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Removal [11/2015 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notice before proceeding with work (Refer to PRECAUTION [11/2015 - 06/2017] and Refer to PRECAUTION [06/2017 - ] ).

  2. DISABLE BRAKE CONTROL 
    1. Wait at least 2 minutes after turning the ignition switch off.
      NOTE:

      When the brake pedal is depressed or the door courtesy switch is turned on even if the ignition switch is off, the brake control system activates. Therefore do not depress the brake pedal or open/close the doors until the reservoir level switch connector is disconnected.

    2. Disconnect the reservoir level switch connector with the parking brake applied.
      GTY324792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Disconnect the cable from the negative (-) auxiliary battery terminal (Refer to REMOVAL [11/2015 - 06/2017] and Refer to REMOVAL [06/2017 - ] ).
    4. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
    5. Check that the brake pedal can not be further depressed.
    6. Release the parking brake.
  3. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    (Refer to REMOVAL [11/2015 - ] )

  4. REMOVE INNER COWL TOP TO COWL BRACE 
    1. Remove the 3 bolts and inner cowl top to cowl brace.
      GTY339984Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE FRONT AIR SHUTTER SEAL 
    1. Disengage the clamp to remove the front air shutter seal.
      GTY339985Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FRONT NO. 1 VENTILATOR SEAL 
    1. Disengage the clamp to remove the front No. 1 ventilator seal.
      GTY339986Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 
    1. Disengage the clamp to separate the wire harness from the outer cowl top panel sub-assembly.
      GTY339987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 8 bolts, nut and outer cowl top panel sub-assembly.
      GTY339990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. DRAIN BRAKE FLUID 
    NOTE:

    If brake fluid leaks onto any painted surface, immediately clean it off.

  9. REMOVE BRAKE PEDAL RETURN SPRING 

    See step  8

  10. REMOVE PUSH ROD PIN 

    See step  12

  11. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Remove the 2 nuts and separate the brake master cylinder reservoir assembly from the reservoir bracket.
      GTY339991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. DISCONNECT NO. 2 RESERVOIR HOSE 
    1. Move the clip and disconnect the No. 2 reservoir hose from the brake booster with master cylinder assembly.
      GTY324809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. DISCONNECT NO. 1 RESERVOIR HOSE 
    1. Move the clip and disconnect the No. 1 reservoir hose from the brake booster with master cylinder assembly.
      GTY339992Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE RESERVOIR BRACKET 
    1. Remove the 2 bolts and reservoir bracket.
      GTY340022Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. DISCONNECT BRAKE ACTUATOR HOSE 
    1. Move the clip and disconnect the brake actuator hose from the brake master cylinder reservoir assembly.
      GTY340023Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
  17. REMOVE TUBE CLAMP BRACKET 
    1. Remove the 2 bolts and tube clamp bracket from the brake booster with master cylinder assembly and front No. 1 brake tube.
      GTY324604Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Release the lock lever and disconnect the connector.
      GTY340021Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Release the lock lever
      Disconnect the connector
      NOTE:

      Be careful not to allow the brake fluid to enter the removed connector.

    2. Using a union nut wrench, disconnect the 5 brake lines from the brake booster with master cylinder assembly.
      GTY730352Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Use tags or make a memo to identify the places to reconnect the lines.
      TEXT IN ILLUSTRATION

      *a to Front Wheel Cylinder LH
      *b to Rear Wheel Cylinder RH
      *c to Brake Booster Pump Assembly
      *d to Rear Wheel Cylinder LH
      *e to Front Wheel Cylinder RH
    4. Remove the 4 nuts and brake booster with master cylinder assembly.
      GTY735360Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Connector Portion
      *2 Union
      *3 Push Rod Clevis
      *4 Boot
      *5 Front No. 2 Brake Tube
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not carry the brake booster with master cylinder assembly by the portion shown in bold in the illustration.
      • Be careful not to allow any brake fluid to enter the connector.
  19. REMOVE BRAKE BOOSTER GASKET 
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