TOYOTA SIENNA 2007 Service Repair Manual

BRAKE – BRAKE MASTER CYLINDERBR–17
BR
REASSEMBLY
1. INSTALL BRAKE MASTER LESS RESERVOIR TANK
CYLINDER SUB-ASSEMBLY
(a) Apply lithium soap base glycol grease to the 2 brake
master cylinder union grommets and install them to
the brake master less reservoir tank cylinder sub-
assembly.
(b) Using a pin punch (
5 mm) and hammer, install the
master cylinder union with the pin.
(c) Install the 2 new O-rings.
(d) Install the brake master less reservoir tank cylinder
sub-assembly with the 2 nuts and, 2 bolts.
Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)
NOTICE:
When the diameter converting unit and master
cylinder are connected, install the No. 3 piston
with no looseness.
(e) Using SST, install the brake tube to the brake
master cylinder.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
(f) Install the new O-ring.
INSTALLATION
1. INSTALL BRAKE MASTER CYLINDER
(a) Install the brake master cylinder with the 2 nuts.
Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf)
(b) Slide the clip and connect the brake master cylinder
reservoir hose.
(c) Using SST, connect the 2 brake tube to the brake
master cylinder.
SST 09023-00101
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
2. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
3. FILL RESERVOIR WITH BRAKE FLUID (See page BR-
3)
4. BLEED BRAKE MASTER CYLINDER (See page BR-3)
5. BLEED BRAKE LINE (See page BR-4)
G024298
G024299
G024300
G024301

BR–18BRAKE – BRAKE MASTER CYLINDER
BR
6. BLEED BRAKE ACTUATOR (w/ VSC) (See page BR-
4)
7. CHECK BRAKE FLUID LEVEL IN RESERVOIR (See
page BR-7)
8. CHECK BRAKE FLUID LEAKAGE
9. INSTALL COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT
10. INSPECT BRAKE PEDAL HEIGHT (See page BR-9)
11. CHECK BRAKE ACTUATOR WITH INTELLIGENT
TESTER
Type of Brake Actuator See Procedure
With VSCBC-178
Without VSCBC-183

BR–20BRAKE – BRAKE BOOSTER
BR
REMOVAL
NOTICE:
• Do not adjust the brake booster push rod.
• Do not change the combination of the diameter
converting unit and brake.
1. REMOVE FRONT WHEEL
2. DRAIN BRAKE FLUID
NOTICE:
Wash the brake fluid off immediately if it attaches to
any painted surfaces.
3. SEPARATE BATTERY NEGATIVE TERMINAL
4. REMOVE FRONT DOOR SCUFF PLATE LH
5. REMOVE COWL SIDE TRIM BOARD LH
(a) Remove the nut and cowl trim board plate LH.
6. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-
ASSEMBLY LOWER LH
(a) Remove the 2 bolts and instrument panel finish
panel sub-assembly lower LH.
7. REMOVE INSTRUMENT PANEL SAFETY PAD
INSERT SUB-ASSEMBLY NO. 1
(a) Remove the 4 bolts and instrument panel safety pad
insert sub-assembly No. 1.
8. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT (See page SP-13)
9. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
10. REMOVE BRAKE ACTUATOR ASSEMBLY (w/o VSC)
SST 09023-00101
HINT:
See page BC-184.
11. REMOVE ABS & TRACTION ACTUATOR ASSEMBLY
(w/ VSC)
SST 09023-00101
HINT:
See page BC-179.
12. REMOVE BRAKE LINE
(a) Remove the front brake tube No. 1, front brake tube
No. 2, front brake tube No. 3 and front brake tube
No. 4.
(b) Remove the rear brake tube No. 1 and rear brake
tube No. 2.
13. REMOVE PUSH ROD PIN
(a) Remove the push rod pin from the brake booster
push rod.
14. REMOVE BRAKE MASTER CYLINDER ASSEMBLY
(a) Slide the clip and disconnect the brake master
cylinder reservoir hose from the brake master
cylinder union.

BRAKE – BRAKE BOOSTERBR–21
BR
(b) Slide the clip and disconnect the vacuum hose from
the brake vacuum check valve assembly.
(c) Remove the 4 nuts and clevis.
(d) Pull out the brake booster with master cylinder.
15. REMOVE BRAKE BOOSTER GASKET
(a) Remove the brake booster gasket from the brake
booster with master cylinder.
16. REMOVE BRAKE VACUUM CHECK VALVE
ASSEMBLY
(a) Remove the brake vacuum check valve assembly
and check valve grommet from the brake booster
assembly.
G024262

BRAKE – BRAKE FLUIDBR–3
BR
BRAKE FLUID
BLEEDING
HINT:
If any work is performed on the brake system or if air in the
brake lines is suspected, bleed the air out of the brake
system.
NOTICE:
Wash the brake fluid off immediately if it adheres to any
painted surfaces.
1. REMOVE COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT (See page SP-13)
2. FILL RESERVOIR WITH BRAKE FLUID
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
NOTICE:
Perform the procedure after confirming the sub-tank
at the upper of the master cylinder assembly is filled
enough.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the bleeder plug.
(b) Depress the brake pedal several times, then loosen
the bleeder plug with the pedal depressed (*1).
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal (*2).
(d) Repeat (*1) and (*2) several times until all the air in
the fluid is completely bled out.
(e) Tighten the bleeder plug completely.
Torque: Disc
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(f) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
4. BLEED MASTER CYLINDER
NOTICE:
When the air is bled from the master cylinder (3rd
chamber), be sure to run the engine.
HINT:
If the master cylinder has been disassembled or if the
reservoir becomes empty, bleed the air out of the master
cylinder.
(a) Run the engine at idle.
(b) Connect the vinyl tube to the brake caliper bleeder
plug.
(c) Open the brake caliper bleeder plug or wheel
cylinder bleeder plug.
G024304
C080826

BR–4BRAKE – BRAKE FLUID
BR
(d) Depress the brake pedal several times, then loosen
the master cylinder (3rd chamber) bleeder plug,
then release the brake pedal (*3).
(e) At the point when the fluid stops coming out, tighten
the master cylinder (3rd chamber) bleeder plug,
then release the brake pedal (*4).
(f) Repeat (*3) and (*4) several times until the air in the
master cylinder is bled out.
(g) Tighten the master cylinder (3rd chamber) bleeder
plug .
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)
(h) Tighten the brake caliper bleeder plug or wheel
cylinder bleeder plug.
Torque: Disc
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
5. BLEED BRAKE LINE
(a) Connect the vinyl tube to the bleeder plug.
(b) Depress the brake pedal several times, then loosen
the bleeder plug with the pedal depressed (*5).
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal (*6).
(d) Repeat (*5) and (*6) several times until all the air in
the fluid is completely bled out.
(e) Tighten the bleeder plug completely.
Torque: Disc
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(f) Repeat the above procedure to bleed the air out of
the brake line for each wheel.
6. BLEED BRAKE ACTUATOR (w/ VSC)
NOTICE:
After bleeding the air from the brake system, if the
height or feel of the brake pedal cannot be obtained,
bleed the air from the brake actuator assembly with
the intelligent tester by following the procedure
below.
(a) Depress the brake pedal more than 20 times with
the engine switch off.
(b) Connect the intelligent tester to the DLC3, then turn
the ignition switch to the ON position.
NOTICE:
Do not start the engine.
(c) Turn the intelligent tester on and select "AIR
BLEEDING" on the screen.
NOTICE:
• Refer to the intelligent tester operator's
manual for farther details.
• Perform air bleeding by following the steps
displayed on the intelligent tester.
F045198
C080826

BRAKE – BRAKE FLUIDBR–5
BR
(d) Perform air bleeding according to "Step 1: Increase"
on the intelligent tester display.
NOTICE:
Make sure that the master cylinder reservoir
tank does not become empty of brake fluid.
(1) Connect a vinyl tube to either one of the
bleeder plugs.
(2) Depress the brake pedal several times, then
loosen the bleeder plug connected to the vinyl
tube with the pedal depressed (*7).
(3) When fluid stops coming out, tighten the
bleeder plug, then release the brake pedal (*8).
(4) Repeat (*7) and (*8) until all the air in the fluid
is completely bled out.
(5) Tighten the bleeder plug completely.
To r q u e : D i s c
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(6) Repeat the above procedures for the rest of the
wheels to bleed the air from the brake line.
(e) Bleed the air from the suction line according to "Step
2: Inhalation" on the intelligent tester display.
NOTICE:
• Bleed the suction line by following the steps
displayed on the intelligent tester.
• Make sure that the master cylinder reservoir
tank does not become empty of brake fluid.
(1) Connect a vinyl tube to the bleeder plug at the
right front wheel or the right rear wheel and
loosen the bleeder plug.
(2) Operate the brake actuator assembly to
perform air bleeding using the intelligent tester
(*9).
NOTICE:
• The operation stops automatically in 4
seconds.
• At this time, be sure to release the brake
pedal.
(3) Check that the operation has stopped by
referring to the intelligent tester display and
tighten the bleeder plug (*10).
(4) Repeat (*9) and (*10) until all the air in the fluid
is completely bled out.
(5) Tighten the bleeder plug completely.
To r q u e : D i s c
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(6) For the rest of the wheels, perform air bleeding
in the same way as stated in the above
procedure.

BR–6BRAKE – BRAKE FLUID
BR
(f) Bleed the air from the pressure reduction line
according to "Step 3: Decrease" on the intelligent
tester display.
NOTICE:
• Bleed the pressure reduction line by
following the steps displayed on the
intelligent tester.
• Make sure that the master cylinder reservoir
tank does not become empty of brake fluid.
(1) Connect a vinyl tube to either one of the
bleeder plugs.
(2) Loosen the bleeder plug (*11).
(3) Using the intelligent tester, operate the brake
actuator assembly, completely depress the
brake pedal, and hold it.
NOTICE:
• The operation stops automatically in 4
seconds. When performing this
procedure continuously, an interval of at
least 20 seconds is required.
• When the operation is completed, the
brake pedal goes down slightly. This is a
normal phenomenon when the solenoid
opens.
• During this procedure, the pedal seems
heavy, but completely depress it so that
the brake fluid comes out from the
bleeder plug.
• Be sure to keep the brake pedal
depressed. Never depress and release
the pedal repeatedly.
(4) Tighten the bleeder plug, then release the
brake pedal (*12).
(5) Repeat (*11) to (*12) until all the air in the fluid
is completely bled out.
(6) Tighten the bleeder plug completely.
Torque: Disc
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(7) Repeat the above procedures for the rest of the
brakes to bleed the air from the brake line.
(g) Bleed the air from the brake line again according to
"Step 4: Increase" on the intelligent tester display.
NOTICE:
• Bleed the brake line by following the steps
displayed on the intelligent tester.
• Make sure that the master cylinder reservoir
tank does not become empty of brake fluid.
(1) Connect a vinyl tube to either one of the
bleeder plugs.
(2) Depress the brake pedal several times, then
loosen the bleeder plug connected to the vinyl
tube with the pedal depressed (*13).

BRAKE – BRAKE FLUIDBR–7
BR
(3) When fluid stops coming out, tighten the
bleeder plug, then release the brake pedal
(*14).
(4) Repeat (*13) and (*14) until all the air in the
fluid is completely bled out.
(5) Tighten the bleeder plug completely.
To r q u e : D i s c
8.3 N*m (85 kgf*cm, 73 in.*lbf)
Drum
11 N*m (112 kgf*cm, 8 ft.*lbf)
(6) Repeat the above procedures for each brake to
bleed the air from the brake line.
(h) Finish "AIR BLEEDING" on the intelligent tester and
turn off the tester.
(i) Disconnect the intelligent tester from the DLC3.
(j) Turn the ignition switch to the OFF position.
7. CHECK FLUID LEVEL IN RESERVOIR
(a) Check the fluid level and add fluid, if necessary.
Fluid:
SAE J1703 or FMVSS No. 116 DOT3
8. INSTALL COWL TOP PANEL SUB-ASSEMBLY
OUTER FRONT

BR–22BRAKE – BRAKE BOOSTER
BR
INSPECTION
1. INSPECT BRAKE VACUUM CHECK VALVE
ASSEMBLY
(a) Check the vacuum check valve.
(1) Slide the clip and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster
to the engine, and no ventilation from the
engine to the booster.
(4) If any fault is found, replace the vacuum check
valve.
F040007E06