Toyota Yaris: Brake Master Cylinder / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Brake / Brake System (other) / Brake Master Cylinder / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the brake master cylinder sub-assembly removal/installation are shown below.

NOTICE:

Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

  • Learning completes when vehicle is driven

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    Stop and start system

    Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

  • Learning completes when vehicle is operated normally

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Power door lock control system

    • Back door opener

    Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

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PROCEDURE

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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2. REMOVE FRONT NO. 1 VENTILATOR SEAL

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3. REMOVE WATER GUARD PLATE RH

Click here

4. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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5. REMOVE ECM

Click here

6. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

7. DISCONNECT NO. 1 CLUTCH RESERVOIR HOSE

(a) Slide the clip and disconnect the No. 1 clutch reservoir hose from the brake master cylinder reservoir assembly.

8. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Disconnect the connector from the brake master cylinder reservoir assembly.

(b) Disengage the 2 clamps from the brake master cylinder reservoir assembly.

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

NOTICE:

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

(d) Remove the 2 nuts and brake master cylinder sub-assembly from the brake booster assembly.

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.
  • Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

9. REMOVE BRAKE MASTER CYLINDER O-RING

(a) Remove the brake master cylinder O-ring from the brake master cylinder sub-assembly.

    Components

    COMPONENTS ILLUSTRATION *1 FRONT NO. 1 VENTILATOR SEAL *2 WATER GUARD PLATE RH *3 OUTER COWL TOP PANEL SUB-ASSEMBLY - - N*m (kgf*cm, ft...

    Disassembly

    DISASSEMBLY PROCEDURE 1. REMOVE BRAKE MASTER CYLINDER RING PIN (a) Secure the brake master cylinder sub-assembly in a vise. NOTICE: Place aluminum plates on the vise to prevent damage to the brake master cylinder sub-assembly...

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    Categories

    Break-In Period

    No special break-in is necessary, but a few precautions in the first 600 miles (1,000 km) may add to the performance, economy, and life of the vehicle.

    Do not race the engine. Do not maintain one constant speed, either slow or fast, for a long period of time. Do not drive constantly at full-throttle or high engine rpm for extended periods of time. Avoid unnecessary hard stops. Avoid full-throttle starts.

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