Last Modified: 07-31-2024 6.11:8.1.0 Doc ID: RM1000000027JW6
Model Year Start: 2023 Model: GR Corolla Prod Date Range: [09/2022 -           ]
Title: BRAKE SYSTEM (OTHER): BRAKE MASTER CYLINDER (for Gasoline Model): REMOVAL; 2023 - 2025 MY Corolla Corolla Hatchback GR Corolla [09/2022 -        ]

REMOVAL

CAUTION / NOTICE / HINT

NOTICE:

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

PROCEDURE

1. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2023 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2022 - 11/2022]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [11/2022 -        ]; WIPER / WASHER: FRONT WIPER MOTOR: REMOVAL

2. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

except G16E-GTS: Click here 2023 MY Corolla Corolla Hatchback Corolla HV [09/2022 - 11/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+ 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV [11/2022 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+

for G16E-GTS: Click here 2023 MY GR Corolla [09/2022 - 11/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (for G16E-GTS): REMOVAL+ 2023 - 2025 MY GR Corolla [11/2022 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (for G16E-GTS): REMOVAL+

3. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

except G16E-GTS: Click here 2023 MY Corolla Corolla Hatchback Corolla HV [09/2022 - 11/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+ 2023 - 2025 MY Corolla Corolla Hatchback Corolla HV [11/2022 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): REMOVAL+

for G16E-GTS: Click here 2023 MY GR Corolla [09/2022 - 11/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (for G16E-GTS): REMOVAL+ 2023 - 2025 MY GR Corolla [11/2022 -        ]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (for G16E-GTS): REMOVAL+

4. DRAIN BRAKE FLUID

NOTICE:

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

5. DISCONNECT NO. 1 CLUTCH RESERVOIR HOSE (for Manual Transaxle)

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

6. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Disengage the clamp and disconnect the connector from the brake master cylinder reservoir assembly.

(b) Disconnect the connector from the vacuum warning switch 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 separate the wire harness.

(e) Remove the 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.

7. REMOVE BRAKE MASTER CYLINDER O-RING

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