Toyota Cressida and Van 1983-1990

Master Cylinder

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REMOVAL & INSTALLATION



Cressida


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Fig. Fig. 1 Exploded view of the brake master cylinder-Cressida (without anti-lock brakes)



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Fig. Fig. 2 Exploded view of the brake master cylinder-Cressida (with anti-lock brakes)



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Fig. Fig. 3 When removing the master cylinder, a brake line tool is necessary to separate the lines from the cylinder-Cressida



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Fig. Fig. 4 Remove the four bolts retaining the master cylinder to the booster-Cressida

  1. Disconnect the negative battery cable. Unplug the level warning switch connector.
  2.  
  3. Draw the brake fluid out of the master cylinder with a syringe.
  4.  
  5. Detach the hydraulic lines from the master cylinder.
  6.  


WARNING
Do not spill brake fluid on the painted surfaces of the vehicle.

  1. Remove the bolts, nuts and clamp (on the ABS models, remove the 3-way union nut) which secure the master cylinder to the brake booster. Pull out the master cylinder from the brake booster.
  2.  
  3. Installation is the reverse of removal. Bleed the system as outlined in this section.
  4.  

Van


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Fig. Fig. 5 Exploded view of the brake master cylinder-Van

  1. Disconnect the negative battery cable.
  2.  
  3. Draw the brake fluid out of the master cylinder with a syringe.
  4.  
  5. Remove the instrument cluster finish panel retaining screws and pull the panel toward you.
  6.  
  7. Remove the combination meter retaining screws.
  8.  
  9. Disconnect the speedometer cable and wiring, then remove the combination meter.
  10.  
  11. Remove the 3 air duct assemblies.
  12.  
  13. Detach the hydraulic lines from the master cylinder and using pliers, disconnect the 2 reservoir hoses from the master cylinder. Do not spill brake fluid on the painted surfaces of the vehicle.
  14.  
  15. Remove the master cylinder mounting nuts and vacuum check valve bracket. Pull the master cylinder out of the vehicle.
  16.  

To install:

  1. Install the master cylinder assembly, retaining nuts and vacuum check valve bracket.
  2.  
  3. Reconnect the hydraulic lines to the master cylinder and the two reservoir hoses.
  4.  
  5. Install the 3 air duct assemblies.
  6.  
  7. Attach the speedometer cable and wiring connectors to the back of the combination meter.
  8.  
  9. Install the combination meter and retaining screws.
  10.  
  11. Install the instrument cluster finish panel and retaining screws.
  12.  
  13. Refill the master cylinder reservoir and install the cap.
  14.  
  15. Reconnect the negative battery cable.
  16.  
  17. Bleed the brake system.
  18.  

OVERHAUL



  1. Remove the reservoir caps and floats. Unscrew the bolts that secure the reservoirs to the main body.
  2.  
  3. Remove the pressure differential warning switch assembly (if equipped). Then, working from the rear of the cylinder, remove the boot, snapring, elbow and O-ring.
  4.  
  5. Using a suitable tool, push in the pistons all the way and remove the piston stopper bolt and gasket.
  6.  
  7. Push in the pistons all the way again and using snapring pliers, remove the snapring.
  8.  
  9. Remove the No.1 piston and spring by hand pulling it straight out, not at an angle.
  10.  
  11. Place a rag on 2 wooden blocks and lightly tap the cylinder flange between the blocks until the No. 2 piston and spring falls out.
  12.  
  13. Remove the two outlet fittings, washers, check valves and springs.
  14.  
  15. Remove the piston cups from their seats only if they are to be replaced.
  16.  
  17. After washing all parts in clean brake fluid, dry them with compressed air (if available). Inspect the cylinder bore for wear, scuff marks, or nicks. Cylinders may be honed slightly, but the limit is 0.15mm. In view of the importance of the master cylinder, it is recommended that it is replaced rather than overhauled if worn or damaged.
  18.  
  19. Assembly is performed in the reverse order of disassembly. Absolute cleanliness is important. Coat all parts with clean brake fluid prior to assembly.
  20.  

Bleed the hydraulic system after the master cylinder is installed, as detailed following.

 
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