Brake Master Cylinder Sub-ASSY: Replacement

1. With the power switch off to prohibit brake control, remove the motor relays No.1 and No.2.
   NOTE: If the pump motor operates while there is air remaining inside the brake actuator hose, the air will enter the actuator, resulting in difficulty in air bleeding. 

   HINT:

   Brake control (ECB) can be prohibited by selecting "ECB INVALID" on the hand-held tester.

   Fig 1: Removing Motor Relays No.1 And No.2

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1. Remove the 2 bolts and separate the engine room R/B No.2.
   Fig 2: Removing Cowl Top Panel Sub-Assy Outer Front

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2. Remove the 3 clamps from the cowl top panel sub-assy outer front.
   Fig 3: Removing 3 Clamps From Cowl Top Panel Sub-Assy Outer Front

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3. Remove the 7 bolts and separate the cowl top panel sub-assy outer front.
   Fig 4: Removing Bolts And Separate Cowl Top Panel Sub-Assy Outer Front

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HINT:

Refer to the procedures from the removal of the engine undercover LH up until the removal of the inverter assy with converter.

1. Remove the brake return spring.
2. Remove the clip and brake master cylinder push rod pin, and separate the push rod clevis from the brake pedal.
   Fig 5: Removing Brake Master Cylinder Sub-Assy

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3. Remove the 4 clips and 2 reservoir tube hoses.
   Fig 6: Removing 4 Clips And 2 Reservoir Tube Hoses

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4. Remove the bolt from the actuator bracket.
5. Using SST, remove the front brake tube No.1. SST 09023-00101
   Fig 7: Removing Bolt From Actuator Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, separate the front brake tube No.2 from the clamp and brake master cylinder sub-assy. SST 09023-00101
   Fig 8: Separating Front Brake Tube No.2 From Clamp And Brake Master Cylinder Sub-Assy

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7. Remove the 2 nuts, and remove the brake master cylinder gasket and brake master cylinder sub-assy from the bracket.
   Fig 9: Removing Brake Master Cylinder Gasket And Brake Master Cylinder Sub-Assy From Bracket

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8. Using SST, remove the brake tube and 2 way from the brake master cylinder sub-assy.

   SST 09023-00101

   Fig 10: Removing Brake Tube And 2 Way From Brake Master Cylinder Sub-Assy

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9. Remove the screw, and remove the brake master cylinder union No.1 and 2 grommets from the brake master cylinder sub-assy.
   Fig 11: Removing Brake Master Cylinder Union No.1 And 2 Grommets From Brake Master Cylinder Sub-Assy

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10. Loosen the clevis lock nut and remove the brake master cylinder push rod clevis.
    Fig 12: Removing Brake Master Cylinder Push Rod Clevis

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1. Install the brake master cylinder push rod clevis to the brake master cylinder sub-assy, and fix by the lock nut.

   HINT:

   After adjusting the brake pedal height, torque the lock nut.

2. Apply lithium soap base glycol grease to the 2 new grommets.
3. Install the brake master cylinder union No.1 and 2 grommets to the brake master cylinder sub-assy with a screw.

   Torque: 1.8 N.m (18 kgf.cm, 16 in..lbf) 

   Fig 13: Installing Brake Master Cylinder Sub-Assy

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4. Using SST, install the brake tube and 2 way to the brake master cylinder sub-assy.

   SST 09023-00101

   Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

   Fig 14: Installing Brake Tube And 2 Way To Brake Master Cylinder Sub-Assy

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5. Placing the gasket in between, install the brake master cylinder sub-assy to the bracket with 2 nuts.

   Torque: 13 N.m (127 kgf.cm, 9 ft.lbf) 

   Fig 15: Installing Brake Master Cylinder Sub-Assy To Bracket

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using SST, connect the front brake tube No.2 to the clamp and brake master cylinder sub-assy.

   SST 09023-00101

   Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

   Fig 16: Connecting Front Brake Tube No.2 To Clamp And Brake Master Cylinder Sub-Assy

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7. Using SST, connect the front brake tube No.1.

   SST 09023-00101

   Torque: 15 N.m (155 kgf.cm, 11 ft.lbf) 

8. Install the bolt to the actuator bracket.

   Torque: 5.0 N.m (51 kgf.cm, 44 in..lbf) 

   Fig 17: Connecting Front Brake Tube No.1

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9. Connect the 2 reservoir tube hoses and hold them there with clips.
   Fig 18: Connecting Reservoir Tube Hoses And Hold With Clips

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10. Install the push rod clevis with the brake master cylinder push rod pin to the brake pedal.
11. Install the clip and brake pedal return spring.
    Fig 19: Installing Clip And Brake Pedal Return Spring

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HINT:

Refer to the procedures from the installation of the inverter assy with converter up until the installation of the engine under cover LH.

1. Install the cowl top panel sub-assy outer front with the 7 bolts.

   Torque: 6.4 N.m (65 kgf.cm, 57 in..lbf) 

   Fig 20: Installing Cowl Top Panel Sub-Assy Outer Front

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2. Install the 3 clamps to the cowl top panel sub-assy outer front.
   Fig 21: Installing 3 Clamps To Cowl Top Panel Sub-Assy Outer Front

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3. Install the engine room R/B No.2 with the 2 bolts.

   Torque: 8.4 N.m (86 kgf.cm, 74 in..lbf) 

   Fig 22: Installing Engine Room R/B No.2 With 2 Bolts

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SST 09023-00101