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:

Onvehicle inspection
1. Check battery electrolyte level Check the electrolyte quantity of each cell (maintenancefree battery).  If under the lower level, replace the battery (or add distilled water if possible) and check the charging system.  check the electrolyte quantity of each cell (e ...

Follow the correction procedures. (vehicles with a smart key system and with a drive monitor display)
After taking the specified steps to correct the suspected problem, check that the warning light turns off. ■SRS warning light This warning light system monitors the airbag sensor assembly, front impact sensors, side impact sensors (front door), side impact sensors (front), side impac ...

Problem symptoms table
Hint: proceed with troubleshooting of each circuit in the table below. Symptom Suspect area When the ignition switch is in the on position, the srs warning light sometimes comes on after approximately 6 seconds.  Srs warning light ci ...

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