1986 TOYOTA CAMRY V20 brake

1. DISCONNECT LEVEL WARNING SWITCH
CONNECTOR
2. TAKE OUT FLUID WITH SYRINGE
NOTICE: Do not let brake fluid remain on a painted surface.
Wash it off immediately.
3. DISCONNECT BRAKE TUBES
Using SST, disconnect brake tubes from the master cylinder.
SST 09751±36011
4. REMOVE MASTER CYLINDER
(a) Remove the three nuts and 3±way union.
(b) Remove the clamp.
(c) Remove the master cylinder from the brake booster
and remove the gasket.
MASTER CYLINDER
REMOVAL OF MASTER CYLINDER
± BRAKE SYSTEMMaster CylinderBR±9

COMPONENTS
± BRAKE SYSTEMMaster CylinderBR±10

INSPECTION OF MASTER CYLINDER
COMPONENTS
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.
DISASSEMBLY OF MASTER
CYLINDER
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
(b) Remove the cap and strainer from the reservoir.
2. REMOVE TWO GROMMETS
3. PLACE CYLINDER IN VISE
5. REMOVE TWO PISTONS AND SPRINGS
(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 hand, pulling
straight out, not at an angle.
NOTICE: If pulled out at an angle, there is possibility of
damaging the cylinder bore.
(c) Place a rag and two wooden blocks on the work table
and lightly tap the cylinder flange against the blocks
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.) 4. 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.
± BRAKE SYSTEMMaster CylinderBR±11

2. INSTALL TWO SPRINGS AND PISTONS
CAUTION: Be careful not to damage the rubber lips on
the pistons.
(a) Insert the two springs and pistons straight in, not at
an angle.
NOTICE: If insert at an angle, there is possibility of damag-
ing the cylinder bore.
(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. INSTALL PISTON STOPPER BOLT
Using a screwdriver, push the piston in all the way and
install the piston stopper bolt over the gasket. Torque the
bolt.
Torque: 100 kg±cm (7 ft±Ib, 10 N±m)
ASSEMBLY OF MASTER CYLINDER
(See page BR±10)
1. APPLY LITHIUM SOAP BASE GLYCOL GREASE TO
RUBBER PARTS INDICATED BY ARROWS
4. INSTALL TWO GROMMETS
± BRAKE SYSTEMMaster CylinderBR±12

5. INSTALL RESERVOIR
(a) Install the cap and strainer to the reservoir.
(b) Push the reservoir onto the cylinder.
(c) Install the set screw while pushing on the reservoir.
Torque: 17.5 kg±cm (15.2 in.±Ib, 1.7 N±m)
NOTICE: Because the master cylinder and reservoir
tank union is a grommet type, the set screw is de-
signed to not separate the reservoir from the cylinder
and will not tighten down the reservoir. Therefore,
there is a clearance at point A. Do not insert washers
or an equivalent when tightening.
± BRAKE SYSTEMMaster CylinderBR±13

6. CONNECT LEVEL WARNING SWITCH CONNECTOR
7. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM
(See page BR±7)
8. CHECK FOR FLUID LEAKAGE
9. CHECK AND ADJUST BRAKE PEDAL
(See page BR±6)
INSTALLATION OF MASTER CYLINDER
(See page BR±9)
1. CLEAN OUT GROOVE ON LOWER INSTALLATION
SURFACE OF MASTER CYLINDER
2. CONFIRM THAT ºUPº MARK ON MASTER CYLINDER
BOOT IS IN CORRECT POSITION
5. CONNECT BRAKE TUBES
Using SST, connect. the brake tubes to the master cylin-
der.
Torque the union nuts.
SST 09751±36011
Torque: 155 kg±cm (11 ft±ib, 15 N ± m)
4. INSTALL MASTER CYLINDER
Set the new gasket and install the master cylinder, clamp
and 3±way union on the brake booster with three nuts.
Torque: 130 kg±cm (9 ft±Ib, 13 N¿ m)
3. ADJUST LENGTH OF BRAKE BOOSTER PUSH ROD
BEFORE INSTALLING MASTER CYLINDER
(See page BR±16)
± BRAKE SYSTEMMaster CylinderBR±14

1. REMOVE MASTER¿CYLINDER
(See page BR±9)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. REMOVE PEDAL RETURN SPRING
4. REMOVE CLIP AND CLEVIS PIN
5. REMOVE BRAKE BOOSTER, GASKET AND CLEVIS
(a) Remove the four nuts and clevis.
(b) Pull out the brake booster and gasket.
BRAKE BOOSTER
REMOVAL OF BRAKE BOOSTER
± BRAKE SYSTEMBrake BoosterBR±15

INSTALLATION OF BRAKE BOOSTER
(See page BR±15)
1. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Set the SST on the master cylinder with the gasket,
and then lower the pin until its slightly touches the
piston.
SST 09737±00010
3. CONNECT CLEVIS TO BRAKE PEDAL
Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
4. INSTALL PEDAL RETURN SPRING
5. INSTALL INSTRUMENT LOWER FINISH PANEL(b) Turn the SST upside down and set it on the booster.
SST 49737±00010
(c) Measure the clearance between the booster push
rod and pin head (SST).
Clearance: 0 mm (0 in.)
2. INSTALL BRAKE BOOSTER, GASKET AND CLEVIS
(a) Install the clevis lock nut and clevis to the brake
booster.
(b) Install the brake booster and gasket.
(c) Install and torque the booster mounting nuts.
Torque: 130 kg±cm (9 ft±Ib, 13 N¿ m)
(d) Adjust the booster push rod length until the push rod
lightly touches the pin head.
± BRAKE SYSTEMBrake BoosterBR±16