Last Modified: 04-05-2023 6.11:8.1.0 Doc ID: RM100000000VIXT
Model Year Start: 2016 Model: Sienna Prod Date Range: [12/2015 - 08/2016]
Title: BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER: REMOVAL; 2016 MY Sienna [12/2015 - 08/2016]

REMOVAL

CAUTION / NOTICE / HINT

NOTICE:

Release the vacuum from booster by depressing the brake pedal several times. Then remove the brake master cylinder from brake booster.

PROCEDURE

1. REMOVE AIR CLEANER INLET COVER ASSEMBLY SEAL

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL+

2. REMOVE BATTERY

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: REMOVAL+

3. REMOVE AIR CLEANER AND HOSE

2016 MY Sienna [12/2015 - 08/2016]; 2GR-FE (ENGINE CONTROL): THROTTLE BODY: REMOVAL+

4. DRAIN BRAKE FLUID

NOTICE:

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

5. DISCONNECT NO. 1 RESERVOIR TUBE

(a) Slide the clip and disconnect the No. 1 reservoir tube from the brake master cylinder reservoir sub-assembly.

6. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Using a union nut wrench (12 mm), disconnect the 2 brake lines from the brake master cylinder sub-assembly.

(b) Remove the 2 nuts and brake master cylinder sub-assembly.

NOTICE:

  • The master cylinder requires careful handling. Do not allow the master cylinder to receive any impact, such as from being dropped. Do not reuse a master cylinder that has been dropped.
  • Do not strike or pinch the master cylinder piston, and do not cause any damage to the master cylinder piston by any other means.
  • Release the vacuum from booster by depressing the brake pedal several times. Then remove the brake master cylinder from brake booster.
  • When installing the master cylinder to the brake booster, or when removing the master cylinder from the brake booster, make sure that the master cylinder is kept horizontal or its tip faces downward (the piston faces upward) to prevent the master cylinder piston from falling out.
  • Do not allow any foreign matter to contaminate the master cylinder piston. If foreign matter gets on the piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the piston.
  • Do not use any other type of grease or fluid.

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