Toyota Yaris: Brake Fluid / Bleeding

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Brake / Brake System (other) / Brake Fluid / Bleeding

BLEEDING

CAUTION / NOTICE / HINT

NOTICE:

  • Move the shift lever to P and apply the parking brake before bleeding the brakes.
  • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.
  • If brake fluid leaks onto any painted surface, immediately wash it off.
  • Do not operate the brake actuator assembly while air is in the brake system or in the brake master cylinder sub-assembly. Doing so may cause air to enter the brake actuator assembly.
  • If bleeding the brake actuator assembly is difficult due to air in the brake actuator assembly, replace it with a new one.
  • When bleeding air, select the suitable procedure listed below.

    Replaced/Installed Item

    Work Procedure

    Flexible hose (front/rear)

    Bleed brake line

    Front disc brake cylinder assembly

    Rear disc brake cylinder assembly

    Brake actuator assembly

    Bleed brake system

    Brake master cylinder sub-assembly

    Brake master cylinder reservoir sub-assembly

    Brake booster assembly

HINT:

If any work is performed on the brake system or if air in the brake lines is suspected, bleed the air from the brake system.

PROCEDURE

1. BLEED BRAKE LINE

(a) Remove the center cowl top ventilator louver.

(1) Disengage the 2 clips and hook to separate the hood to cowl top seal.

(2) Disengage the 2 claws and 5 guides to remove the center cowl top ventilator louver from the cowl top ventilator louver sub-assembly.

(b) Remove the brake master cylinder reservoir filler cap assembly.

(c) Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

Brake Fluid:

"TOYOTA GENUINE BRAKE FLUID DOT4, CLASS6"*, FMVSS No.116 DOT4 or SAE J1704LV*

*: If a fluid type with "TOYOTA GENUINE BRAKE FLUID DOT4, CLASS6", FMVSS No.116 DOT4 or SAE J1704LV is not available, fluid type with TOYOTA GENUINE BRAKE FLUID DOT3, FMVSS No.116 DOT3 or SAE J1703 may be used with no detriment to brake durability.

NOTICE:

  • Make sure that there is sufficient brake fluid in the reservoir.
  • Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

(d) Remove the bleeder plug cap.

(e) Connect a vinyl tube to the bleeder plug.

(f) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

(g) When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2

(h) Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.

(i) Tighten the bleeder plug completely.

Torque:

Front Disc Brake Bleeder Plug: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)

Rear Disc Brake Bleeder Plug: 8.4 N*m (86 kgf*cm, 74 in.*lbf)

(j) Install the bleeder plug cap.

(k) Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.

(l) Inspect for brake fluid leaks.

(m) Inspect the brake fluid level in the reservoir.

Click here

(n) Install the brake master cylinder reservoir filler cap assembly.

(o) Install the center cowl top ventilator louver.

(1) Engage the 5 guides and 2 claws to install the center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.

(2) Engage the 2 clips and hook to install the hood to cowl top seal.

2. BLEED BRAKE SYSTEM

CAUTION:

If air is bleed without using the GTS, damage or accidents may result. Therefore, always use the GTS when bleeding air.

NOTICE:

  • To prevent brake fluid from damaging painted surfaces, cover any surrounding parts with a piece of cloth.
  • Be sure to clean your hands before bleeding the master cylinder to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

(a) Remove the windshield wiper motor and link assembly.

Click here

(b) Remove the front No. 1 ventilator seal.

Click here

(c) Remove the water guard plate RH.

Click here

(d) Remove the outer cowl top panel sub-assembly.

Click here

(e) Remove the brake master cylinder reservoir filler cap assembly.

(f) Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

Brake Fluid:

"TOYOTA GENUINE BRAKE FLUID DOT4, CLASS6"*, FMVSS No.116 DOT4 or SAE J1704LV*

*: If a fluid type with "TOYOTA GENUINE BRAKE FLUID DOT4, CLASS6", FMVSS No.116 DOT4 or SAE J1704LV is not available, fluid type with TOYOTA GENUINE BRAKE FLUID DOT3, FMVSS No.116 DOT3 or SAE J1703 may be used with no detriment to brake durability.

NOTICE:

  • Make sure that there is sufficient brake fluid in the reservoir.
  • Do not remove the filter from the brake master cylinder reservoir assembly and be sure to fill the brake master cylinder reservoir assembly with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

(g) Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

(h) Slowly depress the brake pedal and hold it.*1

(i) Cover the 2 outer holes with fingers and release the brake pedal.*2

(j) Repeat steps *1 and *2, 3 or 4 times.

(k) Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

Torque:

Specified tightening torque :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a

Torque Wrench Fulcrum Length

(l) Remove the bleeder plug cap.

(m) Connect a vinyl tube to the bleeder plug.

(n) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

(o) When fluid stops coming out, tighten the bleeder plug and release the brake pedal.*2

(p) Repeat steps *1 and *2 until all the air in the brake fluid is completely bled out and new brake fluid comes out.

(q) Tighten the bleeder plug completely.

Torque:

Front Disc Brake Bleeder Plug: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)

Rear Disc Brake Bleeder Plug: 8.4 N*m (86 kgf*cm, 74 in.*lbf)

(r) Install the bleeder plug cap.

(s) Repeat the above steps to bleed the brake fluid of the brake lines for each wheel.

(t) Depress the brake pedal more than 20 times with the ignition switch off.

(u) Bleed the brake system following the instructions on the GTS.

Chassis > Brake > Utility

Tester Display

Air Bleeding

NOTICE:

Do not start the engine.

(v) After air bleeding, tighten each bleeder plug while depressing the brake pedal.

Torque:

Front Disc Brake Bleeder Plug: 10.8 N*m (110 kgf*cm, 8 ft.*lbf)

Rear Disc Brake Bleeder Plug: 8.4 N*m (86 kgf*cm, 74 in.*lbf)

(w) Inspect for brake fluid leaks.

(x) Inspect the brake fluid level in the reservoir.

Click here

(y) Install the brake master cylinder reservoir filler cap assembly.

(z) Install the outer cowl top panel sub-assembly.

Click here

(aa) Install the water guard plate RH.

Click here

(ab) Install the front No. 1 ventilator seal.

Click here

(ac) Install the windshield wiper motor and link assembly.

Click here

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