OEM 2004 Toyota Sienna Brake Master Cylinder

2004 Toyota Sienna Parts Questions & Experts Answers

• Q: How to service and repair the brake master cylinder assembly on 2004 Toyota Sienna?

  A: The brake master cylinder assembly repair process starts by extracting the front wheel followed by a brake fluid drain followed by proper cleaning of fluid contact on painted surfaces. Begin the procedure by disconnecting the negative battery terminal followed by the removal of the front door scuff plate LH and the cowl side trim board LH (after its nut is removed). The next steps involve taking off the instrument panel finish panel sub-assy lower LH (2 bolts are required) and the instrument panel safety pad insert sub-assy No.1 (4 bolts need to be removed). First clear away the cowl top panel sub-assy outer front as well as the air cleaner assembly with hose and the brake actuator assembly by using Special Service Tool: 09023-00100 on models with VSC. The brake lines require detachment through the removal of front brake tubes No.1, No.2, No.3, No.4 and the rear brake tubes No.1 and No.2. First disconnect the push rod pin from the brake booster push rod followed by removing the brake master cylinder reservoir hose together with the vacuum hose from the brake vacuum check valve assembly. Start by removing 4 nuts and clevis before pulling out the brake booster assembly including master cylinder. The process ends with removing the brake booster gasket and brake vacuum check valve assembly. The new brake vacuum check valve assembly and check valve grommet should be installed together with a new brake booster gasket. After securing the 4 brake master cylinder assembly nuts to 13 Nm torque specifications users can reconnect their brake master cylinder reservoir hose and vacuum hose while implementing the push rod pin. The brake line attachment requires front tubes to achieve a torque value of 15 Nm and rear tubes to reach 15 Nm. Subscribe to Special Service Tool 09023-00100 for VSC-equipped models before recovering the brake actuator assembly. After attaching the air cleaner assembly with its hose and filling the reservoir, perform master cylinder and brake line bleeding tasks using Special Service Tool 09023-00100. Examine the reservoir fluid content while looking for brake fluid seepage. Reinstall the instrument panel safety pad insert sub-assy No.1 (with 4 bolts), instrument panel finish panel sub-assy lower LH (with 2 bolts), cowl side trim board LH (with the nut), front door scuff plate LH, cowl top panel sub-assy outer front, and front wheel with a torque of 103 Nm. Finish the execution of this procedure by examining brake pedal height while verifying the brake actuator functionality with the Toyota hand-held tester.