Toyota Yaris: Brake Master Cylinder / Installation

Toyota Yaris XP210 (2020-2023) Reapir and Service Manual / Brake / Brake System (other) / Brake Master Cylinder / Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE MASTER CYLINDER O-RING

(a) Install a new brake master cylinder O-ring to the brake master cylinder sub-assembly.

2. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

NOTICE:

When installing a new brake master cylinder sub-assembly, remove the protectors from the master cylinder piston and outlet ports.

(a) When installing a new brake master cylinder reservoir assembly or a new brake master cylinder sub-assembly, remove the protector from the brake master cylinder reservoir assembly.

(b) Install the brake master cylinder sub-assembly to the brake booster assembly with the 2 nuts.

Torque:

12.5 N·m {127 kgf·cm, 9 ft·lbf}

NOTICE:

  • The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. Do not reuse a brake master cylinder sub-assembly that has been dropped.
  • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its reservoir when carrying it.
  • Do not pull out the master cylinder piston.
  • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.
  • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.
  • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of new and dry cloth. Do not use water or detergent. Then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.
  • Do not use any other types of grease.
  • 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.

(c) 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

(d) Engage the 2 clamps to the brake master cylinder reservoir assembly.

(e) Connect the connector to the brake master cylinder reservoir assembly.

3. CONNECT NO. 1 CLUTCH RESERVOIR HOSE

(a) Connect the No. 1 clutch reservoir hose to the brake master cylinder reservoir assembly and slide the clip to secure it.

*a

Paint Mark

Up

NOTICE:

  • When connecting the No. 1 clutch reservoir hose, face the paint mark up.
  • Make sure that the tabs of the clip are aligned as shown in the illustration.

4. BLEED BRAKE SYSTEM

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5. BLEED CLUTCH LINE

Click here

6. INSTALL ECM

Click here

7. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

8. INSTALL WATER GUARD PLATE RH

Click here

9. INSTALL FRONT NO. 1 VENTILATOR SEAL

Click here

10. INSTALL WINDSHIELD WIPER MOTOR AND LINK

Click here

    Reassembly

    REASSEMBLY PROCEDURE 1. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER (a) Install the brake master cylinder reservoir strainer to the brake master cylinder reservoir assembly...

    Brake Pedal

    ..

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