Toyota Tacoma manuals

Toyota Corolla Repair Manual: Overhaul

1. Drain brake fluid

Notice

: wash the brake fluid off immediately if it comes into contact with any painted surface.

2. Remove air cleaner cap subassy

3. Remove brake master cylinder subassy

  1.  disconnect the brake fluid level switch connector from master cylinder reservoir subassy.
  2.  m/t: slide the clip and disconnect the clutch reservoir tube no.1 From master cylinder reservoir subassy.

  1. Using sst, disconnect the 2 brake tubes from the master cylinder.

    Sst 0902300100

  1. Using sst, disconnect the 2 or 3 brake tubes from the no.1 Way.

    Sst 0902300100

  1. Remove the 2 nuts, and pull out the master cylinder, no.1 Way and vacuum check valve bracket.

4. Remove brake master cylinder reservoir subassy

  1.  remove the reservoir stopper screw and master cylinder reservoir subassy.
  2.  remove the 2 cylinder reservoir grommets.

5. Remove brake master cylinder kit

  1.  hold the master cylinder in the vise with the 2 aluminum plates in between.
  2.  remove the oring.

  1. Push in the piston and remove the snap ring with snap ring pliers.

  1. Push in the piston and remove the piston stopper bolt and gasket.
  2.  remove the no.1 Piston subassy by hand, pulling straight out not at an angle.

Notice

: if being pulled out at an angle, the piston may damage the cylinder bore.

  1. Place a cloth and 2 wooden blocks on the work table and lightly edges until the no.2 Piston subassy drops out of the cylinder.

Notice

: if being pulled out at an angle, the piston may damage the cylinder bore.

Hint

: make sure that the distance (a) from the cloth to the top of the blocks is at least 100 mm (3.94 In.).

6. Inspect brake master cylinder

  1.  check the cylinder bore for rust or scoring.

7. Install brake master cylinder kit

  1.  hold the master cylinder in the vise with the 2 aluminum plates in between.
  2.  apply the lithium soap base glycol grease to the no.1 And no.2 Piston subassy.
  3.  install the no.2 And no.1 Piston subassy to the master cylinder.

Notice

:

  1. Push in the piston and install a new gasket and a new piston stopper bolt.

    Torque: 10 nvm (102 Kgfcm, 7 ftlbf)

  1. Push in the piston and install the snap ring with snap ring pliers.
  2.  apply the lithium soap base glycol grease to a new o ring, and install the oring to the master cylinder.

8. Install brake master cylinder reservoir subassy

  1.  apply the lithium soap base glycol grease to 2 brake master cylinder reservoir grommets.
  2.  install the master cylinder reservoir with the screw.

    Torque: 1.8 Nvm (18.4 Kgfcm, 15.9 In.Vlbf)

9. Inspect and adjust brake booster push rod

  1. Apply the chalk to the flat surfaced tip of the sst pin.
  2.  set sst on the master cylinder and lower the pin of the sst until it slightly touches the piston.

    Sst 0973700013

  1. Turn sst upside down and place it on the brake booster.

    Sst 0973700013 clearance: 0 mm (0 in.)

Hint

:

  1. If clearance is outside of the specified range, fix the push rod using sst and adjust the length of the protruding adjusting bolt.

    Sst 0973700020

Hint

: when adjusting the push rod, depress the brake pedal sufficiently so that the push rod sticks out.

10. Install brake master cylinder subassy

  1.  install the master cylinder, no.1 Way and vacuum check valve bracket with the 2 nuts.

    Torque: 12.5 Nvm (127 Kgfcm, 9 ftlbf)

  1. Using sst, connect the 2 or 3 brake tubes to the no.1 Way.

    Sst 0902300100
    torque: 15.2 Nvm (155 Kgfcm, 11 ftlbf)

  1. Using sst, connect the 2 brake tubes to the master cylinder.

    Sst 0902300100
    torque: 15.2 Nvm (155 Kgfcm, 11 ftlbf)

  2. m/t: connect the clutch reservoir tube no.1 With the clip to master cylinder reservoir subassy.
  3.  connect the brake fluid level switch connector to master cylinder reservoir subassy.

11. Install air cleaner cap subassy

12. Fill reservoir with brake fluid

13. Bleed master cylinder 

sst 0902300100

14. Bleed brake line

15. Check fluid level in reservoir

16. Check brake fluid leakage

Components
...

Brake booster assy
...

Other materials:

Installing the spare tire
1 Remove any dirt or foreign matter from the wheel contact surface. If foreign matter is on the wheel contact surface, the wheel nuts may loosen while the vehicle is in motion, causing the tire to come off. 2 Install the tire and loosely tighten each wheel nut by hand by approximately the sa ...

Precheck
1. Precheck Check that the cruise control actuator assy, acceleration wire, accelerator auto drive cable assy, and link assy are installed correctly and that the wire and link are securely connected. check that the operating movement of the acceleration pedal, cruise control actuat ...

Replacement
Hint: installation is in the reverse order of the removal. But the installation is indicated only when it has a point. In the lh side, work in the same procedure as in the rh side. 1. Disconnect battery negative terminal 2. Remove front seat assembly rh 3. Remove front seat inner be ...

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