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Brake Master Cylinder: Removal

NOTE: Make sure to release the vacuum from the brake booster before removing the master cylinder from the brake booster.
  1. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  2. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  3. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  4. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  5. REMOVE COWL TOP VENTILATOR LOUVER RH  (See REMOVAL )
  6. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  7. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  8. REMOVE OUTER COWL TOP PANEL 
    1. Disengage the clamp and bend the water guard plate RH as shown in the illustration.
      Fig 1: Identifying Outer Cowl Top Panel Clamp
      G06035198Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disengage the clamp.
    3. Remove the 12 bolts and outer cowl top panel.
  9. REMOVE SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar)  (See REMOVAL )
  10. REMOVE NO. 2 CYLINDER HEAD COVER (for 2ZR-FE)  (See REMOVAL )
  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2ZR-FE)  (See AIR FUEL RATIO SENSOR )
  12. REMOVE AIR CLEANER CASE (for 2ZR-FE)  (See REMOVAL )
  13. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE)  (See REMOVAL )
  14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE)  (See REMOVAL )
    Fig 2: Locating Outer Cowl Top Panel Bolts
    G06035199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE AIR CLEANER CASE (for 2AZ-FE)  (See REMOVAL )
  16. DRAIN BRAKE FLUID 
  17. DISCONNECT CLUTCH TUBE (for Manual Transaxle) 
    1. Move the clip and disconnect the clutch tube.
      Fig 3: Locating Clutch Tube Clip
      G06010003Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY 
    1. Disconnect the connector and disengage the clamp.
      Fig 4: Locating Brake Master Cylinder Clamp And Connector
      G06010004Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a union nut wrench (10 mm), disconnect the 4 brake lines from the brake master cylinder sub-assembly.
      Fig 5: Disconnecting Brake Lines From Brake Master Cylinder Sub-Assembly
      G06035202Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 nuts, brake tube way and brake master cylinder sub-assembly.
      NOTE:
      • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as 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.
      • Make sure to release the vacuum from the brake booster before removing the master cylinder from the brake booster.
      • 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 off.
      • 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 piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.
      • Do not use any other type of grease or fluid.
        Fig 6: Locating Brake Tube Nuts
        G06010006Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring from the brake master cylinder sub-assembly.
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