W/ Master Cylinder Brake Booster ASSY: Overhaul

NOTE:

When installing, coat the parts indicated by arrows with lithium soap base glycol grease (see COMPONENTS ).
As high pressure is applied to the brake actuator tube No.1, never deform it.
Until the work is over, do not turn the ignition switch to the ON position.
Before starting the work, make sure that the ignition switch is off and depress the brake pedal more than 20 times.

HINT:

When pressure in the power supply system is released, reaction force becomes light and stroke becomes longer.

DRAIN BRAKE FLUID
NOTE: Wash off brake fluid immediately if it comes into contact with a painted surface.
REMOVE FRONT DOOR SCUFF PLATE LH (SEE REPLACEMENT )
REMOVE FRONT FLOOR FOOTREST (SEE REPLACEMENT )
REMOVE COWL SIDE TRIM BOARD LH (SEE REPLACEMENT )
REMOVE INSTRUMENT CLUSTER FINISH PANEL ORNAMENT (SEE REPLACEMENT )
REMOVE INSTRUMENT PANEL FINISH PLATE (SEE REPLACEMENT )
REMOVE INSTRUMENT PANEL LOWER LH (SEE REPLACEMENT )
REMOVE INSTRUMENT PANEL FINISH LOWER PANEL (SEE REPLACEMENT )
REMOVE STEERING COLUMN HOLE COVER
1. Remove the 4 clips and steering column hole cover.
REMOVE PUSH ROD PIN
1. Remove the clip and push rod pin from the clevis.
  
  Fig 1: Removing Clip & Push Rod Pin From Clevis
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE MASTER CYLINDER
1. Disconnect the 3 connectors from the brake master cylinder assy.
  
  Fig 2: Disconnecting Connectors From Brake Master Cylinder Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Use tags or make a memo to identify the place to reconnect.
  
  Fig 3: Using Tags Or Make Memo To Identify Place To Reconnect
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, disconnect the 4 brake lines from the brake master cylinder.
  SST 09023-00101
  
  Fig 4: Disconnecting Brake Lines From Brake Master Cylinder Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the 4 nuts and pull out the brake master cylinder.
  
  Fig 5: Removing Nuts & Pulling Out Brake Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER GASKET
1. Remove the brake booster gasket from the brake master cylinder.
REMOVE BRAKE ACTUATOR BRACKET NO.1
1. Using a hexagon wrench (5 mm), remove the bolt and brake actuator bracket No.1 from the brake master cylinder.
  
  Fig 6: Removing Bolt & Brake Actuator No. 1 From Brake Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a screwdriver, remove the brake fluid level warning switch connector from the brake actuator bracket No.1.
  
  Fig 7: Removing Brake Fluid Warning Switch Connector Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
1. Using a pin punch and hammer, remove the pin from the brake master cylinder reservoir sub-assy.
  
  Fig 8: Removing Pin From Brake Master Cylinder Reservoir Sub-Assy By Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the screw and pull out the brake master cylinder reservoir sub-assy.
  
  Fig 9: Removing Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the master cylinder reservoir filler cap.
REMOVE MASTER CYLINDER GROMMET
1. Remove the 3 master cylinder grommets from the master cylinder reservoir sub-assy.
  
  Fig 10: Removing Master Cylinder Grommets From Master Cylinder Reservoir Sub-Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR HOSE
1. Using needle nose pliers, slide the 2 clips and remove the brake actuator hose and 2 clips.
  
  Fig 11: Removing Brake Actuator Hose & Clips Using Needle Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE ACTUATOR TUBE NO.1
1. Using SST, remove the brake actuator tube No.1 from the brake master cylinder.
  SST 09023-00101
  
  Fig 12: Removing Brake Actuator Tube No. 1 From Brake Master Cylinder Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER W/ACCUMULATOR PUMP ASSY
1. Using a screwdriver, remove the 2 plugs.
  
  Fig 13: Removing Plugs Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 2 screws and disconnect the wire harnesses from the master cylinder solenoid.
  
  Fig 14: Removing Screws & Disconnecting Wire Harnesses From Master Cylinder Solenoid
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a screwdriver, remove the clip.
  
  Fig 15: Removing Clip By Using Screwdriver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the brake booster w/ accumulator pump assy from the brake master cylinder.
5. Remove the 2 brake booster pump collars and the 2 brake booster pump bushes from the brake booster w/ accumulator pump assy.
  
  Fig 16: Removing Brake Booster With Accumulator Pump Assy
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a hexagon wrench (4 mm), remove the 2 pins.
  
  Fig 17: Removing 2 Pins
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER PUMP BRACKET NO.1
1. Using a hexagon wrench (5 mm), remove the 2 bolts and brake booster pump bracket No.1 from the brake master cylinder solenoid.
2. Remove the brake booster pump bush from the brake booster pump bracket No.1.
  
  Fig 18: Removing Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE BOOSTER ACCUMULATOR ASSY
1. Secure the brake booster w/ accumulator pump assy in a vise.
2. Remove the brake booster accumulator assy.
3. Remove the O-ring from the brake booster accumulator assy.
  NOTE: Ensure no foreign matter enters the pump and accumulator.
4. Remove the brake booster accumulator pipe and compression spring.
  
  Fig 19: Securing Brake Booster With Accumulator Assy In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT BRAKE BOOSTER PUMP ASSY
1. Connect the positive (+) lead from the battery to the red cable of the pump motor, and the negative (-) lead to the black cable.
2. Check brake booster pump motor operation.
  
  Fig 20: Connecting Positive Lead From Battery To Red Cable Of Pump Motor & Negative Lead To Black Cable
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
DISPOSE OF BRAKE BOOSTER ACCUMULATOR ASSY
1. Place the brake booster accumulator assy in a vise and cover it with a shop rag or piece of cloth.
2. Using a saw, cut the brake booster accumulator body between A and B as shown in Fig 21 to discharge the gas inside.
  CAUTION:
  - Cover with a shop rag or piece of cloth when working because gas may blow out.
  - Carefully, not abruptly, cut the accumulator.
  - Wear protective glasses.
3. When the outer body of the brake booster accumulator is cut, gas and liquid discharge.
HINT:

The gas is colorless, odorless and non-poisonous.

Fig 21: Identifying Brake Booster Accumulator Body Between A & B
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER SOLENOID
1. Remove the 6 bolts and master cylinder solenoid.
  
  Fig 22: Removing & Bolts & Master Cylinder Solenoid
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the gasket.
  
  Fig 23: Removing Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE MASTER CYLINDER PUSH ROD CLEVIS
1. Loosen the lock nut on the rod operating adapter, and remove the push rod clevis and lock nut.
  
  Fig 24: Loosening Lock Nut On Rod Operating Adapter & Removing Push Rod Clevis & Lock Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Loosen the lock nut on the brake master cylinder side, and remove the rod operating adapter and lock nut.
REMOVE MASTER CYLINDER BOOT

Fig 25: Loosening Lock Nut On Brake Master Cylinder Side
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRAKE MASTER CYLINDER KIT
1. Pressing the piston in with a screwdriver, use a pin or equivalent to push the C-ring from the hole in the master cylinder body then remove it with another screwdriver.
  HINT:
  
  Tape the screwdriver tip before use.
2. Remove the piston, pulling it straight out, not at an angle.
NOTE: If pulled out at an angle, there is a possibility that the cylinder bore could be damaged.

Fig 26: Pressing Piston In With Screwdriver
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE MASTER CYLINDER KIT
1. Apply lithium soap base glycol grease to a new piston.
2. Install the piston.
3. Using 2 screwdrivers, install a new C-ring while pressing on the piston.
  
  Fig 27: Installing New C-Ring While Pressing On Piston Using Screwdrivers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MASTER CYLINDER BOOT
INSTALL MASTER CYLINDER PUSH ROD CLEVIS
1. Install the brake master cylinder side lock nut and rod operating adapter on the brake master cylinder.
  Torque: 26 N.m (260 kgf.cm, 19 ft.lbf)
  
  Fig 28: Installing Brake Master Cylinder Side Lock Nut & Rod Operating Adapter
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the lock nut and master cylinder push rod clevis on the rod operating adapter.
  Torque: 26 N.m (260 kgf.cm, 19 ft.lbf)
  
  Fig 29: Installing Lock Nut & Master Cylinder Push Rod Clevis
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MASTER CYLINDER SOLENOID
1. Install a new gasket.
  NOTE: Keep all surfaces of the master cylinder solenoid, master cylinder and gasket, especially contact surfaces, away from water and dust.
  
  Fig 30: Installing New Gasket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the master cylinder solenoid with 6 new bolts.
  Torque: 32 N.m (326 kgf.cm, 24 ft.lbf)
  
  Fig 31: Installing Master Cylinder Solenoid With New Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE BOOSTER ACCUMULATOR ASSY
1. Install the brake booster accumulator pipe and compression spring.
  NOTE: Ensure that no foreign matter enters the pump.
2. Install a new O-ring to the brake booster accumulator assy.
3. Install the brake booster accumulator assy.
  Torque: 57 N.m (585 kgf.cm, 42 ft.lbf)
  
  Fig 32: Installing Brake Booster Accumulator Pipe & Compression Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE BOOSTER PUMP BRACKET NO.1
1. Install the brake booster pump bush to the brake booster pump bracket No.1.
2. Using a hexagon wrench (5 mm), install the brake booster pump bracket No.1 with the 2 bolts.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
  
  Fig 33: Installing Brake Booster Pump Bracket No. 1 With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE BOOSTER W/ ACCUMULATOR PUMP ASSY
1. Using a hexagon wrench (4 mm), install the 2 pins to the brake master cylinder.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
2. Install the 2 brake booster pump collars and 2 brake booster pump bushes to the brake booster w/ accumulator pump assy.
  
  Fig 34: Installing Pins To Brake Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the brake booster w/ accumulator pump assy to the brake master cylinder.
  
  Fig 35: Installing Brake Booster With Accumulator Pump Assy To Brake Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Install a new clip.
  
  Fig 36: Installing New Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install the wire harnesses with the 2 screws.
  Torque: 2.9 N.m (30 kgf.cm, 26 in.lbf)
  
  Fig 37: Installing Wire Harness With Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Install 2 new plugs.
  
  Fig 38: Installing New Plugs
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR TUBE NO.1
1. Using SST, install the brake actuator tube No.1 to the brake master cylinder assy.
  SST 09023-00101
  
  Torque: 14 N.m (143 kgf.cm, 10 ft.lbf)
NOTE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).

HINT:

This torque value is effective when SST is parallel to the torque wrench.

Fig 39: Installing Brake Actuator Tube No. 1 To Brake Master Cylinder Assy Using SST
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR HOSE
1. Using needle nose pliers, install the brake actuator hose and 2 clips.
  
  Fig 40: Installing Brake Actuator Hose & Clips Using Needle Nose Pliers
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MASTER CYLINDER GROMMET
1. Apply lithium soap base glycol grease to 3 new master cylinder grommets.
2. Install 3 new master cylinder grommets to the brake master cylinder.
HINT:

Be careful of the size of each grommet.

Fig 41: Installing New Master Cylinder Grommets To Brake Master Cylinder
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSY
1. Install the brake master cylinder reservoir sub-assy with the screw.
  Torque: 1.7 N.m (17 kgf.cm, 15 in.lbf)
2. Install the master cylinder reservoir filler cap.
  
  Fig 42: Installing Brake Master Cylinder Reservoir Sub-Assy With Screw
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a pin punch and hammer, install a new pin to the brake master cylinder reservoir sub-assy.
  
  Fig 43: Installing New Pin To Brake Master Cylinder Reservoir Sub-Assy Using Pin Punch & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE ACTUATOR BRACKET NO.1
1. Install the brake fluid level warning switch connector to the brake actuator bracket No.1.
2. Using a hexagon wrench (5 mm), install the brake actuator bracket No.1 to the brake master cylinder with the bolt.
  Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
INSTALL BRAKE BOOSTER GASKET
1. Install a new brake booster gasket on the master cylinder.
  
  Fig 44: Installing Brake Actuator Bracket No. 1 To Brake Master Cylinder With Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL BRAKE MASTER CYLINDER
1. Install the brake master cylinder with the 4 nuts.
  Torque: 14 N.m (145 kgf.cm, 10 ft.lbf)
  
  Fig 45: Installing Brake Master Cylinder With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 4 brake lines to the correct positions of the brake master cylinder as shown in Fig 46.
  
  Fig 46: Connecting Brake Lines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using SST, torque the 4 brake lines.
  SST 09023-00101
  
  Torque: 14 N.m (145 kgf.cm, 10 ft.lbf)
  
  NOTE: Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
  
  HINT:
  
  This torque value is effective when SST is parallel to the torque wrench.
  
  Fig 47: Using SST To Torque Brake Lines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 3 connectors to the brake master cylinder.
  
  Fig 48: Connecting Connector To Brake Master Cylinder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL PUSH ROD PIN
1. Install the clip and push rod pin to the clevis.
  
  Fig 49: Installing Push Rod Pin
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL STEERING COLUMN HOLE COVER
1. Install the steering column hole cover with the 4 clips.
INSTALL INSTRUMENT PANEL FINISH LOWER PANEL
INSTALL INSTRUMENT PANEL LOWER LH
INSTALL INSTRUMENT PANEL FINISH PLATE
INSTALL INSTRUMENT CLUSTER FINISH PANEL ORNAMENT
INSTALL COWL SIDE TRIM BOARD LH
INSTALL FRONT FLOOR FOOTREST
INSTALL FRONT DOOR SCUFF PLATE LH
BLEED BRAKE BOOSTER W/ ACCUMULATOR PUMP ASSY (SEE BLEEDING )
BLEED BRAKE LINE (SEE BLEEDING )
BLEED MASTER CYLINDER SOLENOID (SEE BLEEDING )
CHECK FOR BRAKE FLUID LEAKAGE
CHECK BRAKE MASTER CYLINDER OPERATION (SEE ON-VEHICLE INSPECTION )
INSPECT BRAKE PEDAL HEIGHT (SEE ON-VEHICLE INSPECTION )
CHECK PEDAL FREE PLAY (SEE ON-VEHICLE INSPECTION )
CHECK PEDAL RESERVE DISTANCE (SEE ON-VEHICLE INSPECTION )
CHECK FLUID LEVEL IN RESERVOIR (SEE ON-VEHICLE INSPECTION )