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Brake Stroke Simulator Cylinder Sub-ASSY: Replacement

  1. REMOVE FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  2. REMOVE FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  3. REMOVE HOOD TO COWL TOP SEAL (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  4. REMOVE COWL TOP VENTILATOR LOUVER LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  5. REMOVE COWL TOP VENTILATOR LOUVER RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  6. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  7. BRAKE CONTROL (ECB) OFF (See  REPLACEMENT   ) 
    NOTE: Prohibit the brake control (ECB) certainly before bleeding the brake fluid.
  8. REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT   ) 
  9. DRAIN BRAKE FLUID 
    NOTE: Wash brake fluid off immediately if it adheres to any painted surface. 
  10. REMOVE BRAKE STROKE SIMULATOR CYLINDER SUB-ASSY 
    1. Using SST, separate the 2 brake tubes from the brake simulator cylinder sub-assy.

      SST 09023-00101

    2. Disconnect the connector.
      Fig 1: Disconnecting Connector
      G02592305Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts and 2 bolts, and remove the brake stroke simulator with bracket.
      Fig 2: Removing Brake Stroke Simulator With Bracket
      G02592306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 bolts and clamp of connector, and remove the bracket from the brake stroke simulator.
    5. Remove the 2 stud bolts from the brake stroke simulator.
      Fig 3: Removing Bracket From Brake Stroke Simulator
      G02592307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL BRAKE STROKE SIMULATOR CYLINDER SUB-ASSY 
    1. Install the 2 stud bolts to the brake stroke simulator.

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

    2. Install the brake stroke simulator to the bracket with the 2 bolts.

      Torque: 6.0 N.m (61 kgf.cm, 53 in..lbf) 

    3. Install the connector clamp of brake stroke simulator to the bracket.
      Fig 4: Installing Brake Stroke Simulator Cylinder Sub-Assy
      G02592308Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the brake stroke simulator and bracket to the body with the 2 nuts and 2 bolts.

      Torque: 8.5 N.m (87 kgf.cm, 75 in..lbf) 

      Fig 5: Installing Brake Stroke Simulator And Bracket
      G02592309Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using SST, install the 2 brake tubes to the brake stroke simulator cylinder sub-assy.

      SST 09023-00101

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

    6. Connect the connector.
      Fig 6: Installing Brake Tubes To Brake Stroke Simulator Cylinder Sub-Assy
      G02592310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (See  REPLACEMENT   ) 
  13. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  14. INSTALL FR WIPER ARM LH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  15. INSTALL FR WIPER ARM RH (See  WINDSHIELD WIPER MOTOR ASSY  ) 
  16. FILL RESERVOIR WITH BRAKE FLUID (See  BRAKE FLUID   ) 
  17. BLEED MASTER CYLINDER/STROKE SIMULATOR (See  BRAKE FLUID   ) 
  18. CHECK BRAKE FLUID LEAKAGE 
  19. CHECK FLUID LEVEL IN RESERVOIR 
  20. CHECK AND CLEAR DTC (See  DIAGNOSTIC TROUBLE CODES CHECK/CLEAR  ) 
  21. SYSTEM INITIALIZATION (See  INITIALIZATION  ) 
  22. CHECK OPERATION (See  BRAKE STROKE SIMULATOR CYLINDER SUB-ASSY   )