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Brake: Other Scion xB I

Mechanical - Hydraulic 19 illustrations ~1735 words

PRECAUTION

  1. 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 ones with parts having the same part numbers or equivalent.
  2. It is very important to keep the parts and the working area clean when repairing the brake system.
  3. If the vehicle is equipped with a mobile communication system, refer to «PRECAUTION»(ref-224507-S17686363002006031000000) .

BLEEDING

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.

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

Scheme 94

Scheme 94: BLEEDING
Scheme 94: BLEEDING

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Scheme 95

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Scheme 101

Scheme 101
Scheme 101
  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. Disconnect the brake lines from the master cylinder. SST 09023-00101 Slowly depress and hold the brake pedal. Cover off the outer holes with your fingers, and release the brake pedal. Using SST, Repeat (b) and (c) 3 or 4 times. Connect the brake lines from the master cylinder. SST 09023-00101 Torque: 15 N.m (155 kgf.cm, 11 ft.lbf)
  3. BLEED BRAKE LINE Connect the vinyl tube to either one of 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. Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf) Repeat (b) and (c) until all the air in the fluid is completely bled out. Repeat the above procedure to bleed the air out of the brake line for each wheel.
  4. BLEED BRAKE ACTUATOR NOTE: After performing the usual air bleeding in the brake system, if the height or feel of the brake pedal cannot be obtained, perform air bleeding in the VSC actuator assy with the hand-held tester by following the procedures below. Depress the brake pedal more than 20 times with the engine off. Connect the hand-held tester to the DLC3, then turn the ignition switch ON. NOTE: Do not start the engine. Select "AIR BLEEDING" on the hand-held tester. HINT: Please refer to the Hand-Held Tester Operator's Manual for further details. Bleed out the air out of the brake line in "Step 1: Increase" on the hand-held tester display. NOTE: Perform the air bleeding by following the steps displayed on the hand-held tester. Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. Connect the vinyl tube to either one of the bleeder plugs. Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf) Repeat (2) and (3) until all the air in the fluid is completely bled out. Repeat the above procedure to bleed the air out of the brake line for each wheel. Bleed the air out of the suction line in "Step 2: Inhalation" on the hand-held tester display. NOTE: Perform the air bleeding by following the steps displayed on the hand-held tester. Be careful that the brake fluid in the master cylinder reservoir tank does not become empty. Connect the vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug. Operate the ABS actuator assy using the hand-held tester to bleed the air. NOTE: The operation stops automatically in 4 seconds. At this time, be sure to release the brake pedal. Check that the operation stops by using the screen of the hand-held tester. Repeat (2) and (3) until all the air in the fluid is completely bled out. Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf) For the rest of the wheels, bleed the air in the same way as stated in the above procedure. Bleed the air out of the pressure reduction line in "Step 3: Decrease" on the hand-held tester display. NOTE: Perform the air bleeding by following the steps displayed on the hand-held tester. Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. Connect a vinyl tube to either one of the bleeder plugs. Loosen the bleeder plug. Using the hand-held tester operate the ABS actuator assy using hand-held tester, completely depress the brake pedal and keep depressing it. NOTE: The operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required. When the operation is completed, the brake pedal slightly goes down. This is a normal phenomenon caused when the solenoid opens. During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug. Be sure to keep depressing the brake pedal. Never depress and release the pedal repeatedly. Tighten the bleeder plug, then release the brake pedal. Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf) Repeat (2) to (4) until all the air in the fluid is completely bled out. Repeat the above procedure to bleed the air out of the brake line for each wheel. Bleed the air out of the brake line again in "Step 4: Increase" on the hand-held tester display. NOTE: Perform air bleeding by following the steps displayed on the hand-held tester. Make sure that the brake fluid in the master cylinder reservoir tank does not become empty. Connect the vinyl tube to either one of the bleeder plugs. Depress the brake pedal several times, then loosen the bleeder plug of one of the above wheels with the pedal depressed. When fluid stops coming out, tighten the bleeder plug, then release the brake pedal. Torque: 8.3 N.m (85 kgf.cm, 73 in.lbf) Repeat (2) and (3) until all the air in the fluid is completely bled out. Repeat the above procedure to bleed the air out of the brake line for each wheel.
  5. CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid, if necessary. Fluid: SAE J1703 or FMVSS No. 116 DOT3

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Scheme 102: ADJUSTMENT
Scheme 102: ADJUSTMENT

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Scheme 103
Scheme 103

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Scheme 104
  1. CHECK AND ADJUST BRAKE PEDAL HEIGHT Check brake pedal height. Pedal height from dash panel: 124.5 to 134.5 mm (4.902 to 5.293 in.) Adjust brake pedal height. Remove the instrument finish panel lower. Disconnect the connector from the stop lamp switch assy. Loosen the stop lamp switch lock nut, and remove the stop lamp switch assy. Loosen the brake master cylinder push rod clevis lock nut. Adjust the pedal height by turning the pedal push rod. Tighten the push rod lock nut. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) Install the stop lamp switch assy. Connect the connector to the stop lamp switch assy. Push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), and turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off. After the installation, push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), and check that the stop lamp comes on.
  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 in the pedal until the resistance begins to be felt, and then measure the distance (Scheme 103) Pedal free play: 1 to 6 mm (0.04 to 0.24 in.) If the clearance is not as specified, check the stop lamp switch clearance. If the clearance is OK, then troubleshoot the brake system. Stop lamp switch clearance: 0.5 to 2.4 mm (0.020 to 0.094 in.)
  3. CHECK PEDAL RESERVE DISTANCE Release the parking brake lever. With the engine running, depress the pedal and measure the pedal reserve distance (Scheme 104) Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf): More than 55 mm (2.17 in.) If the distance is within the specification, troubleshoot the brake system.

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Scheme 105: COMPONENTS
Scheme 105: COMPONENTS

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Scheme 106: REPLACEMENT
Scheme 106: REPLACEMENT

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  1. DISCONNECT BATTERY NEGATIVE TERMINAL
  2. REMOVE INSTRUMENT PANEL SUB-ASSY (See «INSTRUMENT PANEL SUB-ASSY»(ref-224567-S17131594782006031000000) )
  3. SEPARATE MASTER CYLINDER PUSH ROD CLEVIS Disconnect the stop lamp switch connector. Remove the brake pedal return spring. Remove the clip and the clevis pin and separate the master cylinder push rod clevis from the brake pedal sub-assy.
  4. REMOVE BRAKE PEDAL SUPPORT ASSY Remove the bolt from the brake pedal support assy. Remove the 4 nuts and the brake pedal support assy.
  5. REMOVE BRAKE PEDAL SUB-ASSY Remove the brake pedal shaft and the nut from the brake pedal support sub-assy. Remove the brake pedal sub-assy and the 2 bushes.
  6. REMOVE STOP LAMP SWITCH ASSY Loosen the stop lamp switch lock nut. Remove the stop lamp switch assy from the brake pedal support sub-assy.
  7. REMOVE BRAKE PEDAL PAD Remove the brake pedal pad from the brake pedal support sub-assy.
  8. INSTALL BRAKE PEDAL PAD Install the brake pedal pad to the brake pedal support sub-assy.
  9. INSTALL STOP LAMP SWITCH ASSY Install the stop lamp switch assy with the nut. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  10. INSTALL BRAKE PEDAL SUB-ASSY Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes. Install the brake pedal sub-assy and the 2 brake pedal bushes on the brake pedal support with the brake pedal shaft and the nut. Torque: 37 N.m (375 kgf.cm, 27 ft.lbf)
  11. INSTALL BRAKE PEDAL SUPPORT ASSY Install the brake pedal support assy with the 4 nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) Install the bolt on the brake pedal support assy. Torque: 21 N.m (214 kgf.cm, 15 ft.lbf)
  12. CONNECT MASTER CYLINDER PUSH ROD CLEVIS Apply lithium soap base glycol grease to the clevis pin. Install the clevis pin and the clip. NOTE: The direction for the clip installation is as follows. Install the brake pedal return spring. Connect the stop lamp switch connector to the stop lamp switch assy.
  13. INSTALL INSTRUMENT PANEL SUB-ASSY (See «INSTRUMENT PANEL SUB-ASSY»(ref-224567-S17131594782006031000000) )
  14. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See «ADJUSTMENT»(ref-224552-S17543161112006031000000) )
  15. CHECK PEDAL FREE PLAY (See «ADJUSTMENT»(ref-224552-S17543161112006031000000) )
  16. CHECK PEDAL RESERVE DISTANCE (See «ADJUSTMENT»(ref-224552-S17543161112006031000000) )
  17. INSPECT SRS WARNING LIGHT (W/SRS AIRBAG) (See «DIAGNOSIS SYSTEM»(ref-224525-S28807549002006031100000) )

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