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Brake Master Cylinder: Installation

  1. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD  (See INSPECTION  )
  2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY 
    1. Install a new O-ring to the brake master cylinder sub-assembly.
    2. Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

      Torque: 13 N*m (132 kgf*cm, 10 ft.*lbf) 

      Fig 1: Identifying Brake Master Cylinder Sub-Assembly
      G05417918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.
      • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
      • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling out.
      • Do not allow any foreign objects to contaminate the master cylinder piston. If a foreign object gets on the piston, remove it by using a shop rag or a piece of cloth and then apply an even layer of lithium soap based glycol grease around the circumference (sliding part) of the piston.
      • Do not use any other type of grease or fluid.
  3. CONNECT BRAKE LINE 
    1. Using a union nut wrench (12 mm), connect the 2 brake lines to the brake master cylinder sub-assembly.

      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 2: 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.
  4. CONNECT NO. 1 RESERVOIR TUBE 
    1. Connect the No. 1 reservoir tube to the brake master cylinder reservoir assembly.
  5. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY  (See INSTALLATION )
  6. INSTALL WINDSHIELD WIPER MOTOR AND LINK  (See INSTALLATION )
  7. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY  (See INSTALLATION )
  8. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See INSTALLATION )
  9. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See INSTALLATION )
  10. INSTALL EJECTOR TUBE (for 1AR-FE) 
    1. Install the ejector tube with the 2 nuts.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  11. FILL BRAKE FLUID RESERVOIR  (See ON-VEHICLE INSPECTION  )
  12. BLEED BRAKE MASTER CYLINDER  (See ON-VEHICLE INSPECTION  )
  13. BLEED BRAKE LINE  (See REPLACEMENT  )
  14. BLEED BRAKE ACTUATOR  (See REPLACEMENT  )
  15. INSPECT FOR BRAKE FLUID LEAK 
  16. INSPECT FLUID LEVEL  (See ON-VEHICLE INSPECTION  )
    Fig 3: Locating Ejector Tube Nuts
    G06116756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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