Removal
1. Disconnect the low brake fluid level sensor connector.
2. Use a syringe to pump out the brake fluid from the reservoir.
Caution: Do not allow brake fluid to come into contact with painted surfaces. If brake fluid does come into contact with a painted surface, wash it off immediately.
3. Using a special tool, disconnect the brake pipes from the master cylinder.
4. Loosen the nuts, remove the bracket, master cylinder and gasket.
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Disassembly
1. Remove the tank.
a) Unscrew the screw and remove the tank.
b) Remove the lid and take out the mesh filter from the tank.
2. Remove the rubber bushings.
3. (Without ABS)
Place the cylinder in a vice, use a screwdriver to push the pistons through their full stroke and remove the lock bolt with the gasket.
Note: Before use, wrap the screwdriver with electrical tape.
4. Remove the pistons.
a) Press the piston with a screwdriver and remove the retaining ring using a special tool.
b) Remove piston No.1 with the spring, pulling it strictly along the axis without distortions.
Caution: If the piston is removed at an angle, the cylinder bore may be damaged.
c) Place a rag on two wooden blocks as shown in the figure and lightly tap the cylinder flange on the blocks until piston No.2 comes out.
Note: Make sure the distance from the cloth to the top of the bars is at least 100 mm.
Examination
Note: Blow out the disassembled brake cylinder parts with compressed air.
1. Check the cylinder bore for rust and scoring.
2. Check the cylinder for wear and damage. Replace the cylinder if necessary.
Assembly
1. Lubricate the surfaces indicated by arrows in the assembly drawings.
2. Install the pistons.
Caution: Be careful not to damage the cuffs.
a) Install the pistons strictly along the axis without distortions.
Caution: If the piston is installed at an angle, the cylinder bore may be damaged.
b) Press the piston with a screwdriver and install the retaining ring.
Note: Before use, wrap the screwdriver with electrical tape.
3. (Without ABS)
Using a screwdriver, push the pistons all the way in and install the lock bolt with a new gasket. Tighten the bolt.
- Tightening torque - 10 Nm
4. Install two rubber bushings
5. Install the tank.
a) Install the mesh filter and cover.
b) Install the tank and secure it with a screw.
- Tightening torque - 1.7 Nm
Removing the master brake cylinder.
1 - master brake cylinder,
2 - connector,
3 - gasket,
4 - tee (without ABS),
5 - tube No.3,
6 - tube No.2 (without ABS),
7 - tube No.4 (without ABS),
8 - tube No.1 (without ABS),
9 - bracket (4S-FE, 3S-FE),
10 - tube No.2 (with ABS).
Master brake cylinder.
1 - cover,
2 - mesh filter,
3 - tank,
4 - piston No.2 and spring,
5 - retaining ring,
6 - piston No.1 and spring,
7 - cylinder body,
8 - rubber bushing,
9 - lock bolt (without ABS),
10 - gasket (without ABS).
Installation
1. Adjust the length of the vacuum booster rod before installing the master brake cylinder on it (see section "Vacuum brake booster").
[The publication is taken from the website: www.toyotaman.ru]
2. Install the new gasket, master cylinder and bracket, tighten the mounting nuts
- Tightening torque - 13 Nm
3 Using the special tool, connect the tubes to the master brake cylinder. Tighten the fittings.
- Tightening torque - 15 Nm
4. Connect the low brake fluid level sensor connector.
5. Fill the reservoir with brake fluid and bleed the brake system.
6. Check for leaks.
7. Check and adjust the brake pedal.