Brake Master Cylinder: Removal: Removal

NOTE:

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

DRAIN BRAKE FLUID
NOTE:
If brake fluid leaks onto any painted surface, immediately wash it off.
REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
Refer to REMOVAL
REMOVE FRONT OUTER COWL TOP PANEL SUB-ASSEMBLY
1. Disengage the 2 clamps and separate the wire harness from the front outer cowl top panel sub-assembly.
  
  Fig 1: Identifying Front Outer Cowl Top Panel Sub-Assembly Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 10 bolts and front outer cowl top panel sub-assembly.
  
  Fig 2: Identifying Front Outer Cowl Top Panel Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE COOL AIR INTAKE DUCT SEAL . Refer to REMOVAL - Step 1
REMOVE INLET AIR CLEANER ASSEMBLY (for 2AR-FE) . Refer to REMOVAL - Step 19
REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2AR-FE) . Refer to REMOVAL - Step 7
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2AR-FE)
REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 2AR-FE) . Refer to REMOVAL - Step 22
REMOVE INLET NO. 2 AIR CLEANER (for 2GR-FE) . Refer to REMOVAL - Step 18
REMOVE AIR CLEANER CAP SUB-ASSEMBLY (for 2GR-FE) . Refer to REMOVAL - Step 7
REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY (for 2GR-FE)
REMOVE AIR CLEANER CASE SUB-ASSEMBLY (for 2GR-FE) . Refer to REMOVAL - Step 21
REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY
1. Disengage the clamp and disconnect the reservoir level switch connector.
  
  Fig 3: Identifying Brake Master Cylinder Sub-Assembly Clamp And Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a union nut wrench, disconnect the 6 brake lines and remove the brake master cylinder to way tube from the brake master cylinder sub-assembly.
  
  Fig 4: Identifying Brake Lines
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not damage or deform the brake lines during the removal procedure.
  - Do not allow any foreign matter such as dirt or dust to enter the brake lines.
3. Remove the 2 nuts, front No. 1 brake tube way and brake master cylinder sub-assembly from the brake booster assembly.
  
  Fig 5: Identifying No. 1 Brake Tube Way And Brake Master Cylinder Sub-Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Master Cylinder Piston
  NOTE:
  - Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.
  - Do not pull out the master cylinder piston.
  - 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 brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or its tip faces downward (the master cylinder piston faces upward) to prevent the master cylinder piston from falling out.
  - Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder 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 master cylinder piston.
REMOVE BRAKE MASTER CYLINDER O-RING
1. Remove the brake master cylinder O-ring from the brake master cylinder sub-assembly.