Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Removal 1. Open engine compartment hood and fit paint protection covers to fenders. Raise and support vehicle. Remove wheels. 2. Release the tension on the parking brake cable by moving the parking brake caliper lever away from the cable end. Remove cable from parking brake cable lever. See Fig. 32 . 3. Remove the parking brake cable from the rear brake caliper. On vehicles with manually adjusted parking brakes, remove the retaining clip. See Fig. 33 . On vehicles with self-adjusting parking brakes, release the tabs on the parking brake cable housing. See Fig. 38 . NOTE: To prevent the loss of brake fluid, apply the brake pedal hold down tool and adjust to hold the brake pedal down 1.6″ (40 mm). Install a bleeder bottle to the bleed nipple and loosen the bleed nipple. 4. Remove union bolt from the rear brake caliper hose and discard sealing washers. See Fig. 61 . Remove brake hose from rear brake caliper. 5. Tighten the bleed nipple and remove the bleeder tube and bottle. Remove and discard the rear brake caliper retaining bolts. See Fig. 62 . Remove the caliper. 6. Clean and inspect all associated parts. Installation CAUTION: Retracting the caliper piston may cause the fluid reservoir to overflow. Remove brake fluid spillage immediately from paint work with clean water. NOTE: The left rear brake caliper piston retracts counterclockwise and the right rear caliper piston retracts clockwise. 1. Using the Brake Caliper Piston Retractor Tool (206-080) and Crankshaft Pulley/Damper Remover (303- 588), fully retract the rear brake caliper piston into the caliper housing. See Fig. 64 . NOTE: Make sure the piston location mark is in the correct position so that the

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Brake caliper housing with integral parking brake on the rear axle. To ensure that the parking brake works perfectly, when a new brake caliper is fitted, and every time the brake pads are replaced the piston must be adjusted as described below: Removal: Release / unclip the handbrake cable Remove screw plug (a) – see Fig. 1 Slacken the hexagon socket screw (Fig. 2). Withdraw the piston until it stops moving. Installation: Screw in the hexagon socket screw in a clockwise direction (Figure 3) until the brake shoes touch the brake disc and the brake disc becomes difficult to turn. Then slacken the adjuster screw by one third to half of a turn (Brake disc will turn easily – see Fig. 4). Screw in and tighten screw plug (1) – Fig. 5. Attach brake cable and adjust it in accordance with the manufacturer’s instructions.

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Introduction Some 2010 Prius vehicles may experience rear brake squeak when backing up or moving forward during the ?rst few brake applications when the brakes are cold. An updated rear brake shim kit is available to reduce the likelihood of this condition occurring. Repair Procedure 1. Test drive the vehicle to con?rm the squeak is coming from the rear brakes. The condition occurs more frequently when backing up during light brake pedal application after cold soak. 2. Remove rear brake shims. Refer to the Technical Information System (TIS) 2010 Prius Repair Manual: Brake – Brake (Rear) Brake: Rear Brake: Removal 3. Clean the rear brake pad backing plates with a clean shop towel and apply a small amount of black disc brake grease to the backing plate of each rear brake pad. NOTE Make sure disc brake grease is not applied to the lining of the rear brake pads. 4. Install the No. 1 Anti-squeal shims. Install the No. 2 Anti-squeal shims. Figure 3. 5. Using the Variable Pin Wrench (SST 09960-10010), slowly rotate the caliper piston until the piston groove is positioned as shown in the illustration below. 6. Install new rear brake anti-squeal shims with brake pads into the rear caliper assemblies brackets. Refer to (TIS), 2010 Prius Repair Manual: Brake – Brake (Rear) Brake: Rear Brake: Installation NOTE • When installing the rear disc brake caliper assembly on the rear disc brake caliper mounting bracket, ensure the protrusion on the brake pad is centered in the caliper piston groove. • It is important to ensure the protrusion is not contacting the outer edges of the caliper piston groove. (both sides) 7. Road test the vehicle to con?rm the condition has been reduced.

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Getting started 1. Apply the handbrake. 2. Place chocks under the front wheels and engage 1st gear. Remove the Brake Caliper 6. The brake caliper needs to be removed to allow the brake disc to be removed. Working under the car remove the clip securing the brake hose in place. 3. Loosen the rear wheel nuts using a 19mm wheel wrench with the car on the ground. 4. Jack up the car and support safely using axle stands or ramps. Preferably jack up both sides at the same time, as it makes it easier to balance the handbrake action at the end. This will free the hose and pipe. Carefully slip the pipe fitting out of the bracket. 7. Remove the caliper lower fixing bolt (16mm socket). 5. Remove the road wheel. 8. Remove the plastic cap over the upper fixing bolt. Remove the Brake Disc 11. Loosen the brake disc holding screw using a T-30 Torx bit. 9. Use a 6mm allan key to remove the upper fixing bolt. 12. Release the hand brake and remove the brake disc. If this proves difficult, it may be necessary loosen the brake adjuster. To do this, remove the rubber plug…. 10. The caliper will now be loose and can be carefully lifted away from the disc, taking care to route the brake pipe gently to avoid strain. Support the caliper from the suspension spring using string or ties. …and turn the adjuster with a screwdriver inserted through the hole. The disc has been removed here to show the teeth on the adjuster.

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CAUTION: Refer to Brake Dust Caution in Cautions and Notices. 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 4. Remove the rear tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 5. Install a hand tightened lug nut to retain the rotor to the hub. 6. Compress the caliper piston enough for clearance. Use a C-clamp (3). NOTE: NOTE: Use care to avoid damaging pin boot when rotating caliper. Support the brake caliper with heavy mechanic’s wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.