Student Assignments for EM-123-TY05_053372 Brake trainer for hydraulic diagnosis 95-EM-123-TY05_REVA © 2026 ConsuLab Educatech Inc. All rights reserved. consulab.com info@consulab.com 2 95-EM-123-TY05 Table of Contents Table of Contents Product Description 3 Application: 3 Specifications: 3 Educational Advantages 3 Student Assignments SA-1 — Components and Circuits Identification 5 SA-2 — Master Cylinder Inspection 7 SA-3 — Master Cylinder Replacement 8 SA-4 — Inspect Vacuum Brake Booster 13 SA-5 — Disassemble, Inspect and Reassemble Front Brakes 17 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes 26 SA-7 — Stop Light Switch Installation and Adjustment 34 SA-8 — Inspect and Adjust Brake Pedal Height 35 SA-9 — Brake Pedal Problem Diagnosis #1 37 SA-10 — Brake Pedal Problem Diagnosis #2 38 SA-11 — Brake Pedal Problem Diagnosis #3 39 SA-12 — Brake Pedal Problem Diagnosis #4 40 SA-13 — Brake Pedal Problem Diagnosis #5 41 SA-14 — Brake Pedal Problem Diagnosis #6 42 SA-15 — Brake Pedal Problem Diagnosis #7 43 SA-16 — Brake Pedal Problem Diagnosis #8 44 SA-17 — Brake Pedal Problem Diagnosis #9 45 SA-18 — Using the On-Car Rotor Lathe (extra) 46 © 2026 ConsuLab Educatech Inc. All rights reserved. No part of this work may be reproduced or transmitted in any form by any means, electronic, mechanical, including photocopying and recording, or by any information storage or retrieval system, without written permission from the publisher. Printed in Canada. The content of this manual is applicable to models 053372 and above. © Portions of materials contained herein are sourced form Motologic.com consulab.com info@consulab.com 3 95-EM-123-TY05 Product Description Product Description The EM-123-TY05 Brake Trainer for Hydraulic Diagnosis, based on a Toyota platform, is a comprehensive training tool for teaching and assessing brake service skills. Assembled with OEM components, trainer faithfully replicates a vacuum brake system equipped with discs and drums. It allows students to perform all routine brake maintenance procedures, including component replacement, adjustments, and hydraulic bleeding. Trainer reproduces real braking system behav- iors with different pedal sensations (soft, hard, descending or spongy). Application: 2019 Toyota Corolla Sedan 1.8 L Specifications: • Genuine automotive components (OEM) with fully functional hydraulic system • Hydraulic pressure gauges at each wheel • Lockable fault box with graphical representation of nine (9) hydraulic faults • Components with mechanical defects • Four-wheel disc and drum brake assemblies (NOTE: Rotors, drums, wheel cylinders, disc brake cylinder and pads are new. Other bench components are recy- cled) • 120 VAC to 12 VDC, 7.5 A power supply included • Sturdy powder coated metal stand with two locking swivel and two fixed casters for easy transport • All routine brake maintenance procedures may be performed with this assembly, including component replacement, adjustments and hydraulic bleeding of the system • Fully functional brake booster • This product can be used with the Pro-Cut resurfacing machine NOTE: The EM-123-TY05 Brake Trainer for Hydraulic Diagnosis uses MOTOREX DOT 4 biodegradable brake fluid. Educational Advantages The product would be used to assess technical skills for: • All brake wheel end inspections, maintenance and repair procedures • Diagnosis, repair and bleeding of the hydraulic system • Various customer complaints regarding pedal feel, pull and noise • Using pressure gauges to visualize the effects of hydraulic faults • The procedure for bleeding the master cylinder in the vehicle • Adjusting the brake booster pusher clearance using a special tool (supplied with the product) • Precision measurements for brake disc thickness/runout and pad thickness, for drum diameter and pad thickness consulab.com info@consulab.com 4 95-EM-123-TY05 Student Assignments Student Assignments consulab.com info@consulab.com 5 95-EM-123-TY05 SA-1 — Components and Circuits Identification SA-1 — Components and Circuits Identification 1. Using the diagram below, identify the components numbered 1 to 12. Write your answers below: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 1 2 6 8 10 11 3 4 5 7 9 12 consulab.com info@consulab.com 6 95-EM-123-TY05 SA-1 — Component and Circuit Identification (continued) 1. What color did you use to identify the primary circuit? 2. What color did you use to identify the secondary circuit? 3. What color did you use to identify the vacuum circuit? 4. Which brake assembly is connected to the primary circuit? 5. Which brake assembly is connected to the secondary circuit? 6. Why do we have this type of configuration on this vehicle? 2. Using the diagram below, identify by highlighting the primary circuit, secondary circuit and vacuum circuit using different colors for each one and answer the following questions: Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 7 95-EM-123-TY05 SA-2 — Master Cylinder Inspection SA-2 — Master Cylinder Inspection 1. Refer to Toyota Brake Safety and Maintenance Service Information before proceeding. Please identify the components numbered 1 to 6. Write your answers below 1. 2. 3. 4. 5. 6. 2. Inspect these items and their service instructions. 3. Check all parts for dirt or other harmful particles. Why is this step important? 4. Do not allow dirt or impurities to contaminate the brake fluid. Why? 5. Clean your work area, return the tools to the correct location and your job card to the supervisor. Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 8 95-EM-123-TY05 SA-3 — Master Cylinder Replacement SA-3 — Master Cylinder Replacement 1. Refer to Toyota Brake Safety and Maintenance Service Information before proceeding. NOTE: When replacing the master cylinder, the booster rod must be checked and adjusted if necessary, and the master cylinder must be bled before connecting to the circuit. This worksheet is used to practice both of these procedures. Caution: Trainer is equipped with flexible hydraulic hoses at the master cylinder and therefore it is not necessary to re- move them from the component or bleed the fluid. The following questions are only used to review the service manual procedure as if the master cylinder needs to be replaced. 2. Are special tools required? 3. What should be done to the power brake booster before removing the master cylinder? 4. Be careful not to damage or bend the brake lines during disassembly and reassembly. DO NOT disassemble brake lines. 5. After removing the hoses, seal the hose ends and joints to prevent spillage of brake fluid. Why? 6. Remove the cap from the reservoir and extract the brake fluid using a syringe. DO NOT drain brake fluid. 7. Why is it important to immediately clean all surfaces of the vehicle that have been in contact with brake fluid? 8. Disconnect the brake fluid level switch connector (A). What is the role of that and how does it warn the vehicle operator of abnormal conditions? 9. Go to the brake trainer and make sure the vacuum pump is turned off. Pump the pedal until the pressure gauge reads zero vacuum. consulab.com info@consulab.com 9 95-EM-123-TY05 SA-3 — Master cylinder Replacement If the toggle switch is enabled, a red light comes on and the vacuum pump is activated. If the toggle switch is disabled, the vacuum pump is turned off. 10. Remove two cap screws (A) & (B) holding master cylinder to booster. Do not disconnect the brake lines 11. Remove the master cylinder from the booster, taking care that the piston does not fall out. 12. Position master cylinder on studs (C) & (D) of trainer bracket and hand secure with removed bolts. Inspect/adjust booster rod length 13. Refer to Toyota Brake Safety and Maintenance Service Infor- mation before proceeding. 14. According to the repair manual, when should the booster rod length be adjusted? A B C D consulab.com info@consulab.com 10 95-EM-123-TY05 SA-3 — Master cylinder Replacement 15. According to service information, where is the tool (E) needed to measure the brake booster rod length adjust- ment? 16. What is the clearance value between the brake booster rod and the adjustment tool? 17. According to the service information, what should you use on the tool to mark the tip of the rod when there is contact? 18. Measure the clearance between the brake booster rod and the adjustment tool. Note: Make sure that the numbers engraved on the tool and the master cylinder are identical, as each tool comes with its own master cylinder. 19. When the rod measuring tool rests against the booster, chalk or mark should transfer to the tip of the booster rod. E consulab.com info@consulab.com 11 95-EM-123-TY05 SA-3 — Master cylinder Replacement Notes: - If the stem is too short: No marks are transferred to the stem. - If the rod is too long: The tool does not rest completely on the brake booster. 20. What tools are needed to adjust the brake booster rod? 21. Adjust the booster rod as required so that the clearance meets the specification in the service manual. 22. Position the master cylinder on the brake booster and tighten the bolts to the recommended torque. What is the specification? 23. If the booster stem is too long, what is the most likely result? 24. If the booster stem is too short, what is the most likely result? Bleeding the master cylinder (on the workbench, fixed in a vice) 25. Place the master cylinder flange in the jaws of the vice and tighten it. NOTE: Do not tighten the vice too hard: You could damage the master cylinder. 26. Select the correct adapters from the bleed kit that exactly match the master cylinder outlets and screw them in consulab.com info@consulab.com 12 95-EM-123-TY05 SA-3 — Master cylinder Replacement place. 27. Connect the two transparent hoses to the bleed adapters and fill the reservoir. 28. Fill the master cylinder reservoir to the "MAX" mark. NOTE: Water can be used to replace the brake fluid for this exercise, but do not return the master cylinder filled with water to the brake trainer. Instead, use the right fluid (MOTOREX DOT 4 biodegradable). 29. Bleed the master cylinder by repeatedly pushing the piston (with a screwdriver handle or wooden rod) until the transparent hoses are completely filled without any air bubbles. 30. Remove the bleed hoses and adapters 31. Install the supplied brake line fittings into the master cylinder outlet ports and hand tighten only. 32. What is the torque specification for the brake lines at the master cylinder? 33. Use the formula to calculate the torque wrench setting. 34. Tighten the brake line fittings to the master cylinder using a pipe nut wrench (union wrench) after the torque wrench is correctly adjusted. 35. Why do I need to adjust the torque setting when using an adapter? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 13 95-EM-123-TY05 SA-4 — Inspect Vacuum Brake Booster SA-4 — Inspect Vacuum Brake Booster Objective: Check the firmness, operation and check valve of the brake booster system. The brake booster increases pedal force and brake pressure. A vacuum leak (in the brake booster or lines) reduces the assistance and therefore the braking effectiveness. *The brake booster vacuum line is normally connected to engine intake manifold vacuum. An electric vacuum pump is used to simulate engine vacuum. Leak test (without load) 1. The leak test verifies that the brake booster and vacuum check valve maintain vacuum in the system after the vacu- um pump has stopped. If the vacuum cannot be maintained, the maximum level may not be reached during the test bench operation. NOTE: All of these tests assume that the vacuum source is in good condition. 2. Make sure that all trainer valves (V1-V8) are “reset” to no fault. Ask your instructor the instructions to perform the reset. 3. Turn on the vacuum pump switch on the dashboard (in the center, below the 4 hydraulic pressure gauges). Let the pump run until it stops. (Approximately 19-20 inHg on gauge. a. Turn off the pump switch once the vacuum pump has stopped and 19-20 inches of mercury (inHg) on the pressure gauge be reached b. Press the brake pedal slowly 3 to 7 times. c. if the pedal drops as low as possible the first time, but gradually rises after the second or third time the booster consulab.com info@consulab.com 14 95-EM-123-TY05 SA-4 — Inspect Vacuum Brake Booster is sealed. 4. What happens to the position of the brake pedal after pressing it each time? Select the answer based on the results. a. The reserve distance increased with each pedal press as the vacuum decreased b. the reserve distance decreased with each pedal press as the vacuum decreased 5. Why does the pedal change position? 6. If the position changes this way, what does that indicate? (select all that apply) a. Sealed check valve b. Sealed diaphragm c. Sealed brake booster air valve 7. If the position does not change, probable causes? a. Blocked check valve b. Incorrect pedal height adjustment c. Brake booster diaphragm leak d. Leak on vacuum hose (motor → check valve) Leak test under load (pedal held) 1. Turn on the vacuum pump switch and let the pump run until it stops. Leave the pump switch on. • Depress the brake pedal and maintain constant pressure. If the pump starts to run, let it stop. • Turn off the vacuum pump switch • If the brake pedal reserve distance remains unchanged after holding the pedal down for 30 seconds, the booster is sealed. 2. If the brake pedal position changes, what are the two possible causes? consulab.com info@consulab.com 15 95-EM-123-TY05 SA-4 — Inspect Vacuum Brake Booster Operation check 1. Press the brake pedal 6 to 7 times with the vacuum pump switch off. This will drain the vacuum in the brake booster. The vacuum is purged when the vacuum gauge reads zero: • Depress the brake pedal (moderate foot pressure, as if holding a vehicle at a red light) and turn on the vacuum pump while holding the pedal down. • When vacuum enters the power brake booster, the brake pedal should touch the floor. 2. What happened to the brake pedal when the vacuum pump was restarted while the brake pedal was depressed? 3. Why does the pedal move? (select all that apply) a. Pedal depressing opens the brake booster air valve. b. The pressure difference on either side of the diaphragm pushes the master cylinder. c. The pump fills the constant vacuum pressure chamber. 4. Release the brake pedal. 5. Turn off the vacuum pump switch. 6. If the position of the brake pedal did not change when the vacuum pump was switched on, what are the possible causes? consulab.com info@consulab.com 16 95-EM-123-TY05 SA-4 — Inspect Vacuum Brake Booster 7. Ask your instructor to set the V4 valve position to "R". 8. Perform a second brake booster operation check. (Repeat steps 1 to 5). 9. Release the brake pedal and turn off the vacuum pump switch. 10. What was the result of the second operation check? a. The brake pedal did not lower when the pump was started during the test. b. Brake pedal lowered when pump was turned on during test. 11. According to the result of the operation check, what condition did the V4 valve modification simulate? 12. Depress the brake pedal to release all vacuum from the brake booster (vacuum gauge should read 0). Ask your instructor to ensure that all valves (V1-V8) on the simulator are “reset” to no fault. Inspect the vacuum check valve 1. Ask the instructor for a vacuum check valve to perform the test: • Check the presence of ventilation between the brake booster and the engine, and that there is no ventilation between the engine and the brake booster. • Use low air pressure regulated from a rubber-tipped compressed air gun. 2. What was the result of the vacuum check valve test? 3. What is the role of the vacuum check valve? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 17 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes SA-5 — Disassemble, Inspect and Reassemble Front Brakes Objective: Learn the steps prescribed by the manufacturer (tightening torques, dismantling/reassembly sequence, in- spection of tolerances, warping, wear, etc) so as to prepare the student to work according to industry standards. Disassembly 1. Remove the front disc brake cylinder assembly. • Hold the 2 sliding pins of the front disc brake cylinder and unscrew the 2 bolts and remove the front disc brake cylinder assembly. a) To unscrew b) To hold 2. Inspect the front disc brake cylinder assembly dust cover 3. Remove the front brake pads consulab.com info@consulab.com 18 95-EM-123-TY05 SA-5 — Disassemble, inspect and reassemble front brakes 4. Remove the front brake pad carrier plates NOTE: Each front brake pad carrier plate has a different shape. Be sure to put an identification mark on each plate so that it can be reinstalled in its original position. 5. Remove the front disc brake cylinder carrier slide pins. 6. Using a screwdriver with protective tape on the tip, remove the rubber bushing from each pin (end side) consulab.com info@consulab.com 19 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes 7. Remove the front disc brake cylinder carrier dust sleeves. 8. Remove the front disc brake cylinder carrier: • Remove the 2 front disc brake cylinder carrier bolts attached to the steering knuckle. 9. Remove the front disc. NOTE: Mark the front disc and the front axle hub subassembly. consulab.com info@consulab.com 20 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes Inspection 1. Using a ruler, measure the thickness of the front disc brake lining. 2. What are the specifications for standard thickness and minimum thickness? What are your measurements tak- en? Are there components to replace, if so which ones? NOTE: If the lining thickness of the front disc brake pads is less than the minimum set, replace the front disc brake pads. • Be sure to check the front disc thickness when replacing the front brake pads with new ones. consulab.com info@consulab.com 21 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes 3. Inspect the front disc brake pad carrier plates: • Make sure that the front disc brake pad carrier plates have sufficient bounce, are free of deformation, cracks or wear, and that all rust and dirt have been removed. If necessary, replace the plates. 4. Inspect the thickness of the disc • Using a micrometer, measure the thickness of the front disc 5. What are the specifications for standard thickness and minimum thickness and write your measurements taken? NOTE: If the front disc thickness is less than the minimum set, replace the front disc 6. Inspect the disc runout • Temporarily install the front disc using the 5 hub nuts. Torque: 103 Nm (1050 kgf/cm, 76 ft.lbf) 7. Using a magnetic base dial indicator, measure the disc runout 10 mm (0.394 in) from the outside edge of the front disc. 8. What is the maximum allowed front disc runout? What are your measurements taken? Are there components to replace, if so which ones? consulab.com info@consulab.com 22 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes NOTE: If the runout exceeds the maximum set, change the front disk installation position to minimize it. If the runout exceeds the maximum even after changing the installation position, refinish the front disc. If the thickness of the front disc is less than the minimum set, replace it. 9. Unscrew the 5 hub nuts and remove the front disc. Reassembly 1. Install the front disc. Align the marks on the front disc and the front axle hub subassembly, and install the disc. NOTE: When replacing the front disc with a new one, choose the installation position where the front disc has minimal runout. consulab.com info@consulab.com 23 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes 2. Install the front disc brake cylinder mount: • Install the front disc brake cylinder carrier to the axle stub with the 2 bolts. 3. What is the torque specification for the two front disc brake cylinder carrier bolts? 4. Install the front disc brake cylinder carrier pin dust sleeves. 5. Install the front disc brake cylinder carrier pins: • Apply a thin coat of grease to the sliding pins. consulab.com info@consulab.com 24 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes • Install a new rubber bushing on the slide pin (end side) Apply grease to the shaded areas: • Install the 2 front slide pins to the disc brake cylinder carrier. • Push each pin into its dust boot to engage the pin in the boot. 6. Install the front brake pad carrier plates: • Install the 4 front brake pad carrier plates to the disc brake cylinder carrier NOTE: Be sure to install each front disc brake pad carrier plate in the correct position and direction. 7. Install the front brake pads: • Install the 2 front brake pads to the front disc brake cylinder carrier. NOTE: Keep the friction surfaces of the pads and the front disc free of oil and grease. Install the front disc brake pads so that the wear indicator plate is mounted on the top of the vehicle. consulab.com info@consulab.com 25 95-EM-123-TY05 SA-5 — Disassemble, Inspect and Reassemble Front Brakes 8. Install the front brake disc brake cylinders: • Hold each front brake disc brake cylinder slide pin and secure to disc brake cylinder holder with 2 bolts. • What is the torque specification of its two bolts? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 26 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes SA-6 — Disassemble, Inspect and Reassemble Rear Brakes Objective: Learn the steps prescribed by the manufacturer (tightening torques, disassembly/reassembly sequence, in- spection of tolerances, wear, etc.) so as to prepare the student to work according to industry standards. Disassembly 1. Remove the brake drum. NOTE: If the rear brake drum subassembly cannot be easily removed, proceed as follows: Remove the gasket from the adjustment hole on the rear side of the drum assembly, insert a screwdriver into the hole, and then hold the rear brake adjustment lever away from the mechanism. Using another screwdriver, engage the brake shoe by turning the adjustment bolt. 2. Remove the rear brake shoes: • Detach the brake shoe tension spring (front). • What tool is suggested in the manufacturer’s procedure to perform this task? • What should you pay attention to during this step according to the manufacturer's procedure? consulab.com info@consulab.com 27 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes • Remove the front shoe retaining spring and cup. • What tool is suggested in the manufacturer’s procedure to perform this task? • Remove the bottom retaining spring. consulab.com info@consulab.com 28 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes • Remove the retaining spring and cup from the rear shoe. 3. Remove the self-adjustment lever from the rear brake shoe. Inspection 1. Measure the inner diameter of the drum: • Use a drum dial indicator or equivalent. 2. What are the inner diameter specifications? What are your measurements taken? Are there components to replace, if yes which ones? consulab.com info@consulab.com 29 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes • Using a ruler, measure the thickness of the shoe lining. • What are the specifications for standard thickness and minimum thickness? What are your measurements taken? Are there components to replace, if so which ones? 3. What should be done if the brake shoes on one side are out of specifications? consulab.com info@consulab.com 30 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes Installation 1. Install the rear drum self-adjustment lever • Install the rear brake self-adjustment lever and the retaining spring onto the front brake shoe. 2. Prepare and install the strut set (spreader). 3. Grease: • The anchor plate contact areas. • The adjustment bolt. 4. Why high temperature grease is applied? consulab.com info@consulab.com 31 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes 5. Assemble the strut set (refer to illustration below) 6. Install the strut set (spreader) on the rear boot. 7. Install the rear and front shoes : • Install the rear shoe. • Install the retaining spring and cup. • Install the front shoe. • Install the retaining spring and cup. • Install the transversal spring. consulab.com info@consulab.com 32 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes 8. Check the complete assembly: • No grease or oil on friction surfaces must be applied. • All springs and levers must be in the correct position. • Strut set must be correctly mounted. 9. Why should you never have grease on friction surfaces? 10. Reinstall the drum • Temporarily install 2 wheel nuts. consulab.com info@consulab.com 33 95-EM-123-TY05 SA-6 — Disassemble, Inspect and Reassemble Rear Brakes 11. Rear brake adjustment • Through the rear opening: Turn the adjuster to expand the brake shoes until the drum locks. • Measure the brake drum inner diameter and the brake shoes diameter. Check that the difference between the diameters is equal to the play specified for the brake shoes. 12. What is the standard play between drum and shoes ? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 34 95-EM-123-TY05 SA-7 — Stop Light Switch Installation and Adjustment SA-7 — Stop Light Switch Installation and Adjustment Objective: Learn how to install, adjust and check the brake light switch to ensure proper operation of the brake light system. 1. Insert the switch until the threaded part touches the pedal until the threaded sleeve touches the pedal. NOTE: When inserting the brake light switch, hold the pedal from the rear so that it is not depressed. Turn the brake light switch unit 1/4 turn (1/4) clockwise to install. 2. Why should I hold the pedal during insertion? 3. After installation, measure the part that exceeds the plunger. 4. What are the minimum and maximum accepted values for the plunger protrusion? 5. What should be done if the protrusion exceeds the maximum value? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 35 95-EM-123-TY05 SA-8 — Inspect and Adjust Brake Pedal Height SA-8 — Inspect and Adjust Brake Pedal Height Objective: Learn how to inspect, measure, and properly adjust the brake pedal height of a 2019 Toyota Corolla to OEM specifications. 1. Pedal height measurement 2. What is the correct pedal height range? 3. If the height does not comply with, it must be adjusted. 4. Remove the brake lamp switch. 5. Why the brake light switch must be removed before adjusting the pedal? 6. Loosen the lock nut on the push rod *1 - Brake pedal cushion *a - Brake pedal height *b - Floor panel *1 Brake Light Switch Assembly *2 Jam Nut *at Brake pedal Height *b floor Panel consulab.com info@consulab.com 36 95-EM-123-TY05 SA-8 — Inspect and Adjust Brake Pedal Height 7. Turn the push rod to raise or lower the pedal. 8. When the correct height is reached (148–158 mm), tighten the lock nut. 9. What is the torque of the lock nut? 10. Reinstall the brake light switch according to the procedure. 11. Brake pedal free play check: • Eliminate the vacuum assistance by turning off the pump switch. • Pump the pedal firmly several times until there is no vacuum in the brake servo. 12. Why does the pedal need to be pumped before measuring free play? 13. Measure the pedal free play. 14. Slowly depress the pedal. 15. Pinpoint the moment when a slight resistance begins. 16. Measure this free play as shown in illustration. 17. What is the free play allowed according to the manufacturer? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 37 95-EM-123-TY05 SA-9 — Brake Pedal Problem Diagnosis #1 SA-9 — Brake Pedal Problem Diagnosis #1 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: The pedal seemed normal at first, but if I keep it depressed at the red light, the pedal eventually goes down to the floor. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. 3. Describe the brake pedal sensation during braking. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 38 95-EM-123-TY05 SA-10 — Brake Pedal Problem Diagnosis #1 SA-10 — Brake Pedal Problem Diagnosis #2 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: The pedal is very hard and the stroke is short. The vehicle brakes poorly and strangely pulls to one side. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. 3. Describe the brake pedal sensation during braking. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 39 95-EM-123-TY05 SA-11 — Brake Pedal Problem Diagnosis #3 SA-11 — Brake Pedal Problem Diagnosis #3 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes.. Customer Concern: The pedal is a little harder than before and it takes longer to descend when braking hard. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. 3. Describe the brake pedal sensation during braking. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 40 95-EM-123-TY05 SA-12 — Brake Pedal Problem Diagnosis #4 SA-12 — Brake Pedal Problem Diagnosis #4 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: With each stop, the pedal becomes harder and harder. The vehicle requires more effort to brake. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Has the vacuum pump stopped? 3. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 4. Describe the brake pedal sensation during braking. 5. Describe what happens on the vacuum gauge when applying the brakes. 6. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 41 95-EM-123-TY05 SA-13 — Brake Pedal Problem Diagnosis #5 SA-13 — Brake Pedal Problem Diagnosis #5 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Note: With each stop, the pedal becomes slightly harder than before. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Has the vacuum pump stopped? 3. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 4. Describe the brake pedal sensation during braking. 5. Describe what happens on the vacuum gauge when applying the brakes. 6. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 42 95-EM-123-TY05 SA-14 — Brake Pedal Problem Diagnosis #6 SA-14 — Brake Pedal Problem Diagnosis #6 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: The pedal is a little harder and goes down longer with noise/erratic braking effect at the rear. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 3. Describe the brake pedal sensation during braking. 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 43 95-EM-123-TY05 SA-15 — Brake Pedal Problem Diagnosis #7 SA-15 — Brake Pedal Problem Diagnosis #7 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: The pedal is very hard and the stroke is short. The vehicle brakes poorly and seems unstable. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 3. Describe the brake pedal sensation during braking. 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 44 95-EM-123-TY05 SA-16 — Brake Pedal Problem Diagnosis #8 SA-16 — Brake Pedal Problem Diagnosis #8 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Customer: The pedal is very hard with little stroke causing unbalanced braking at the rear. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 3. Describe the brake pedal sensation during braking. 4. Describe what happens on the vacuum gauge when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 45 95-EM-123-TY05 SA-17 — Brake Pedal Problem Diagnosis #9 SA-17 — Brake Pedal Problem Diagnosis #9 Objective: Identify various problems related to the brake pedal, such as a hard, soft or gradually descending pedal. These pedal sensations can easily cause concern to a customer, and it is essential to understand the causes. Customer Concern: The pedal is spongy and goes down to the floor, especially during prolonged braking. 1. Turn on the vacuum pump switch on the dashboard (in the center below the four hydraulic pressure gauges). Let the pump run until it stops automatically (approximately 19–20 inHg on gauge). 2. Apply normal pressure to the brake pedal (as when braking a vehicle), then write the readings from the four brake pressure gauges on the dashboard. Pressure Gauge Readings (psi) Front Left Front Right Rear Left Rear Right 3. Describe the brake pedal sensation during braking. 4. Describe what happens on the vacuum gauges when applying the brakes. 5. What is the most likely cause? Name: Group: Date: Instructor: Note: consulab.com info@consulab.com 46 95-EM-123-TY05 SA-18 — Using the On-Car Rotor Lathe (extra) SA-18 — Using the On-Car Rotor Lathe (extra) Objective: Learn how to prepare a vehicle, install a rotor lathe on the vehicle, compensate for runout, make a pro cut, then inspect and clean the disc before reassembly. This assignment helps student to understand how to obtain an opti- mal braking surface , essential to avoid vibration and braking noise on a vehicle. consulab.com info@consulab.com 16 95-EM-123-4HN02 SA2-B - Student activity #2-B Year and Model: VIN: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Attach to R.O. # Disc Brake Rotor Refinishing Worksheet © 2002 American Honda Motor Co., Inc. - All Rights Reserved GJA 24213 (0212) Date: Rotor Location: LF RF RR LR Rotor thickness before refinishing Rotor run-out before refinishing Rotor thickness variation (measure in 8 places): 1. 2. 3. 4. 5. 6. 7. 8. Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Technician Signature Technician Number Rotor thickness after refinishing Rotor run-out after refinishing Thickest part Thinnest part Maximum variation Refinishing time overall min. Rough-cut time min. Fine-cut time min. – = Rotor thickness after refinishing Rotor run-out after refinishing Copyright 2009 - 2013 Service Repair Solutions, Inc. Portions of materials contained herein are sourced from American Honda Motor Inc., Co. Copyright 2009 - 2013 Service Repair Solutions, Inc. SA2-B - Student activity #2-B Front brake disc refinishing Name: Group: Date: Instructor: Note: 400-6330 Zéphirin-Paquet St. QUEBEC QC G2C 0M3 Canada © 2025 ConsuLab Educatech Inc. All rights reserved. Product Description Application: Specifications: Educational Advantages Student Assignments SA-1 — Components and Circuits Identification SA-2 — Master Cylinder Inspection SA-3 — Master Cylinder Replacement SA-4 — Inspect Vacuum Brake Booster SA-5 — Disassemble, Inspect and Reassemble Front Brakes SA-6 — Disassemble, Inspect and Reassemble Rear Brakes SA-7 — Stop Light Switch Installation and Adjustment SA-8 — Inspect and Adjust Brake Pedal Height SA-9 — Brake Pedal Problem Diagnosis #1 SA-10 — Brake Pedal Problem Diagnosis #2 SA-11 — Brake Pedal Problem Diagnosis #3 SA-12 — Brake Pedal Problem Diagnosis #4 SA-13 — Brake Pedal Problem Diagnosis #5 SA-14 — Brake Pedal Problem Diagnosis #6 SA-15 — Brake Pedal Problem Diagnosis #7 SA-16 — Brake Pedal Problem Diagnosis #8 SA-17 — Brake Pedal Problem Diagnosis #9 SA-18 — Using the On-Car Rotor Lathe (extra)
