Toyota Corolla

1992-1998 of release

Repair and operation of the car



Toyota Corolla
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 4. Cooling systems, heating
+ 5. Fuel, exhaust systems
+ 6. System of decrease in toxicity
+ 7. Transmissions
+ 8. Coupling and half shafts
- 9. Brake system
   9.1. Specifications
   9.2. System of anti-blocking of brakes (ABS)
   9.3. Brake shoes of forward brakes
   9.4. Support of forward brakes
   9.5. Brake shoes of back disk brakes
   9.6. Support of back disk brakes
   9.7. Brake disk
   9.8. Brake shoes of back drum brakes
   9.9. Working cylinder
   9.10. Main cylinder of brake system
   9.11. Brake hoses and tubes
   9.12. Hydraulic system of brakes
   9.13. Vacuum amplifier
   9.14. Emergency brake
   9.15. Ropes of the emergency brake
   9.16. Brake pedal
   9.17. Switch of headlights of a stoplight
   9.18. Valve of restriction of pressure sensitive to car loading
+ 10. Suspension bracket and steering
+ 11. Body
+ 12. Electric equipment



9.10. Main cylinder of brake system

GENERAL INFORMATION

Elements of fastening of the main cylinder of brake system

 
Brake system without ABS:
1. Tee
2. Main cylinder
3. Laying
4. Vacuum amplifier

 
Brake system with ABS:
1. Branching
2. Main cylinder
3. Laying
4. Vacuum amplifier

Elements of the main cylinder of brake system

 
Brake system without ABS:
1. Cylinder
2. Lock bolt of the piston
3. Laying
4. N2 piston and spring
5. Cutting lock ring
6. Cover
7. N1 piston and spring
8. Plug
9. Tank
10. Filter
11. Cap

 
Brake system with ABS:
1. Plug
2. Cylinder
3. Lock bolt of the piston
4. Laying
5. N2 piston and spring
6. Cutting lock ring
7. Cover
8. N1 piston and spring
9. Tank
10. Filter
11. Cap

Prevention

Before repair of the main brake cylinder get a repair kit. If you decide to repair the cylinder, examine its internal surface, being guided by the instructions provided in item 9 before purchase of spare parts.


Removal

PERFORMANCE ORDER
1. Remove the air filter (see subsection 5.9).
2. Disconnect the socket of connection of the switch of an alarm bulb of low level of brake fluid (the arrow specified the left fixing nut of the main cylinder of brake system).
3. Pump out as much as possible brake fluid from a tank of the main cylinder.

Prevention

Best of all brake fluid can be pumped out by means of a pure syringe.


4. Put rags under connections and prepare caps or plastic packages to close the ends of tubes after a detachment.

Prevention

Brake fluid is harmful to paint. Close all details of a body and try not to spill brake fluid during the work.


5. Weaken connections on the ends of brake tubes in those places where they enter the main cylinder (are specified by shooters). Not to break a side, use a cap wrench.
6. Take away tubes from the main cylinder and close the ends of tubes for prevention of hit in dirt or moisture.
7. Turn off three nuts fixing the main cylinder to the vacuum amplifier (see rice. Elements of fastening of the main cylinder of brake system). Remove the main cylinder from fastening bolts to the vacuum amplifier. Be accurate and try not to spill brake fluid. Remove and utilize old laying between the main cylinder and the vacuum amplifier.

Partition

PERFORMANCE ORDER
1. Before a partition of the main cylinder, get a repair set which will contain all necessary spare parts, and also instructions which can be specific to your model.
2. Turn off the fixing screw of a tank, remove a tank.
3. After removal of a tank remove plugs from openings of the main cylinder; if they hardened, burst, are damaged or proceed, replace them.
4. Clamp the cylinder in a vice and with the help a small beard or a crosswise screw-driver lower pistons on the bottom of the cylinder. Holding pistons in this situation, remove a lock bolt of the main cylinder.
5. Accurately remove a cutting lock ring on the end of the main cylinder.
6. Now it is possible to get internal elements of the cylinder (see rice. Elements of the main cylinder of brake system). At removal remember an order of installation of elements in order that at their assembly it was possible to establish correctly.
7. After removal of a cutting lock ring it is possible to remove the first piston (N1).
8. Get the cylinder from a vice and knock with it on a wooden surface so that the second piston (N2) seemed. Pull out the piston absolutely directly, – if its stories aside, the internal proverkhnost of the cylinder can be damaged.

Prevention

Two springs of the cylinder differ among themselves therefore pay special attention to the provision of their installation.


9. Carefully examine an internal surface of the main cylinder. In the presence of deep scratches or other damages, the cylinder needs to be replaced. Do not try to restore an internal surface of the cylinder.
10. Replace all elements included in a repair set, following instructions which are attached to a set. Wash out all old elements the cleaning liquid of brake system.

Prevention

Do not use solvents on the basis of gasoline. At assembly grease all elements with pure brake fluid.


11. Install collected elements in the cylinder and press them deep into the cylinder. Then, establish a lock bolt.
12. Establish a new cutting lock ring, having checked that it densely sat in the flute.
13. Install tank plugs, a tank and the fixing screw.
14. Before installation of the main cylinder it needs to be pumped over on a desktop. As you should apply pressure to the piston of the main cylinder and, in the same time, to control an exit of brake fluid from channels of the cylinder, the main cylinder needs to be installed in a vice so that sponges of a vice clamped a fixing flange of the cylinder.
15. Twirl caps in the openings intended for brake tubes on the main cylinder so that they did not pass air, but is not too strong that they could be turned off easily.
16. Fill a tank with brake fluid of the recommended type (see subsection 2.1).
17. Turn off one of caps and press the piston into the cylinder in order that air left the cylinder. To press the piston deep into of the cylinder it is possible to use a big crosswise screw-driver.
18. In order that air again did not get to the main cylinder, it is necessary to twirl a cap before releasing the piston.
19. Repeat this operation until from an opening of the cylinder there is no pure brake fluid without vials of air. Then perform the same operation on connection of the second brake tube. Watch the level of brake fluid in a tank in order that air again did not get to the main cylinder.
20. As at preliminary pumping of the main cylinder on a desktop there is no need to apply the big pressure upon the piston, there is other way to pump over the cylinder, without turning off and twisting a cap with each piston stroke. Before pressing on the piston, turn off a cap as it is described in item 17. Before releasing the piston instead of twisting a cap, simply densely close an opening a finger in order that air did not get back to the cylinder. Wait some seconds until brake fluid from a tank gets to the main cylinder, and then press on the piston again, having taken away a finger at an exit of brake fluid. Do not forget to close again a finger an opening before releasing the piston. Upon completion of pumping on connection of one brake tube, pass to other opening.

Installation

PERFORMANCE ORDER
1. Install the main cylinder on bolts of the vacuum amplifier and acquire fixing nuts. Do not forget to establish new laying.
2. Establish brake tubes on the main cylinder. As the main cylinder is not fixed finally yet, it can be moved a little in order that it is correct and to twirl connections of tubes without distortions.
3. Tighten fixing nuts of the main cylinder till the demanded moment of an inhaling specified in the section of technical characteristics at the beginning of this chapter. Reliably twirl connections of brake tubes.
4. Fill a tank with brake fluid and pump over the main cylinder and brake system (see subsection 9.12). To pump over the main cylinder after it was installed on the car, ask the assistant to squeeze out a pedal of a brake and to hold it in this situation. Weaken connection of a brake tube to let out brake fluid and the air.
5. Twirl connection, then ask the assistant to release a brake pedal. Repeat this operation on both connections until brake fluid leaves free from vials of air. Carefully check work of brake system before normal operation of the car.