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Brake Master Cylinder: Removal

NOTE:
  • The structure of the master cylinder allows the piston to pop out, so observe the following:
    1. The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.
    2. Do not scratch or damage the circumference of the piston. For the seal to function correctly, all sliding surfaces must not have any damage.
    3. Do not pull out the master cylinder piston.
    4. Make sure to release the vacuum from the brake booster (by removing a vacuum hose, etc.) before removing the master cylinder from the brake booster.
    5. When installing the master cylinder, remove the protectors for the piston and the discharge port.
    6. Apply the supplied grease to the outer diameter of the piston and the inner diameter of the brake booster.
  1. DRAIN BRAKE FLUID 
    NOTE:
    • Stop the engine and depress the brake pedal several times until no vacuum is left in the brake booster.
    • If the brake fluid leaks onto any painted surface, wash off and remove the brake fluid completely.
  2. REMOVE COOL AIR INTAKE DUCT SEAL  (See REMOVAL )
  3. REMOVE HOOD HINGE COVER (for LH Side)  (See REMOVAL )
  4. REMOVE HOOD HINGE COVER (for RH Side)  (See REMOVAL )
  5. REMOVE ENGINE ROOM SIDE COVER LH  (See REMOVAL )
  6. REMOVE ENGINE ROOM SIDE COVER RH  (See REMOVAL )
  7. REMOVE AIR CLEANER CAP SUB-ASSEMBLY  (See REMOVAL )
  8. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
  9. REMOVE FRONT SUSPENSION UPPER CENTER BRACE 
    1. Remove the 4 nuts and the front suspension upper center brace.
    Fig 1: Locating Front Suspension Upper Center Brace Nuts
    G05250559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  11. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  12. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See REMOVAL )
  13. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  14. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY 
    1. Disconnect the connector.
      Fig 2: Locating Brake Master Cylinder Connector
      G04978333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, disconnect the 6 brake lines and remove the brake master cylinder to way tube.

      SST 09023-00101 

      Fig 3: Disconnecting Brake Lines
      G04978334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, the front brake tube way, the CD-ring and the brake master cylinder sub-assembly.
      Fig 4: Locating Brake Master Cylinder Sub-Assembly Bolts
      G04978335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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