusting the parking brake, make sure that the
rear brake shoe clearance has been adjusted.
For shoe clearance adjustment, see page BR±49.
(a) Remove the cup holder.
(b) Using a socket driver and spanner wrench, remove the adjusting lock nut.
HINT: Tape the socket driver before use.
(c) Turn the adjusting nut until the lever travel is correct.
(d) Install the adjusting lock nut.
(e) Using a socket driver and s panner wrench, tighten the
adjusting lock nut.
Torque: 5.4 N Vm (55 kgf Vcm, 48 in. Vlbf)
(f) Install the cup holder.
±
BRAKE SYSTEM CHECK AND ADJUSTMENTBR±11
WhereEverybodyKnowsYourName

3. REMOVE RESERVOIRRemove the set screw and pull out the reservoir.
4. REMOVE 2 GROMMETS
5. PLACE CYLINDER IN VISE
6. w/ TRAC: REMOVE NO.1 PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and re-
move the No.1 piston stopper bolt and gasket.
HINT: Tape the screwdriver tip before use.
7. REMOVE NO.2 PISTON STOPPER BOLT Using a screwdriver, push the pistons in all the way and re-
move the No.2 piston stopper bolt and gasket.
8. REMOVE PISTONS
(a) Push in the piston with a screwdriver and remove the snap ring with snap ring pliers.
(b) Remove the No. 1 piston and spring by hand, pulling straight out, not at an angle.
NOTICE: If pulled out at an angle, there is a possibility that the
cylinder bore could be damaged.
(c) Place a rag and 2 wooden blocks on the work table and lightly
tap the cylinder flange against the block edges until the piston
drops out of the cylinder.
HINT: Make sure the distance (A) from the rag to the top of
the blocks is at least 100 mm (3.94 in.).
MASTER CYLINDER COMPONENTS
INSPECTION
BR03V±05
HINT: Clean the disassembled parts with compressed air.
1. INSPECT CYLINDER BORE FOR RUST OR SCORING
2. INSPECT CYLINDER FOR WEAR OR DAMAGE If necessary, clean or replace the cylinder.
±
BRAKE SYSTEM MASTER CYLINDERBR±15
WhereEverybodyKnowsYourName

MASTER CYLINDER ASSEMBLY
BR0EH±05
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TORUBBER PARTS INDICATED BY ARROWS
2. INSTALL PISTONS
NOTICE: Be careful not to damage the rubber lips on the pis-
tons.
(a) Insert the 2 pistons straight in, not at an angle.
NOTICE: If inserted at an angle, there is a possibility that the
cylinder bore could be damaged.
(b) Push in the piston with a screwdriver and install the snap ring
with snap ring pliers.
HINT: Tape the screwdriver tip before use.
3. w/ TRAC: INSTALL NO. 1 PISTON STOPPER BOLT
Using a screwdriver, push the piston in all the way and install
the No. 1 piston stopper bolt over a new gasket.
Torque: 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
4. INSTALL NO. 2 PISTON STOPPER BOLT
Using a screwdriver, push the piston in all the way and install
the No. 2 piston stopper bolt over a new gasket.
Torque: 10 N Vm (100 kgf Vcm, 7 ft Vlbf)
5. INSTALL 2 GROMMETS
6. INSTALL RESERVOIR
(a) Install the strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 1.7 N Vm (17.5 kgf Vcm, 15.2 in. Vlbf)
7. INSTALL RESERVOIR CAP
(a) Align the matchmark on the reservoir cap with the matchmark
on the ªopenº side of reservoir.
(b) Push down on the reservoir cap and turn it clockwise until it locks.
(c) Check that the matchmark on the reservoir cap is now aligned with the matchmark on the ªcloseº side of the
reservoir.
BR±16
±
BRAKE SYSTEM MASTER CYLINDER
WhereEverybodyKnowsYourName

2. INSTALL CALIPER
(a) Temporarily install the caliper on the torque plate with 2installation bolts.
(b) Hold the sliding pin and torque the installation bolt.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
3. CONNECT FLEXIBLE HOSE
Install the flexible hose on the caliper with 2 new gaskets.
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Insert the flexible hose lock securely in the lock hole in
the caliper.
4. FILL BRAKE R ESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±8)
5. CHECK FOR LEAKS
BR±36
±
BRAKE SYSTEM FRONT BRAKE (SC400)
WhereEverybodyKnowsYourName

3. INSTALL PISTON SEAL AND PISTON IN CALIPER
4. INSTALL CYLINDER BOOT AND CYLINDER BOOT SETRING
CALIPER INSTALLATION
BR0ER±04
1. INSTALL FOLLOWING PARTS:
(a) 2 brake pads
(b) 2 anti±squeal springs
2. INSTALL CALIPER
(a) Temporarily install the caliper on the torque plate with 2installation bolts.
(b) Hold the sliding pin and torque the installation bolts.
Torque: 34 N Vm (350 kgf Vcm, 25 ft Vlbf)
3. CONNECT FLEXIBLE HOSE
Install the flexible hose on the caliper with 2 new gaskets.
Torque: 30 N Vm (310 kgf Vcm, 22 ft Vlbf)
HINT: Install the flexible hose lock securely in the lock hole
in the caliper.
4. FILL BRAKE R ESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±8)
5. CHECK FOR LEAKS
±
BRAKE SYSTEM REAR BRAKE (Disc Brake)BR±43
WhereEverybodyKnowsYourName

6. INSTALL SHOE STRUT WITH SPRINGInstall the strut with the spring forward.
7. INSTALL SHOE RETURN SPRINGS Using needle±nose pliers, install the front shoe return spring
and then install the rear shoe return spring.
8. INSTALL DISC
(a) Before installing, polish the disc and shoe surfaces with sandpaper.
(b) Align the matchmarks and install the disc. HINT: If there are no matchmarks, temporarily install the disc,
then measure the disc runout and install the disc in the posi-
tion.
(See page BR±41)
9. ADJUST PARKING BRAKE SHOE CLEARANCE
(a) Temporarily install the hub nuts.
(b) Remove the hole plug.
(c) Turn the adjuster and expand the shoes until the disc locks.
(d) Return the adjuster 8 notches.
(e) Install the hole plug.
10. INSTALL REAR DISC BRAKE ASSEMBLY Install the disc brake assembly and torque the 2 mounting
bolts.
Torque: 104 N Vm (1,065 kgf Vcm, 77 ft Vlbf)
11. INSTALL REAR WHEEL
±
BRAKE SYSTEM REAR BRAKE (Parking Brake)BR±49
WhereEverybodyKnowsYourName

ANTI±LOCK BRAKE SYSTEM (ABS)
BR0EU±04
DESCRIPTION

ABS is a brake system which controls the brake cylinder hydraulic pressure \
to all 4 wheels during sudden
braking and braking on slippery road surfaces, preventing the wheels from locki\
ng. ABS provides the
following benefits:
(1) Enables steering round an obstacle with a greater degree of certai\
nty even when panic braking.
(2) Enables stopping during panic braking while keeping the effect upon stability and steerability to a mini-
mum, even on curves.

In case a malfunction occurs, a diagnosis function and fail±safe system have been adopted for the ABS.
SYSTEM PARTS LOCATION
BR02L±05
BR±52±
BRAKE SYSTEM ANTI±LOCK BRAKE SYSTEM (ABS)
WhereEverybodyKnowsYourName

BR0EV±04
HYDRAULIC SYSTEM DIAGRAM
w/o TRAC:
±
BRAKE SYSTEM ANTI±LOCK BRAKE SYSTEM (ABS)BR±53
WhereEverybodyKnowsYourName

w/ TRAC:
BR±54±
BRAKE SYSTEM ANTI±LOCK BRAKE SYSTEM (ABS)
WhereEverybodyKnowsYourName

BR0EW±05
WIRING DIAGRAM
w/o TRAC:
±
BRAKE SYSTEM ANTI±LOCK BRAKE SYSTEM (ABS)BR±55
WhereEverybodyKnowsYourName