Brake Master Cylinder: Installation

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.

INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD
1. Set SST on the master cylinder and lower the rod of SST until it just touches the piston.
  SST 09737-00013
2. Apply chalk to the flat tip of the SST rod. Turn SST upside down and measure the clearance between the brake booster push rod and SST.
  Standard Clearance:
  
  -0.21 to 0 mm (-0.0083 to 0 in.)
  
  If there is clearance between the SST main body and the shell of the brake booster, the push rod is protruding too far. If the chalk does not stick to the tip of the brake booster push rod, the push rod protrusion is insufficient.
  
  Fig 1: Measuring Clearance Between Brake Booster Push Rod & SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. If the clearance is not within the standard, adjust the length by holding the rod using SST and turning the tip of the rod using a 7 mm socket driver.
  SST 09737-00020
  
  NOTE: Check the push rod clearance again after adjusting.
INSTALL BRAKE MASTER CYLINDER
1. Install a new O-ring onto the brake master cylinder.
  
  Fig 2: Turning Tip Of Rod Using Socket Driver
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. w/ ABS:
  1. Install the brake master cylinder with the 2 nuts.
    Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)
    
    Fig 3: Locating Brake Master Cylinder Nuts (With ABS)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. w/o ABS:
  1. Install the brake master cylinder and brake tube way with the 2 nuts.
    Torque: 13 N*m (127 kgf*cm, 9 ft.*lbf)
    
    Fig 4: Locating Brake Master Cylinder Nuts (Without ABS)
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using SST, install the 2 brake tubes onto the brake master cylinder.
  SST 09023-00100
  
  Torque: for use without SST
  
  15 N*m (155 kgf*cm, 11 ft.*lbf)
  
  for use with SST
  
  14 N*m (143 kgf*cm, 10 ft.*lbf)
  
  HINT:
  - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
  - This torque value is effective when SST is parallel to a torque wrench.
    
    Fig 5: Separating Brake Tubes From Brake Master Cylinder
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. w/o ABS:
  1. Using SST, install the 3 brake tubes to the brake tube way.
    SST 09023-00100
    
    Torque: for use without SST
    
    15 N*m (155 kgf*cm, 11 ft.*lbf)
    
    for use with SST
    
    14 N*m (143 kgf*cm, 10 ft.*lbf)
    
    HINT:
    - Use a torque wrench with a fulcrum length of 300 mm (11.81 in.).
    - This torque value is effective when SST is parallel to a torque wrench.
6. Connect the brake fluid level warning switch connector.
  
  Fig 6: Separating Brake Tubes From Brake Tube Way
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT CLUTCH RESERVOIR TUBE (for Manual Transaxle)
1. Connect the reservoir tube with the clip.
INSTALL BATTERY CARRIER (See INSTALLATION )
INSTALL BATTERY TRAY
INSTALL BATTERY (See INSTALLATION )
FILL RESERVOIR WITH BRAKE FLUID (See BLEEDING )
BLEED MASTER CYLINDER (See BLEEDING )
BLEED BRAKE LINE (See BLEEDING )
CHECK FLUID LEVEL IN RESERVOIR (See BLEEDING )