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 sub–assy
3. Remove brake master cylinder sub–assy
- disconnect the brake fluid level switch connector from
master cylinder reservoir sub–assy.
- m/t:
slide the clip and disconnect the clutch reservoir tube
no.1 From master cylinder reservoir sub–assy.

- Using sst, disconnect the 2 brake tubes from the master
cylinder.
Sst 09023–00100

- Using sst, disconnect the 2 or 3 brake tubes from the
no.1 Way.
Sst 09023–00100

- Remove the 2 nuts, and pull out the master cylinder, no.1
Way and vacuum check valve bracket.
4. Remove brake master cylinder reservoir sub–assy
- remove the reservoir stopper screw and master cylinder reservoir
sub–assy.
- remove the 2 cylinder reservoir grommets.
5. Remove brake master cylinder kit
- hold the master cylinder in the vise with the 2 aluminum
plates in between.
- remove the o–ring.

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

- Push in the piston and remove the piston stopper bolt and
gasket.
- remove the no.1 Piston sub–assy by hand, pulling
straight out not at an angle.
Notice
:
if being pulled out at an angle, the piston may damage the
cylinder bore.

- Place a cloth and 2 wooden blocks on the work table and
lightly edges until the no.2 Piston sub–assy 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
- check the cylinder bore for rust or scoring.
7. Install brake master cylinder kit
- hold the master cylinder in the vise with the 2 aluminum
plates in between.
- apply the lithium soap base glycol grease to the no.1 And
no.2 Piston sub–assy.
- install the no.2 And no.1 Piston sub–assy to the master
cylinder.
Notice
:
- if being inserted at an angle, the piston may damage
the cylinder bore.
- Be careful not to damage the rubber lips on the pistons.

- Push in the piston and install a new gasket and a new piston
stopper bolt.
Torque: 10 nvm (102 Kgf·cm, 7 ft·lbf)

- Push in the piston and install the snap ring with snap ring
pliers.
- apply the lithium soap base glycol grease to a new o–
ring, and install the o–ring to the master cylinder.
8. Install brake master cylinder reservoir sub–assy
- apply the lithium soap base glycol grease to 2 brake master
cylinder reservoir grommets.
- install the master cylinder reservoir with the screw.
Torque: 1.8 Nvm (18.4 Kgf·cm, 15.9 In.Vlbf)
9. Inspect and adjust brake booster push rod

- Apply the chalk to the flat surfaced tip of the sst pin.
- set sst on the master cylinder and lower the pin of the
sst until it slightly touches the piston.
Sst 09737–00013

- Turn sst upside down and place it on the brake booster.
Sst 09737–00013
clearance: 0 mm (0 in.)
Hint
:
- if there is a space between the sst main body and the
booster shell (chalk is applied to the booster push rod), it
means that the clearance is too small.
- If chalk is not applied to the booster push rod after placing
the sst on the brake booster, it means that the clearance
is too large.

- If clearance is outside of the specified range, fix the push
rod using sst and adjust the length of the protruding adjusting
bolt.
Sst 09737–00020
Hint
:
when adjusting the push rod, depress the brake pedal sufficiently
so that the push rod sticks out.
10. Install brake master cylinder sub–assy

- install the master cylinder, no.1 Way and vacuum check
valve bracket with the 2 nuts.
Torque: 12.5 Nvm (127 Kgf·cm, 9 ft·lbf)

- Using sst, connect the 2 or 3 brake tubes to the no.1
Way.
Sst 09023–00100
torque: 15.2 Nvm (155 Kgf·cm, 11 ft·lbf)

- Using sst, connect the 2 brake tubes to the master cylinder.
Sst 09023–00100
torque: 15.2 Nvm (155 Kgf·cm, 11 ft·lbf)
- m/t:
connect the clutch reservoir tube no.1 With the clip to
master cylinder reservoir sub–assy.
- connect the brake fluid level switch connector to master
cylinder reservoir sub–assy.
11. Install air cleaner cap sub–assy
12. Fill reservoir with brake fluid
13. Bleed master cylinder
sst 09023–00100
14. Bleed brake line
15. Check fluid level in reservoir
16. Check brake fluid leakage
Other materials:
Inspection
1. Power window system circuit
2. Inspect power window regulator master switch assy
Inspect the master switch continuity.
[Driver’s switch (window unlock and lock)]
Standard:
[Front passenger’s switch (window unlock)]
standard:
[Front passenger’s switch (window lock)]
standa ...
Safety information
Warning
Loose objects or devices with a cable connection
to the vehicle, for instance mobile phones,
can be thrown into the car's interior while driving,
for instance in the event of an accident or
during braking and evasive maneuvers. There is
a risk of injury. Secure loose objects or devices
with ...
Inspection procedure
1 Reconfirm dtc
Check the dtc
2 Inspect skid control ecu connector securely connected
3 Inspect skid control ecu connector(ig1 terminal voltage)
In case of using hand–held tester:
check the voltage condition output from the ecu displayed on the
hand–held tester.
Ok:
...