Contents: Removal ↓ Installation ↓
Removal
On pre-2001 models, remove the air cleaner cover and fuse/relay box on the left side of the engine compartment.
Figure 11.35. Master brake cylinder: A – electrical connector; B – brake pipe connection points; C – nuts
Disconnect the electrical connector from the brake fluid level sensor (figure 11.35).
Remove the cap from the brake system expansion tank and, using a syringe, pump out the brake fluid.
Label the brake lines that go to the master cylinder. Place a clean rag under the master cylinder to collect any leaking brake fluid.
Loosen the connecting nuts securing the brake pipes and move the pipes away from the master cylinder. Close the ends of the tubes with suitable stoppers.
Warning: Brake fluid used in the hydraulic brake system is toxic, so if it comes into contact with your skin, immediately flush the affected area with plenty of water. Brake fluid dissolves paint and plastic, so if the fluid gets on your car's paintwork, rinse it with plenty of water.
(The original version is published on the website: ToyotaMan.ru)
Remove the two nuts and the master cylinder from the brake booster along with the gasket. Check the condition of the sealing ring at the end of the master cylinder and replace it if necessary.
Installation
Figure 11.41. Clearance between the pusher (2) of the brake booster and the piston (1) of the brake master cylinder: X = 0 mm
Before installing a new brake master cylinder, check the clearance between the vacuum booster pushrod and the brake master cylinder piston (see Figure 11.41). Adjust the push rod length if necessary.
Before installing the master cylinder, fill it with brake fluid and bleed any air by securing the master cylinder in a vice and sealing the outlet holes of the master cylinder with threaded plugs.
Fill the reservoir with clean brake fluid.
Unscrew one plug and, by moving the piston in the master brake cylinder, squeeze the air out of it.
Before releasing the piston, screw the threaded plug back into place.
Repeat the bleeding operation until only clean brake fluid without air bubbles comes out of the hole. Repeat the master cylinder bleeding operation on the second outlet.
Install the master cylinder with a new gasket onto the brake booster studs and secure with nuts, tightening them by hand at this stage.
Remove the threaded plugs from the master brake cylinder and install the brake pipes in their place.
Finally tighten the brake master cylinder mounting nuts.
Pour brake fluid into the brake system expansion tank.
Connect the electrical connector to the brake fluid level sensor.
Figure 11.36. Bleeding air from the master cylinder
Bleed any air that entered the brake master cylinder when installing the brake lines. Press the brake pedal sharply, loosen the nut securing the brake pipe to the master brake cylinder by half a turn while keeping the pedal depressed (figure 11.36). While continuing to press the pedal, force out the fluid and air from the system. Once the pedal reaches its extreme forward position and the fluid stops leaking, tighten the brake pipe mounting nut. Repeat these operations until air stops leaking from the master cylinder.