TOYOTA CAMRY 1999 Service Repair Manual

BR2237
BR0AK±03
BR2238
1st3rd
2nd
GOOD
NO GOOD
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±17
2040 Author: Date:
BRAKE BOOSTER ASSEMBLY
ON±VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.

BR0AL±03
Z19121
Master Cylinder

GasketBrake Booster

Gasket
Pin
Clip
Clevis 2±way

Non±reusable part
N´m (kgf´cm, ft´lbf) : Specified torquew/ ABS (& TRAC)
3±way
15 (155, 11)
13 (130, 9)
25 (260, 19)
13 (130, 9)
BR±18
± BRAKEBRAKE BOOSTER ASSEMBLY
2041 Author: Date:
COMPONENTS

BR0AM±03
F06431
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±19
2042 Author: Date:
REMOVAL
1. REMOVE AIR CLEANER COVER WITH AIR CLEANER
HOSE
2. REMOVE MASTER CYLINDER (See page BR±11)
3. REMOVE CHARCOL CANISTER
4. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
5. REMOVE PEDAL RETURN SPRING
6. REMOVE CLIP AND CLEVIS PIN
7. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS
(a) Remove the 4 nuts and clevis.
(b) Pull out the brake booster and gasket.

BR0AN±03
F03521
SST
Gasket
R11347
SST BR±20
± BRAKEBRAKE BOOSTER ASSEMBLY
2043 Author: Date:
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(d) Install the clevis, and torque the lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(e) Install the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(f) Install the pedal return spring.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install a new gasket on the master cylinder.
(b) Set the SST on the gasket, and lower the pin until its tip
slightly touches the piston.
SST 09737±00010
(c) Turn the SST upside down, and set it on the booster.
SST 09737±00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod light-
ly touches the pin head.
3. INSTALL CHARCOAL CANISTER TO ORIGINAL POSI-
TION
4. INSTALL MASTER CYLINDER (See page BR±16)
5. INSTALL AIR CLEANER COVER WITH AIR CLEANER
HOSE
6. CONNECT VACUUM HOSE TO BRAKE BOOSTER
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR±4)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR±5)
10. DO OPERATIONAL CHECK (See page BR±17)

BR0AO±03
F06983F07224
F07225
Anti±squeal Shim
Inner Anti±squeal Shim
Anti±squeal Spring
Pad Support Plate
Inner PadOuter Pad
1MZ±FE engine: 5S±FE engine:
Anti±squeal Shim
Inner Anti±squeal Shim
Pad Wear Indicator Plate
Outer Pad
Pad Support Plate
Inner Pad
Disc brake grease
N´m (kgf´cm, ft´lbf): Specified torque
34 (350, 25)
34 (350, 25)
± BRAKEFRONT BRAKE PAD
BR±21
2044 Author: Date:
FRONT BRAKE PAD
COMPONENTS

BR0AP±03
F07213
R02874
BR±22
± BRAKEFRONT BRAKE PAD
2045 Author: Date:
REPLACEMENT
1. REMOVE FRONT WHEEL
Remove the wheel and temporarily fasten the disc with hub
nuts.
2. INSPECT PAD LINING THICKNESS
Check the pad thickness through the caliper inspection hole
and replace the pads if they are not within the specification.
Minimum thickness: 1.0 mm (0.039 in.)
3. LIFT UP CALIPER
(a) Remove the bolt and flexible hose from the bracket.
(b) 5S±FE engine:
Hold the sliding pin on the bottom and loosen the installa-
tion bolt, and remove the installation bolt.
(c) 1MZ±FE engine:
Remove the bottom side installation bolt.
(d) Lift up the caliper and suspend it securely.
HINT:
Do not disconnect the flexible hose from the caliper.
4. 5S±FE engine:
REMOVE 2 ANTI±SQUEAL SPRINGS
5. REMOVE 2 BRAKE PADS
6. REMOVE 4 ANTI±SQUEAL SHIMS
7. 1MZ±FE engine:
REMOVE PAD WEAR INDICATOR PLATE
8. 1MZ±FE engine:
REMOVE 2 PAD SUPPORT PLATES
9. 5S±FE engine:
REMOVE 4 PAD SUPPORT PLATES
NOTICE:
The anti±squeal springs and support plates can be used
again provided that they have sufficient rebound, no de-
formation, cracks or wear, and have had all rust, dirt and
foreign particles cleaned off.
10. CHECK DISC THICKNESS AND RUNOUT
(See page BR±28)
11. INSTALL 2 OR 4 PAD SUPPORT PLATES
12. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti±squeal shims and
wear indicator plates must be replaced together with the
pads.

R00595
R02981
± BRAKEFRONT BRAKE PAD
BR±23
2046 Author: Date:
(a) 1MZ±FE engine:
Install a pad wear indicator plate on the inner pad.
(b) Apply disc brake grease to both sides of the inner anti±
squeal shims (See page BR±21).
(c) Install the 2 anti±squeal shims on each pad.
(d) Install inner pad with the pad wear indicator plate facing
upward.
(e) Install inner pad.
(f) Install outer pad.
NOTICE:
There should be no oil or grease adhering to the friction
surfaces of the pads or the disc.
(g) 5S±FE engine:
Install the 2 anti±squeal springs.
13. INSTALL CALIPER
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the piston with a hammer handle or similar imple-
ment.
HINT:
If the piston is difficult to push in, loosen the bleeder plug and
push in the piston while letting some brake fluid escape.
(c) Install the caliper.
(d) 5S±FE engine:
Hold the sliding pin and torque the installation bolt.
(e) 1MZ±FE engine:
Install the installation bolt.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(f) Install the flexible hose and bolt to the bracket.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
14. INSTALL FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
15. DEPRESS BRAKE PEDAL SEVERAL TIMES
16. CHECK THAT FLUID LEVEL IS AT MAX LINE

BR0AQ±02
F07212
Caliper
Torque Plate
Disc

Gasket
Piston
Piston SealSliding Pin

Dust Boot
Pad Support Plate Sliding Pin

Sliding Bushing

Dust Boot
Anti±squeal Spring
Outer Pad Anti±squeal Shim
Inner Anti±squeal Shim
Inner Pad
Disc brake greaseLithium soap base glycol grease
Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque Bleeder Plug
Boot
Set Ring 5S±FE engine:
34 (350, 25)
107 (1,090, 79)29 (300, 21)
8.3 (85, 74 in.´lbf)
29 (300, 21)
BR±24
± BRAKEFRONT BRAKE CALIPER
2047 Author: Date:
FRONT BRAKE CALIPER
COMPONENTS

F07226
1MZ±FE engine:
Caliper
Torque Plate
Disc
PistonSliding pin

Sliding Bushing

Dust Boot
Pad Support Plate Sliding Pin

Dust Boot
Pad Wear Indicator Plate
Inner Pad Piston Seal
BootSet Ring
Outer Pad
Inner Anti±squeal Shim
Anti±squeal Shim
Disc Brake grease Lithium soap base glycol grease
Non±reusable part
N´m (kgf´cm, ft´lbf)
: Specified torque Bleeder Plug
34 (350, 25)
107 (1,090, 79)29 (300, 21)
8.3 (85, 74 in.´lbf)
29 (300, 21)

Gasket
± BRAKEFRONT BRAKE CALIPER
BR±25
2048 Author: Date:

BR0AR±03
R02840
BR±26
± BRAKEFRONT BRAKE CALIPER
2049 Author: Date:
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1.050 kgf´cm, 76 ft´lbf)
2. DISCONNECT FLEXIBLE HOSE
(a) Remove the union bolt and 2 gaskets from the caliper,
then disconnect the flexible hose from the caliper.
Torque: 29 N´m (300 kgf´cm, 21 ft´lbf)
HINT:
At the time of installation, please refer to the following item.
Install the flexible hose lock securely in the lock hole in the cali-
per.
(b) Use a container to catch the brake fluid as it drains out.
3. REMOVE CALIPER
(a) 5S±FE engine:
Hold the sliding pin and loosen the 2 installation bolts, and
remove the installation bolts.
(b) 1MZ±FE engine:
Remove the 2 installation bolts.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
4. 5S±FE engine:
REMOVE 2 ANTI±SQUEAL SPRINGS
5. REMOVE 2 BRAKE PADS WITH ANTI±SQUEAL
SHIMS
6. 1MZ±FE engine:
REMOVE 2 PAD SUPPORT PLATES
7. 5S±FE engine:
REMOVE 4 PAD SUPPORT PLATES