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Brake Fluid: Replacement

HINT:

If any work is performed on the brake system or if air in the brake lines is suspected, bleed the brake system.

NOTE:
  • Move the shift lever to the P position and apply the parking brake before bleeding the brakes.
  • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  • If brake fluid leaks onto any painted surface, immediately wash it off.
  1. FILL BRAKE FLUID RESERVOIR 
    1. Fill the reservoir with brake fluid.

      Brake Fluid: SAE J1703 or FMVSS No. 116 DOT 3 

      NOTE: Make sure that there is sufficient brake fluid in the reservoir.
  2. BLEED BRAKE MASTER CYLINDER 
    NOTE:
    • If the master cylinder is reinstalled or if the reservoir becomes empty, bleed the master cylinder.
    • To prevent brake fluid from adhering, cover the painted surfaces with a shop rag or a piece of cloth.
    Fig 1: Identifying Brake Master Cylinder
    G05417881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Using a union nut wrench (12 mm), disconnect the 2 brake lines from the master cylinder.
      Fig 2: Disconnecting Brake Lines From Master Cylinder Using Union Nut Wrench
      G05417882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slowly depress the brake pedal and hold it (*1).
      Fig 3: Depressing Brake Pedal
      G05417883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Cover the 2 outer holes with fingers, and release the brake pedal (*2).
      Fig 4: Releasing Brake Pedal
      G05417884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat (*1) and (*2) 3 or 4 times.
    5. Using a union nut wrench (12 mm), connect the 2 brake lines to the master cylinder.

      Torque: without union nut wrench 

      20 N*m (204 kgf*cm, 15 ft.*lbf) 

      with union nut wrench 

      18 N*m (184 kgf*cm, 13 ft.*lbf) 

      NOTE:
      • Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
      • This torque value is effective when the union nut wrench is parallel to the torque wrench.
      Fig 5: Connecting Brake Lines To Master Cylinder Using Union Nut Wrench
      G05417885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. BLEED BRAKE LINE 
    NOTE:
    • Bleed the brake line of the wheel farthest from the master cylinder first.
    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
    1. Connect a vinyl tube to the bleeder plug.
    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed (*3).
      Fig 6: Depressing Brake Pedal & Loosening Bleeder Plug
      G05417886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*4).
      Fig 7: Tightening Bleeder Plug & Releasing Brake Pedal
      G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Repeat (*3) and (*4) until all the air in the fluid is completely bled out.
    5. Tighten the bleeder plug completely.

      Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

    6. Repeat the above procedure for each wheel to bleed the brake line.
  4. BLEED BRAKE ACTUATOR 
    NOTE: After bleeding the brake system, if the specified height or feel of the brake pedal cannot be obtained, bleed the brake actuator assembly with Techstream by following the procedure below.
    1. Depress the brake pedal more than 20 times with the ignition switch off.
    2. Connect Techstream to the DLC3, and then turn the ignition switch on (IG).
      NOTE: Do not start the engine.
    3. Turn Techstream on and select "AIR BLEEDING" on the screen.
      NOTE:
      • Refer to the Techstream operator's manual for further details.
      • Bleed the air by following the steps displayed on Techstream.
    4. Bleed the air according to "Step 1: Increase Line" on the Techstream display.
      NOTE:
      • Make sure that the master cylinder reservoir tank does not run out of brake fluid.
      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
      1. Connect a vinyl tube to either one of the bleeder plugs.
      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*5).
        Fig 8: Depressing Brake Pedal And Loosening Bleeder Plug
        G05417886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*6).
      4. Repeat (*5) and (*6) until all the air in the fluid is completely bled out.
      5. Tighten the bleeder plug completely.

        Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

        Fig 9: Tightening Bleeder Plug & Releasing Brake Pedal
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Repeat the above procedure for the rest of the wheels to bleed the brake lines.
    5. Bleed the suction line according to "Step 2: Inhalation Line" on the Techstream display.
      NOTE:
      • Bleed the suction line by following the steps displayed on Techstream.
      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
      1. Connect a vinyl tube to the bleeder plug at the right front wheel or the right rear wheel and loosen the bleeder plug.
        Fig 10: Connecting Vinyl Tube To Bleeder Plug
        G05417890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Operate the brake actuator assembly to bleed the air using Techstream (*7).
        NOTE:
        • During this step, be sure to release the brake pedal.
        • The actuator operation stops automatically in 4 seconds.
      3. Check that the actuator operation has stopped by referring to the Techstream display, and tighten the bleeder plug (*8).
      4. Repeat (*7) and (*8) until all the air in the fluid is completely bled out.
      5. Tighten the bleeder plug completely.

        Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

        Fig 11: Tightening Bleeder Plug
        G05417891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. For the rest of the wheels, bleed the air in the same way as stated in the above procedure.

        Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

    6. Bleed the pressure reduction line according to "Step 3: Decrease Line" on the Techstream display.
      NOTE:
      • Bleed the pressure reduction line by following the steps displayed on Techstream.
      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
      1. Connect a vinyl tube to either one of the bleeder plugs.
      2. Loosen the bleeder plug (*9).
      3. While keeping the brake pedal fully depressed, operate the brake actuator assembly using Techstream.
        NOTE:
        • The actuator operation stops automatically in 4 seconds. When performing this procedure continuously, an interval of at least 20 seconds is required.
        • After the operation is completed, the brake pedal goes down slightly. This is a normal phenomenon when the solenoid opens.
        • During this procedure, the pedal seems heavy, but completely depress it so that the brake fluid comes out from the bleeder plug.
        • Be sure to keep the brake pedal depressed. Never depress and release the pedal repeatedly.
        Fig 12: Identifying Bleeder Plug & Depressing Brake Pedal
        G05417892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Tighten the bleeder plug, and then release the brake pedal (*10).
      5. Repeat steps (*9) to (*10) until all the air in the fluid is completely bled out.
      6. Tighten the bleeder plug completely.

        Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

        Fig 13: Tightening Bleeder Plug & Releasing Brake Pedal
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      7. Repeat the above procedures for the rest of the brakes to bleed the brake lines.
    7. Bleed the brake lines again according to "Step 4: Increase Line" on the Techstream display.
      NOTE:
      • Bleed the air by following the steps displayed on Techstream.
      • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
      1. Connect a vinyl tube to either one of the bleeder plugs.
      2. Depress the brake pedal several times, and then loosen the bleeder plug connected to the vinyl tube with the pedal depressed (*11).
        Fig 14: Depressing Brake Pedal & Loosening Bleeder Plug
        G05417892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal (*12).
      4. Repeat (*11) and (*12) until all the air in the fluid is completely bled out.
      5. Tighten the bleeder plug completely.

        Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf) 

        Fig 15: Tightening Bleeder Plug & Releasing Brake Pedal
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      6. Repeat the above procedures for each brake to bleed the brake lines.
    8. Finish "AIR BLEEDING" on Techstream, and then turn off Techstream.
    9. Disconnect Techstream from the DLC3.
    10. Turn the ignition switch off.
  5. INSPECT FLUID LEVEL  (See ON-VEHICLE INSPECTION  )
  6. INSPECT FOR BRAKE FLUID LEAK 
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