Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Toyota Sienna 2004-2007 Approved SRM 04 32 200mj w040001
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32-22
BRAKE - FRONT BRAKE
320V2-06
OVERHAUL
HINT:
Overhaul the RH side by the same procedure as the LH side.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it attaches to any painted surface.
3. REMOVE FRONT DISC BRAKE CYLINDER
SUB-ASSY
(a) Remove the union bolt and 2 gaskets from the front disc
brake cylinder sub-assy, then disconnect the flexible
hose.
(b) Hold the front disc brake cylinder slide pin and remove the
2 bolts.
C97868
4. REMOVE DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Remove the disc brake pad kit front from the front disc brake cylinder mounting LH.
5. REMOVE ANTI SQUEAL SHIM KIT FRONT
(a) Remove the anti squeal shim and pad wear indicator plate from the each pad.
6. REMOVE FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Remove the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2)
from the front disc brake cylinder mounting LH.
7. REMOVE FRONT DISC BRAKE CYLINDER SLIDE PIN
Cylinder Slide Pin (No.1)
(a) Remove the front disc brake cylinder slide pin (No.1) and
front disc brake cylinder slide pin (No.2) from the front disc
brake cylinder mounting LH.
Cylinder Slide Pin (No.2) F45565
8. REMOVE FRONT DISC BRAKE CYLINDER SLIDE
Cylinder Slide Bush BUSH
(a) Using a screwdriver, remove the front disc brake cylinder
slide bush from the front disc brake cylinder slide pin
(No.2).
NOTICE:
Do not damage the front disc brake cylinder slide pin
(No.2).
Cylinder Slide Pin (No.2)
F45566
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2770
32-23
BRAKE - FRONT BRAKE
9. REMOVE FRONT DISC BRAKE CYLINDER
MOUNTING LH
(a) Remove the 2 bolts and front disc brake cylinder mount-
ing LH.
F45344
10. REMOVE FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake cylin-
der mounting LH in the vise through aluminum plates.
(b) Using a screwdriver and hammer, remove the 2 front disc
brake bush dust boots from the front disc brake cylinder
mounting LH.
C68791
11. REMOVE CYLINDER BOOT
(a) Using a screwdriver, remove the set ring and cylinder
boot.
R09298
12. REMOVE FRONT DISC BRAKE PISTON
(a) Place a shop rug, between the front disc brake piston and
the disc brake cylinder sub-assy.
(b) Use compressed air to remove the front disc brake piston
from the disc brake cylinder sub-assy.
CAUTION:
Do not place your fingers in front of the piston when using
compressed air.
C97869 NOTICE:
Do not spatter the brake fluid.
13. REMOVE PISTON SEAL
(a) Using a screwdriver, remove the piston seal from the front
disc brake cylinder sub-assy.
NOTICE:
Do not damage the inner cylinder and cylinder groove.
G23223
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2771
32-24
BRAKE - FRONT BRAKE
14. REMOVE FRONT DISC BRAKE BLEEDER PLUG
(a) Remove the front disc brake bleeder plug from the front disc brake cylinder sub-assy.
15. REMOVE FRONT DISC BRAKE BLEEDER PLUG CAP
16. INSPECT BRAKE CYLINDER AND PISTON
(a) Check the brake cylinder bore and front disc brake piston for rust or scoring.
17. INSPECT PAD LINING THICKNESS
(a) Using a ruler, measure the pad lining thickness.
Standard thickness: 12.0 mm (0.472 in.)
Minimum thickness: 1.0 mm (0.039 in.)
R02951
18. INSPECT FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Inspect the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2).
Make sure that they have sufficient rebound, no deformation, cracks or wear, and have had all rust and
dirt cleaned off.
19. INSPECT DISC THICKNESS
(a) Using a micrometer, measure the disc thickness.
Standard thickness: 28.0 mm (1.102 in.)
Minimum thickness: 26.0 mm (1.024 in.)
F42895
Matchmarks
20. REMOVE FRONT DISC
(a) Place matchmarks on the front disc and the axle hub.
(b) Remove the front disc.
21. INSTALL FRONT DISC
(a) Aligning the matchmarks, install the front disc.
HINT:
Select the installation position where the disc has the minimum
runout.
F41543
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2772
32-25
BRAKE - FRONT BRAKE
22. INSPECT DISC RUNOUT
(a) Temporarily fasten the disc with the hub nuts.
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
(b) Using a dial indicator, measure the disc runout 10 mm
(0.39 in.) away from the outer edge of the disc.
Maximum disc runout: 0.05 mm (0.0020 in.)
(c) If the disc runout is the maximum value or greater, check
the bearing play in the axial direction and check for the
C97900 axle hub runout (See page 30-3 ). If the bearing play and
axle hub runout are normal, adjust the disc runout or grind
it on a "On-car" brake lathe.
23. TEMPORARILY TIGHTEN FRONT DISC BRAKE BLEEDER PLUG
(a) Temporarily install the front disc brake bleeder plug to the front disc brake cylinder sub-assy.
24. INSTALL FRONT DISC BRAKE BLEEDER PLUG CAP
25. INSTALL PISTON SEAL
(a) Apply lithium soap base glycol grease to a new piston seal.
(b) Install the piston seal to the front disc brake cylinder sub-assy.
26. INSTALL FRONT DISC BRAKE PISTON
(a) Apply lithium soap base glycol grease to the front disc
brake piston and new cylinder boot.
(b) Install the cylinder boot to the front disc brake piston.
(c) Install the front disc brake piston to the front disc brake
cylinder sub-assy.
NOTICE:
Do not install the piston forcibly in the front disc brake cyl-
Lithium soap base glycol grease F45277 inder sub-assy.
27. INSTALL CYLINDER BOOT
Cylinder Boot Front Disc
Brake Piston (a) Install a new cylinder boot to the front disc brake cylinder
sub-assy .
NOTICE:
Install the boot securely to the grooves of the cylinder and
piston.
(b) Using a screwdriver, install the set ring.
NOTICE:
Set Ring
F42832 Do not damage the cylinder boot.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2773
32-26
BRAKE - FRONT BRAKE
28. INSTALL FRONT DISC BRAKE BUSH DUST BOOT
(a) Using soft jaws on the vise, hold the front disc brake cylin-
der mounting LH in the vise through aluminum plates.
(b) Place front disc brake cylinder mounting LH in vise.
(c) Apply lithium soap base glycol grease to the sealing sur-
face of 2 new front disc brake bush dust boots.
(d) Using a socket wrench (19 mm) and hammer, drive the 2
front disc brake bush dust boots to the front disc brake cyl-
C68792 inder mounting LH.
29. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH
(a) Apply the lithium soap base glycol grease to a new front disc brake cylinder slide bush.
(b) Install the cylinder slide bush to the bottom side of the front disc brake cylinder slide pin (No.2).
30. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN
(a) Apply the lithium soap base glycol grease to the sliding
part and the sealing surface of the front disc brake cylin-
Cylinder Slide Pin
der slide pin (No.1) and front disc brake cylinder slide pin
(No.2).
(b) Install the front disc brake cylinder slide pin (No.1) and
front disc brake cylinder slide pin (No.2) to the front disc
brake cylinder mounting LH.
Lithium soap base glycol grease F45565 (c) Install the front disc brake cylinder slide pin (No.2) to the
front disc brake cylinder mounting LH.
31. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING
LH
(a) Install the front disc brake cylinder mounting with the 2
bolts.
Torque: 107 Nm (1,090 kgfcm, 79 ftlbf)
F45344
32. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE
(a) Install the front disc brake pad support plate (No.1) and front disc brake pad support plate (No.2) to
the front disc brake cylinder mounting LH.
33. INSTALL ANTI SQUEAL SHIM KIT FRONT
NOTICE:
If necessary, replace the anti squeal shim kit when replacing the brake pad.
(a) Apply disc brake grease to each anti squeal shim.
(b) Install anti squeal shims on each pad.
(c) Install the pad wear indicator plate facing upward, and install each pad.
34. INSTALL DISC BRAKE PAD KIT FRONT (PAD ONLY)
(a) Intsall the disc brake pad kit front to the front disc brake cylinder mounting LH.
NOTICE:
There should be no oil or grease on the friction surfaces of the pads and the disc.
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2774
32-27
BRAKE - FRONT BRAKE
35. INSTALL FRONT DISC BRAKE CYLINDER SUB-ASSY
(a) Install the front disc brake cylinder sub-assy with the 2
bolts.
Torque: 34 Nm (350 kgfcm, 25 ftlbf)
(b) Install a 2 new gaskets and flexible hose with the union
bolt.
Torque: 29 Nm (296 kgfcm, 21 ftlbf)
HINT:
C97868 Install the flexible hose lock securely in the lock hole in the disc
brake cylinder.
36. FILL RESERVOIR WITH BRAKE FLUID (See page 32-4 )
37. BLEED MASTER CYLINDER (See page 32-4 )
SST 09023-00101
38. BLEED BRAKE LINE (See page 32-4 )
39. CHECK FLUID LEVEL IN RESERVOIR (See page 32-4 )
40. CHECK BRAKE FLUID LEAKAGE
41. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgfcm, 76 ftlbf)
2005 SIENNA REPAIR MANUAL (RM1163U)
Author : Date : 2775
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