Brake Master Cylinder (For Tasa Made) Installation

Apply a light coat of lithium soap base glycol grease to the 2 new grommets and install them to the master cylinder.

Install the reservoir with the screw.

Install a new O-ring to the master cylinder.

Install the master cylinder and bracket (with 4-way) to the booster with the 2 nuts.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Using a union nut wrench, connect the 6 brake lines labeled C to the brake master cylinder and 4-way.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (HILUX_TGN26 RM000004QR1006X.html).

Connect the brake fluid level warning switch connector labeled B to the master cylinder.

Connect the clutch reservoir tube labeled A to the master cylinder.

Install a new O-ring to the master cylinder.

Install the master cylinder and bracket (with 3-way) to the booster with the 2 nuts.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Using a union nut wrench, connect the 5 brake lines labeled C to the master cylinder and 3-way.

Torque:

15 N*m{155 kgf*cm, 11 ft.*lbf}

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Connect the brake fluid level warning switch connector labeled B to the master cylinder.

for Manual Transmission:
Connect the clutch reservoir tube labeled A to the master cylinder.

Bleed the brake master cylinder.

1. Remove the brake master cylinder reservoir filler cap assembly.
   

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

   Fluid:

   SAE J1709 or FMVSS No. 116 DOT 3
   

3. Using a union nut wrench, disconnect the 2 brake tubes from the master cylinder.
   





4. Slowly depress and hold the brake pedal.
   





5. Block the tube holes with your fingers, and then release the brake pedal.
   

6. Remove your fingers, slowly depress and hold the brake pedal, block the tube holes with your fingers again, and then release the brake pedal. Repeat this step 3 or 4 times.
   

7. Using a union nut wrench, connect the 2 brake tubes to the brake master cylinder assembly.
   

   Torque:

   15 N*m{155 kgf*cm, 11 ft.*lbf}

   NOTICE:

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (HILUX_TGN26 RM000004QR1006X.html).

Bleed the load sensing proportioning valve.

1. Remove the bleeder plug cap.
   

2. Connect a vinyl tube to the bleeder plug.
   

3. Depress the pedal several times, and then loosen the bleeder plug with the pedal depressed.
   

4. When fluid stops coming out, immediately tighten the bleeder plug. Then release the pedal.
   

5. Repeat the 2 previous steps until all the air in the brake fluid is gone.
   

6. Tighten the bleeder plug.
   

   Torque:

   11 N*m{107 kgf*cm, 8 ft.*lbf}

7. Install the bleeder plug cap.
   

Bleed the brake line.

1. Remove the bleeder plug cap.
   

2. Connect a vinyl tube to the bleeder plug.
   

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

4. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2
   

5. Repeat *1 and *2 until all the air in the fluid is completely bled out.
   

6. Tighten the bleeder plug completely.
   

   Torque:

   for Front Brake:

   11 N*m{110 kgf*cm, 8 ft.*lbf}

   for Rear Brake:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

7. Repeat the above procedure for each wheel to bleed the brake line.
   

8. Install the bleeder plug cap.
   

Check for brake fluid leaks.

Check the brake fluid level in the reservoir (HILUX_TGN26 RM0000010K4010X_01_0001.html).

Remove the bleeder plug cap of the release cylinder.

Connect a vinyl tube to the bleeder plug.

Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

Repeat the previous 2 steps until all the air in the fluid is completely bled.

Tighten the bleeder plug.

Torque:

11 N*m{110 kgf*cm, 8 ft.*lbf}

Install the bleeder plug cap.

Check that all the air has been bled from the clutch line.