TOYOTA CAMRY 1999 Service Repair Manual

BR0YI±01
F07004
Lower Panel Insert

Bushing ClipClevis PinNo.1 Lower Panel
Return Spring
Cushion Plate
Collar
Brake Pedal
Cowl Side Trim Front Opening Cover
Brake Pedal
Inside Scuff PlateM/T: Stop Light Switch
Wave Washer
Cruise Control ECU
Lithium soap base glycol grease
13 (130, 9)
5.0 (51, 44 in.´lbf)
13 (130, 9)
Pedal Pad
Pedal Pad
Bushing A/T:
39 (400, 29)
: Specified torqueN´m (kgf´cm, ft´lbf)

Non±reusable partBrake Pedal Bracket
± BRAKEBRAKE PEDAL
BR±7
2030 Author: Date:
COMPONENTS

W03254
W03255
Lock Nut
Adjusting Nut
BR0AD±03
BR±8
± BRAKEPARKING BRAKE LEVER
2031 Author: Date:
PARKING BRAKE LEVER
ON±VEHICLE INSPECTION
1. CHECK THAT PARKING BRAKE LEVER TRAVEL
Pull the parking brake lever all the way up, and count the num-
ber 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 LEVER
TRAVEL
HINT:
Before adjusting the parking brake lever travel, make sure that
the rear brake shoe clearance has been adjusted. For shoe
clearance adjustment, see step 2 on page BR±35 or step 1 on
page BR±48.
(a) Remove the console box.
(b) Loosen the lock nut and adjust the adjusting nut until the
lever travel is correct.
(c) Tighten the lock nut.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(d) Install the console box.

BR0AE±02
Z19120
w/ ABS (& TRAC)
2±way
15 (155, 11)
13 (130, 9)
Master Cylinder

GasketBrake Booster
N´m (kgf´cm, ft´lbf) : Specified torque

Non±reusable part w/o ABS
3±way
W03569
N´m (kgf´cm, ft´lbf) : Specified torque
Lithium soap base glycol grease
Grommet
Cylinder BodyNo. 2 PistonNo. 1 Piston SpringSpring Cap
Strainer
Reservoir
Grommet Straight PinReservoir Set Screw
1.7 (18, 16 in.´lbf)
w/ TRAC
± BRAKEBRAKE MASTER CYLINDER
BR±9
2032 Author: Date:
BRAKE MASTER CYLINDER
COMPONENTS

Z19122
w/o ABS
w/ ABSCap
Strainer
Reservoir
No. 2 Piston and Spring
No. 1 Piston and Spring
Cylinder Body
Stopper Bolt
Gasket Reservoir Set Screw
GrommetSnap Ring
Grommet
Cap
Strainer
Reservoir
Reservoir Set Screw
Cylinder Body

Gasket
Stopper Bolt GrommetGrommet
No. 1 Piston and SpringNo. 2 Piston and SpringSnap Ring
Lithium soap base glycol grease
Non±reusable part
N´m (kgf´cm, ft´lbf): Specified torque
1.7 (18, 16 in.´lbf)
10 (100, 7)
1.7 (18, 16 in.´lbf)
10 (100, 7)
BR±10
± BRAKEBRAKE MASTER CYLINDER
2033 Author: Date:

BR0AF±03
W04697
SST
R11405
± BRAKEBRAKE MASTER CYLINDER
BR±11
2034 Author: Date:
REMOVAL
1. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
3. DISCONNECT BRAKE LINES
(a) w/ ABS (& TRAC):
Using SST, disconnect the 4 brake lines.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
(b) w/o ABS:
Using SST, disconnect the 5 brake lines.
SST 09023±00100
Torque: 15 N´m (155 kgf´cm, 11 ft´lbf)
4. REMOVE MASTER CYLINDER
Remove the 2 nuts, and pull out the 2 or 3±way, master cylinder
and gasket.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)

BR0AG±02
R11406
Soft Jows
R11407
Soft Jows
R12236
A BR±12
± BRAKEBRAKE MASTER CYLINDER
2035 Author: Date:
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (18 kgf´cm, 16 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. Except w/ TRAC:
PLACE CYLINDER IN VISE
4. w/o TRAC:
REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. w/o TRAC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
HINT:
Tape the screwdriver tip before use.
(b) Remove the No. 1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

At the time of reassembly, please refer to the follow-
ing item.
Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table, and
lightly tap the cylinder flange against the block edges until
the No. 2 piston drops out of the cylinder.
HINT:
Make sure that the distance (A) from the rag to the top of the
blocks is at least 100 mm (3.94 in.).

W03570
W03590
± BRAKEBRAKE MASTER CYLINDER
BR±13
2036 Author: Date:
6. w/ TRAC:
REMOVE 2 PISTONS AND SPRINGS
(a) Push in the piston with a screwdriver, and remove the 2
straight pins by turning over the cylinder body.
HINT:
Tape the screwdriver tip before use.
(b) Remove the 2 pistons and springs by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

At the time of reassembly, be careful not to damage
the rubber lips on the pistons.
HINT:
At the time of reassembly, insert the pistons with elliptic hole
facing vertically.

BR0AH±01
BR±14
± BRAKEBRAKE MASTER CYLINDER
2037 Author: Date:
INSPECTION
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.

BR0AI±02
± BRAKEBRAKE MASTER CYLINDER
BR±15
2038 Author: Date:
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR±12).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows
(See page BR±9).

BR0AJ±02
BR±16
± BRAKEBRAKE MASTER CYLINDER
2039 Author: Date:
INSTALLATION
Installation is in the reverse order of removal (See page BR±11).
HINT:

Before installation, adjust length of the brake booster push rod (See page BR±20).

After installation, fill the brake reservoir with brake fluid, bleed the brake system and check for leaks
(See page BR±4).

Check and adjust brake pedal (See page BR±5).