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Removal [11/2015 - 12/2018]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the power 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 notices before proceeding with work.

    Refer to PRECAUTION [11/2015 - 11/2017] , or refer to PRECAUTION [11/2017 - 12/2018]

  2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [11/2015 - ]

  3. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL 

    Refer to PROCEDURE - Step 3

  4. REMOVE WATER GUARD PLATE LH 

    Refer to PROCEDURE - Step 4

  5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH 

    Refer to PROCEDURE - Step 5

  6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  7. PERFORM ACCUMULATOR PRESSURE ZERO DOWN 
    1. Using the Techstream, perform the accumulator pressure zero down.
      1. Connect the Techstream to the DLC3 with the power switch off.
      2. Turn the power switch on (IG).
      3. Turn the Techstream on and enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake system) Utility.

        Chassis > ABS/VSC/TRAC > Utility 

        Tester Display
        ECB Utility
      4. Select "Motor Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.
      5. Perform "Motor Invalid" according to the display on the Techstream.
      6. Enter the following menus: Chassis / ABS/VSC/TRAC / Utility / ECB (Electronically Controlled Brake system) Utility.

        Chassis > ABS/VSC/TRAC > Utility 

        Tester Display
        ECB Utility
      7. Select "ECB (Electronically Controlled Brake system) Invalid" on the "ECB (Electronically Controlled Brake system) Utility" screen.
      8. Perform "ECB (Electronically Controlled Brake system) Invalid" according to the display on the Techstream.
      9. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.

        HINT: 

        A buzzer may sound due to low accumulator pressure. As this is not a malfunction, continue the procedure.

      10. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down is not complete.

      11. Turn the Techstream off and turn the power switch off.
      12. Disconnect the Techstream from the DLC3.
      13. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to PROCEDURE - Step 2

    2. When the accumulator pressure zero down could not be performed using the Techstream.
      NOTE:

      If DTCs are output, accumulator pressure zero down may not be complete. In this case, perform the following procedure.

      1. With the power switch off, release the lock lever and disconnect the brake booster pump assembly connector as shown in the illustration.
        GTY552341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        Release the lock lever
        Disconnect the connector
      2. Depress the brake pedal 40 times or more to return all the fluid in the accumulator back to the reservoir.
      3. Check that the brake pedal is firm.
        NOTE:

        If the brake pedal is not firm or the pump motor continues to operate even after depressing the brake pedal 40 times or more, the accumulator pressure zero down is not complete.

      4. Disconnect the cable from the negative (-) auxiliary battery terminal.

        Refer to PROCEDURE - Step 2

  8. DRAIN BRAKE FLUID 
    NOTE:

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

  9. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 13 [11/2015 - 08/2016] , or refer to PROCEDURE - Step 13 [08/2016 - 12/2018]

  10. DISCONNECT ENGINE WIRE 

    Refer to PROCEDURE - Step 9

  11. DISCONNECT ENGINE ROOM MAIN WIRE 
    1. Disconnect the connector from the brake booster with master cylinder assembly.
      GTY581431Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Push the lock arm of the connector to release the lock and rotate the lock lever to the position shown in the illustration.
      GTY554323Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lock Lever
      *b Lock Arm
      *c Push
      Release the lock lever
    3. Using a screwdriver, release the pre-lock and disconnect the connector from the brake booster with master cylinder assembly as shown in the illustration.
      GTY602660Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Screwdriver Insertion Point
      *b Pre-lock
      Disconnect the connector
    4. Disengage the clamp to separate the engine room main wire.
  12. DISCONNECT NO. 2 BRAKE ACTUATOR HOSE 
    1. Slide the clip and disconnect the No. 2 brake actuator hose from the brake booster with master cylinder assembly.
      GTY581420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. SEPARATE NO. 1 BRAKE ACTUATOR TUBE 
    1. Remove the nut and separate the No. 1 brake actuator tube from the vehicle body.
      GTY581435Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. SEPARATE BRAKE LINE 
    1. Using a union nut wrench, disconnect the 3 brake lines from the brake booster with master cylinder assembly.
      GTY607115Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
    2. Disengage the clamp and separate the 3 brake lines.
      GTY581489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not damage the clamp.
      • Do not kink or damage the brake lines.
  15. REMOVE FRONT DOOR SCUFF PLATE LH 

    Refer to PROCEDURE - Step 14

  16. REMOVE COWL SIDE TRIM BOARD LH 

    Refer to PROCEDURE - Step 15

  17. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 9 [11/2015 - 11/2017] , or refer to PROCEDURE - Step 9 [11/2017 - 12/2018]

  18. REMOVE BRAKE PEDAL RETURN SPRING 

    See step  5

  19. REMOVE PUSH ROD PIN 

    See step  6

  20. REMOVE BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY 
    1. Remove the 4 nuts and brake booster with master cylinder assembly.
      GTY596730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Skid Control ECU
      *b No. 1 Reservoir Hose
      *c Brake Master Cylinder Push Rod Clevis
      *d Boot
      *e Master Cylinder Reservoir Assembly
      *f Brake Actuator Bracket
      NOTE:
      • Do not kink or damage the brake lines.
      • Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.
      • Be careful not to allow any brake fluid to enter the connector.
  21. REMOVE BRAKE MASTER CYLINDER GASKET 
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