TOYOTA SEQUOIA 2001 Service Repair Manual

BR08U±05
F16312
F16313
BR±16
± BRAKEBRAKE MASTER CYLINDER
3183 Author: Date:
2005 SEQUOIA (RM1146U)
REMOVAL
1. DRAW OUT FLUID WITH SYRINGE
NOTICE:
Wash the brake fluid off immediately if it comes into con-
tact with any painted surface.
2. DISCONNECT LEVEL WARNING SWITCH CONNEC-
TOR
3. DISCONNECT 2 MASTER CYLINDER PRESSURE
SENSOR CONNECTORS
4. DISCONNECT WIRE HARNESS
Using a clip remover, disconnect the wire harness from the wire
harness bracket.
5. DISCONNECT BRAKE LINES
Using SST, disconnect the 2 brake lines from the master cylin-
der.
SST 09023±38201
Torque: 19.5 N´m (195 kgf´cm, 14 ft´lbf)
6. REMOVE MASTER CYLINDER
(a) Remove the 2 nuts and wire harness bracket.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Pull out the master cylinder from the brake booster.

BR1ND±02
± BRAKEBRAKE MASTER CYLINDER
BR±17
3184 Author: Date:
2005 SEQUOIA (RM1146U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.5 N´m (15 kgf´cm, 13 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. REMOVE SEAL
4. REMOVE 2 MASTER CYLINDER PRESSURE SENSORS
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)

BR08X±06
BR±18
± BRAKEBRAKE MASTER CYLINDER
3185 Author: Date:
2005 SEQUOIA (RM1146U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page BR±17).
NOTICE:
Apply lithium soap base glycol grease to the rubber parts indicated by the arrows (See page
BR±15).

BR08Y±07
± BRAKEBRAKE MASTER CYLINDER
BR±19
3186 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
Installation is in the reverse order of removal (See page BR±16).
HINT:

After installation, fill the brake reservoir with brake fluid and bleed brake system (See page BR±4).

Check for leaks.
NOTICE:
In case of replacing the master cylinder assembly or master cylinder pressure sensor, perform the
zero point calibration of the steering angle, master cylinder pressure, yawrate and deceleration sen-
sors (See page DI±897).

BR2237
BR0AK±07
BR2238
1st3rd
2nd
GOOD
NO GOOD BR±20
± BRAKEBRAKE BOOSTER ASSEMBLY
3187 Author: Date:
2005 SEQUOIA (RM1146U)
BRAKE BOOSTER ASSEMBLY
ON±VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is airtight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is airtight.

BR10G±04
F16311
Master CylinderVacuum Hose
Level Warning
Switch ConnectorBrake Booster

GasketClevis Pin Brake Booster Bracket Clip
: Specified torque
N´m (kgf´cm, ft´lbf)

Non±reusable partPedal Return Spring
Wire Harness
Bracket
Lower Finish Panel
Food Lock Release Lever No. 2 Heater to Register Duct
Cowl Side Trim Board
Front Door Scuff Plate

GasketClevis
Vacuum Switch Connector
19.5 (195, 14)
25 (250, 18)
25 (250, 18)
ClipCheck Valve
25 (250, 18)
Side Panel
Wire Harness
13 (130, 9)
Clip
Master Cylinder
Presser Sensor Connector
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±21
3188 Author: Date:
2005 SEQUOIA (RM1146U)
COMPONENTS

BR10H±05
BR3753
BR±22
± BRAKEBRAKE BOOSTER ASSEMBLY
3189 Author: Date:
2005 SEQUOIA (RM1146U)
REMOVAL
1. REMOVE MASTER CYLINDER (See page BR±16)
2. DISCONNECT VACUUM HOSE FROM BRAKE
BOOSTER
3. DISCONNECT 2 VACUUM SWITCH CONNECTORS
FROM BRAKE BOOSTER
4. REMOVE FRONT DOOR SCUFF PLATE, COWL SIDE
TRIM BOARD, SIDE PANEL, LOWER FINISH PANEL
AND NO. 2 HEATER TO REGISTER DUCT (See page
BO±89)
5. REMOVE PEDAL RETURN SPRING
6. REMOVE CLIP AND CLEVIS PIN
7. REMOVE BRAKE BOOSTER
(a) Remove the 4 nuts, pull out the brake booster.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Remove the gasket from the brake booster bracket.
(c) Loosen the lock nut then remove the clevis.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(d) Remove the check valve.
(e) Remove the 4 nuts, brake booster bracket and gasket
from the brake booster.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)

BR1NE±03
± BRAKEBRAKE BOOSTER ASSEMBLY
BR±23
3190 Author: Date:
2005 SEQUOIA (RM1146U)
INSTALLATION
Installation is in the reverse order of removal (See page BR±22).
HINT:

Fill the brake reservoir with brake fluid and bleed brake system (See page BR±4).

Check the brake pedal hight (See page BR±6).

Do the operational check (See page BR±20).

BR10J±04
F07750
Clip
Inner Pad
Anti±rattle
SpringOuter Pad
Anti±squeal Shim
Pin
Inner Anti±squeal
Shim
Disc brake grease BR±24
± BRAKEFRONT BRAKE PAD
3191 Author: Date:
2005 SEQUOIA (RM1146U)
FRONT BRAKE PAD
COMPONENTS

BR10K±04
F07748
F07749
R13537
± BRAKEFRONT BRAKE PAD
BR±25
3192 Author: Date:
2005 SEQUOIA (RM1146U)
REPLACEMENT
1. REMOVE FRONT WHEEL
2. INSPECT PAD LINING THICKNESS
Check the pad thickness and replace pads if not within specifi-
cation.
Minimum thickness: 1.0 mm (0.039 in.)
3. REMOVE CLIP, 2 PINS AND ANTI±RATTLE SPRING
4. REMOVE 2 PADS WITH 4 ANTI±SQUEAL SHIMS
NOTICE:
The anti±rattle spring and clip can be used again provided
that they have sufficient rebound, no deformation, cracks
or wear, and have had all rust, dirt and foreign particles
cleaned off.
5. CHECK DISC THICKNESS AND RUNOUT
(See page BR±30)
6. INSTALL NEW PADS
NOTICE:
When replacing worn pads, the anti±squeal shims must be
replaced together with the pads.
(a) Draw out a small amount of brake fluid from the reservoir.
(b) Press in the pistons with a monkey wrench handle or
equivalent.
HINT:

Tape the monkey wrench handle before use.

Always change the pad on one wheel at a time as there
is a possibility of the opposite piston flying out.

If the piston is difficult to push in, loosen the bleeder plug
and push in the piston while letting some brake fluid es-
cape.
(c) Install the 4 anti±squeal shims to new pads.