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Brake: Other Scion tC I

Mechanical - Hydraulic 47 illustrations ~2890 words

PRECAUTION

Note. Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with ones having 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 PRECAUTION .

BLEEDING

Note. Wash brake fluid off immediately if it adheres to any painted surface.

HINT

If any work is performed on the brake system or if air in the brake lines is suspected, bleed the air out of the brake system.

Scheme 82

Scheme 82: BLEEDING
Scheme 82: BLEEDING

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  1. FILL RESERVOIR WITH BRAKE FLUID Fluid: SAE J1703 or FMVSS No. 116 DOT3
  2. BLEED MASTER CYLINDER HINT: If the master cylinder has been disassembled or if the reservoir becomes empty, bleed the air out of the master cylinder. Using SST, disconnect the brake lines from the master cylinder sub-assy. SST 09023-00101 Slowly depress and hold the brake pedal. Cover the outer holes with your fingers, and release the brake pedal. Repeat ( b ) and ( c ) 3 or 4 times. Using SST, connect the brake lines to the master cylinder sub-assy. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
  3. BLEED BRAKE LINE Connect the vinyl tube to the bleeder plug. Depress the brake pedal several times, then loosen the bleeder plug with the pedal depressed. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Repeat ( b ) and ( c ) until all the air in the fluid is completely bled out. Tighten the bleeder plug completely. Torque: 8.3 N.m (85 kgf.cm, 74 in.lbf) Repeat the above procedures for each wheel to bleed the air out of the brake line.
  4. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3

Scheme 87

Scheme 87: ADJUSTMENT
Scheme 87: ADJUSTMENT

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Scheme 90
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Scheme 91

Scheme 91
Scheme 91
  1. CHECK AND ADJUST BRAKE PEDAL HEIGHT Check brake pedal height. Pedal height from asphalt sheet: M/T: 146.1 to 156.1 mm (5.752 to 6.146 in.) A/T: 146.9 to 156.9 mm (5.784 to 6.177 in.) Adjust brake pedal height. Disconnect the connector from the stop lamp switch assy. Remove the stop lamp switch assy. Loosen the clevis lock nut. Adjust the pedal height by turning the push rod. Tighten the clevis lock nut. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Insert the stop lamp switch assy into the adjuster until it slightly touches the pedal sub-assy. NOTE: Do not depress the brake pedal. Make a quarter turn clockwise to install the stop lamp switch assy. NOTE: Do not depress the brake pedal. HINT: The turning torque for installing the stop lamp switch assy: Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) or less Connect the connector to the stop lamp switch assy. Check the stop lamp switch clearance. Stop lamp switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.)
  2. CHECK PEDAL FREE PLAY Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. Press the pedal until resistance is felt. Measure the distance (Scheme 90) Pedal freeplay: 1.0 to 6.0 mm (0.039 to 0.236 in.) If incorrect, proceed to the following step: Check the stop lamp switch clearance. Stop lamp switch clearance: 1.5 to 2.5 mm (0.059 to 0.098 in.) If the clearance is OK, troubleshoot the brake system. If incorrect, adjust the stop lamp switch clearance.
  3. CHECK PEDAL RESERVE DISTANCE Release the parking brake pedal. With engine running, depress the pedal and measure the pedal reserve distance (Scheme 91) Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf): More than 90 mm (3.54 in.) If incorrect, troubleshoot the brake system.

Scheme 92

Scheme 92: COMPONENTS
Scheme 92: COMPONENTS

Scheme 93

Scheme 93: REPLACEMENT
Scheme 93: REPLACEMENT

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Scheme 100
  1. REMOVE METER HOOD SUB-ASSY (See «COMBINATION METER ASSY»(ref-224792-S08256492392006031100000) )
  2. REMOVE COMBINATION METER ASSY (See «COMBINATION METER ASSY»(ref-224792-S08256492392006031100000) )
  3. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS Remove the return spring. Remove the clip and the clevis pin, and separate the push rod clevis from the brake pedal sub-assy.
  4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY Disconnect the stop lamp switch connector. Separate the wire harness clamp from the pedal support sub-assy. Remove the bolt from the pedal support sub-assy. Remove the 4 nuts and pedal support sub-assy.
  5. REMOVE BRAKE PEDAL SUB-ASSY Remove the nut, brake pedal shaft, and brake pedal sub-assy. Remove the 2 bushes from the brake pedal sub-assy.
  6. REMOVE STOP LAMP SWITCH ASSY Turn the stop lamp switch assy counterclockwise and remove it. Remove the mounting adjuster from the pedal support sub-assy.
  7. REMOVE BRAKE PEDAL PAD
  8. INSTALL BRAKE PEDAL PAD
  9. INSTALL BRAKE PEDAL SUB-ASSY Apply lithium soap base glycol grease to 2 new bushes. Install them to the brake pedal sub-assy. Install the brake pedal sub-assy to the pedal support sub-assy with the nut and brake pedal shaft. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf)
  10. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY Install the pedal support sub-assy with the 4 nuts. Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) Install the bolt to the pedal support sub-assy. Torque: 24 N.m (241 kgf.cm, 17 ft.lbf)
  11. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS Apply lithium soap base glycol grease to the clevis pin. Install the push rod clevis with the clevis pin and the clip. Install the return spring.
  12. INSTALL STOP LAMP SWITCH ASSY Install the mounting adjuster to the pedal support sub-assy. Insert the stop lamp switch assy to the adjuster until it slightly touches the pedal sub-assy. NOTE: Do not depress the brake pedal. Make a quarter turn clockwise to install the stop lamp switch assy. NOTE: Do not depress the brake pedal. HINT: The turning torque for installing the stop lamp switch assy: Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) or less Install the wire harness clamp to the pedal support sub-assy. Connect the stop lamp switch connector to the stop lamp switch assy.
  13. INSTALL COMBINATION METER ASSY
  14. INSTALL METER HOOD SUB-ASSY
  15. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )
  16. CHECK PEDAL FREE PLAY (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )
  17. CHECK PEDAL RESERVE DISTANCE (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )

Scheme 101

Scheme 101: OVERHAUL
Scheme 101: OVERHAUL

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Scheme 117
  1. DRAIN BRAKE FLUID NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
  2. REMOVE FRONT WIPER ARM HEAD CAP
  3. REMOVE FR WIPER ARM & BLADE ASSY LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  4. REMOVE FR WIPER ARM & BLADE ASSY RH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  5. REMOVE HOOD TO COWL TOP SEAL (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  6. REMOVE COWL TOP VENTILATOR LOUVER LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  7. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  8. REMOVE COWL TOP PANEL SUB-ASSY OUTER Remove the 7 bolts and cowl top panel sub-assy outer.
  9. REMOVE COWL WATER EXTRACT HOSE NO.1 Remove the clip and water extract hose No.1.
  10. REMOVE COWL BODY MOUNTING BRACKET LOWER LH Remove a bolt and body mounting bracket lower LH.
  11. REMOVE AIR CLEANER CAP SUB-ASSY
  12. REMOVE BRAKE MASTER CYLINDER SUB-ASSY Using SST, disconnect the 2 brake tubes from the master cylinder sub-assy. SST 09023-00101 Using SST, disconnect the 2 brake tubes from the No.1 way. SST 09023-00101 Remove the clips and disconnect the 2 reservoir tubes from the master cylinder sub-assy. Remove the 2 nuts, and pull out the master cylinder sub-assy and No.1 way.
  13. REMOVE UNION Remove the stopper screw and master cylinder union. Remove the 2 grommets from the master cylinder sub-assy.
  14. REMOVE BRAKE MASTER CYLINDER KIT Hold the master cylinder sub-assy in a vise with the 2 aluminum plates in between. Remove the O-ring from the master cylinder sub-assy. Push in the piston and remove the snap ring using snap ring pliers. NOTE: When pushing in the piston, the fluid left in the cylinder may spatter. Push in the piston and remove the piston stopper bolt and gasket. Remove the No.1 piston from the master cylinder body by pulling it straight out. NOTE: Do not scratch the inside of the cylinder body. Tap the flanged part against wooden blocks until the end of the No.2 piston comes out. When the end of the No.2 piston comes out, pull out the No.2 piston straight from the master cylinder body. NOTE: Do not scratch the inside of the cylinder body.
  15. INSPECT BRAKE MASTER CYLINDER Check the inside of the brake master cylinder for scratch. HINT: Replace the master cylinder sub-assy if necessary.
  16. INSTALL BRAKE MASTER CYLINDER KIT Placing aluminum plates between the vise and the master cylinder sub-assy, place the master cylinder sub-assy in the vise. Apply lithium soap base glycol grease to the rubber part (Scheme 108) Install the No.1 and No.2 pistons to the master cylinder body. NOTE: Install the piston straight carefully not to give any damage to the inside of the cylinder. Do not damage the lip of the cylinder cup. Push in the piston and install a new gasket and a new piston stopper bolt. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) Install the hole snap ring using snap ring pliers with the piston pushed in. NOTE: Do not scratch the inside of the cylinder body. Apply lithium soap base glycol grease to a new O-ring. Install the O-ring to the master cylinder body.
  17. INSTALL UNION Apply lithium soap base glycol grease and silicon grease to the 2 grommets (Scheme 111) Install the 2 grommets to the master cylinder body. Install the master cylinder union with the stopper screw.
  18. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD Set SST on the master cylinder and lower the rod of the SST until it slightly touches the piston. SST 09737-00013 Apply chalk to the flat tip of the SST rod. Turn the SST upside down and measure the clearance between the brake booster push rod and the SST. Clearance: 0 mm (0 in.) HINT: If there is a clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick on the tip of the brake booster push rod, the push rod protrusion is insufficient. If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a socket driver (7 mm). SST 09737-00020 HINT: Check the push rod clearance again after adjustment.
  19. INSTALL BRAKE MASTER CYLINDER SUB-ASSY Install the master cylinder sub-assy and No.1 way with the 2 nuts. Torque: 12.5 N.m (127 kgf.cm, 9 ft.lbf) Connect the 2 reservoir tubes to the master cylinder sub-assy with the clips. Using SST, connect the 2 brake tubes to the No.1 way. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) Using SST, connect the 2 brake tubes to the master cylinder sub-assy. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
  20. INSTALL AIR CLEANER CAP SUB-ASSY
  21. INSTALL COWL BODY MOUNTING BRACKET LOWER LH Install the body mounting bracket lower LH with a bolt. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
  22. INSTALL COWL WATER EXTRACT HOSE NO.1 Install the water extract hose No.1 with the clip.
  23. INSTALL COWL TOP PANEL SUB-ASSY OUTER Install the cowl top panel sub-assy outer with the 7 bolts. Torque: 13 N.m (133 kgf.cm, 10 ft.lbf)
  24. FILL RESERVOIR WITH BRAKE FLUID (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  25. BLEED MASTER CYLINDER (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) ) SST 09023-00101
  26. BLEED BRAKE LINE (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  27. CHECK FLUID LEVEL IN RESERVOIR (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  28. CHECK FOR BRAKE FLUID LEAKAGE
  29. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  30. INSTALL COWL TOP VENTILATOR LOUVER LH
  31. INSTALL HOOD TO COWL TOP SEAL (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  32. INSTALL FR WIPER ARM & BLADE ASSY RH
  33. INSTALL FR WIPER ARM & BLADE ASSY LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  34. INSTALL FRONT WIPER ARM HEAD CAP

Scheme 118

Scheme 118: ON-VEHICLE INSPECTION
Scheme 118: ON-VEHICLE INSPECTION

Scheme 119

Scheme 119
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Scheme 120

Scheme 120
Scheme 120
  1. INSPECT BRAKE BOOSTER ASSY Airtightness check. Start the engine and stop it after 1 or 2 minutes. Depress the brake pedal several times slowly. HINT: If the pedal goes down farthest the 1st time, but gradually rises after the 2nd or 3rd time, the booster is airtight. If incorrect, inspect the vacuum check valve. If the vacuum check valve is normal, replace the brake booster assy. 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. If incorrect, inspect the vacuum check valve. If the vacuum check valve is normal, replace the brake booster assy. Operation check. Depress the brake pedal several times with the ignition switch off and check that there is no change in the pedal reserve distance. Depress the brake pedal and start the engine. HINT: If the pedal goes down slightly, operation is normal. If incorrect, inspect the vacuum check valve. If the vacuum check valve is normal, replace the brake booster assy.
  2. INSPECT VACUUM CHECK VALVE ASSY Inspect vacuum check valve. Slide the clip and disconnect the vacuum hose. Remove the vacuum check valve. Check that there is ventilation from the booster to engine, and no ventilation from the engine to the booster. HINT: If any fault is found, replace the vacuum check valve.

Scheme 121

Scheme 121: COMPONENTS
Scheme 121: COMPONENTS

Scheme 122

Scheme 122: REPLACEMENT
Scheme 122: REPLACEMENT

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Scheme 123
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Scheme 127
Scheme 127
  1. DRAIN BRAKE FLUID NOTE: Wash brake fluid off immediately if it adheres to any painted surface.
  2. REMOVE FRONT WIPER ARM HEAD CAP
  3. REMOVE FR WIPER ARM & BLADE ASSY LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  4. REMOVE FR WIPER ARM & BLADE ASSY RH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  5. REMOVE HOOD TO COWL TOP SEAL (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  6. REMOVE COWL TOP VENTILATOR LOUVER LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  7. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  8. REMOVE COWL TOP PANEL SUB-ASSY OUTER (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  9. REMOVE COWL WATER EXTRACT HOSE NO.1 (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  10. REMOVE COWL BODY MOUNTING BRACKET LOWER LH (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  11. REMOVE AIR CLEANER CAP SUB-ASSY
  12. REMOVE BRAKE MASTER CYLINDER SUB-ASSY (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) ) SST 09023-00101
  13. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See «REPLACEMENT»(ref-224778-S03794895622006031100000) )
  14. REMOVE FRONT WHEEL LH
  15. REMOVE FRONT BRAKE TUBE NO.5 Using SST, disconnect the front brake tube No.5 and remove it. SST 09023-00101
  16. SEPARATE BRAKE TUBE Separate the 3 brake tubes from the clamps (Scheme 123) Remove the clamp from the brake tubes.
  17. REMOVE BRAKE BOOSTER ASSY Loosen the clevis lock nut and remove the push rod clevis from the brake booster assy. Slide the clip, disconnect the vacuum hose from the brake booster assy. Remove the 4 nuts and brake booster assy. Remove the check valve assy and grommet from the brake booster assy.
  18. REMOVE BRAKE BOOSTER GASKET
  19. INSTALL BRAKE BOOSTER GASKET Install a new brake booster gasket to the brake booster assy.
  20. INSTALL BRAKE BOOSTER ASSY Install the grommet and check valve assy to the brake booster assy. Install the brake booster assy with the 4 nuts. Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) Connect the vacuum hose to the brake booster assy with the clip. Install the push rod clevis and clevis lock nut to the brake booster assy. HINT: After adjusting the brake pedal height, torque the clevis lock nut.
  21. INSTALL BRAKE TUBE Install the 3 brake tubes to the clamps (Scheme 126) Install the clamp to the brake tubes.
  22. INSTALL FRONT BRAKE TUBE NO.5 Using SST, connect the front brake tube No.5. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) NOTE: Make sure that the grommet is installed correctly.
  23. INSTALL FRONT WHEEL LH Torque: 103 N.m (1,050 kgf.cm, 76 ft.lbf)
  24. INSTALL BRAKE MASTER CYLINDER SUB-ASSY (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) ) SST 09023-00101
  25. INSTALL AIR CLEANER CAP SUB-ASSY
  26. INSTALL COWL BODY MOUNTING BRACKET LOWER LH (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  27. INSTALL COWL WATER EXTRACT HOSE NO.1 (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  28. INSTALL COWL TOP PANEL SUB-ASSY OUTER (See «BRAKE MASTER CYLINDER SUB-ASSY»(ref-224778-S42215583282006031100000) )
  29. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS (See «REPLACEMENT»(ref-224778-S03794895622006031100000) )
  30. FILL RESERVOIR WITH BRAKE FLUID (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  31. BLEED MASTER CYLINDER (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) ) SST 09023-00101
  32. BLEED BRAKE LINE (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  33. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )
  34. CHECK PEDAL FREE PLAY (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )
  35. CHECK PEDAL RESERVE DISTANCE (See «BRAKE PEDAL SUB ASSY»(ref-224778-S09786621832006031100000) )
  36. CHECK FLUID LEVEL IN RESERVOIR (See «BRAKE FLUID»(ref-224778-S03975965282006031100000) )
  37. CHECK FOR BRAKE FLUID LEAKAGE
  38. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  39. INSTALL COWL TOP VENTILATOR LOUVER LH
  40. INSTALL HOOD TO COWL TOP SEAL (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  41. INSTALL FR WIPER ARM & BLADE ASSY RH
  42. INSTALL FR WIPER ARM & BLADE ASSY LH (See «WINDSHIELD WIPER MOTOR ASSY»(ref-224789-S33009965512006031100000) )
  43. INSTALL FRONT WIPER ARM HEAD CAP
  44. INSPECT BRAKE BOOSTER ASSY (See «BRAKE BOOSTER ASSY»(ref-224778-S02251821682006031100000) )

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Scheme 128: COMPONENTS
Scheme 128: COMPONENTS

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