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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.
      Fig 1: Locating Master Cylinder Reservoir Filler Cap
      G05417881Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
    1. Using a union nut wrench (12 mm), disconnect the 2 brake lines from the master cylinder.
      Fig 2: Locating Brake Master Cylinder Assembly Brake Tubes
      G05417882Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Slowly depress the brake pedal and hold it (*1).
      Fig 3: Depressing Brake Pedal
      G06116721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Cover the 2 outer holes with fingers, and release the brake pedal (*2).
    4. Repeat (*1) and (*2) 3 or 4 times.
      Fig 4: Depressing Brake Pedal
      G05417884Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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) 

      Fig 5: Locating Brake Master Cylinder Assembly Brake Tubes
      G05417885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  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: Connecting Vinyl Tube To 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).
    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.
      Fig 7: Tightening Bleeder Plug
      G06116725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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: Connecting Vinyl Tube To 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. 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) 

      6. Repeat the above procedure for the rest of the wheels to bleed the brake lines.
        Fig 9: Tightening Bleeder Plug
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
      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.
          Fig 10: Connecting Vinyl Tube To Bleeder Plug
          G05417890Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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) 

      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) 

        Fig 11: Tightening Bleeder Plug
        G05417891Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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.
        Fig 12: Depressing Brake Actuator Assembly
        G05417892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        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.
      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) 

      7. Repeat the above procedures for the rest of the brakes to bleed the brake lines.
        Fig 13: Tightening Bleeder Plug
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Actuator Assembly
        G05417892Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal
      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) 

      6. Repeat the above procedures for each brake to bleed the brake lines.
        Fig 15: Tightening Bleeder Plug
        G05417887Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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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