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Toyota 5L-E engine factory workshop and repair manual

Tools & consumables
- Jack, jack stands (or a lift), wheel chocks
- Socket set, ratchet, extensions
- Torque wrench
- Flare-nut wrenches (metric sizes common on Toyotas: 10, 11, 12, 14mm)
- Tubing cutter (for brake line steel)
- Tubing deburring tool / round file
- Tube bender (spring bender or hand bender)
- Double‑flare tool kit (or the correct flare type kit — see note below)
- Bench vise (or clamp) for flaring
- Penetrating oil (PB Blaster, etc.)
- Line‑locking pliers or brake line clamp
- Brake line fittings, unions, copper crush washers/banjo washers (new recommended)
- Replacement hard brake line (pre‑formed line or steel tubing to fabricate)
- Replacement rubber flex hoses if needed
- Brake fluid (DOT 3/4 as specified for vehicle)
- Bleeder kit (vacuum bleeder, pressure bleeder, or 2‑person pump/bleed)
- Safety glasses, nitrile gloves, rags, catch pan
- Wire brush, rust penetrant, anti‑seize (for non‑pressure threads)

Safety precautions (must do)
- Work on a flat surface, chock wheels. Never rely on a jack alone — always use rated jack stands.
- Wear eye protection and gloves. Brake fluid is corrosive to paint — cover panels and wipe spills immediately.
- Open master cylinder cap before loosening lines to avoid vacuum locking and to allow fluid to move.
- Catch all fluid; dispose of used brake fluid properly.
- If heating seized fittings, protect rubber lines, nearby wiring, and paint — heat only as a last resort using a small torch and experience.
- After repair, fully bleed system and do static/leak tests before driving. Road test at low speed.

Preliminary checks
- Identify which line(s) need replacement: hard line from master to proportioning valve, chassis lines, or flex hose to caliper/ wheel cylinder.
- Decide: buy a pre‑formed replacement line (recommended) or fabricate a new one. Pre‑formed reduces risk of incorrect flares/bends.
- Verify flare type for the vehicle (Toyota 5L‑E era typically uses SAE double flares on steel brake lines — confirm by inspecting existing fitting). If unsure, buy pre‑flared lines or consult repair manual.

Step‑by‑step replacement (generalized — follow exact routing/manifold/valve locations for your model)
1) Prepare
- Park, chock rear wheels, loosen front wheel lugs slightly if removing front wheel.
- Open master cylinder cap and clean area around it to avoid contamination.
- Jack and support vehicle on stands. Remove wheel for access.

2) Relieve and protect
- Apply penetrating oil to unions and flare nuts; let it soak.
- Clamp the line downstream of the work area with a line clamp to minimize fluid loss and air ingress (if you’re able to isolate only a section).
- Place catch pan under the fitting you’ll open and have rags handy.

3) Remove old line
- Using a flare‑nut wrench, back off the flare nut at the caliper/union/valve. Use a second wrench to hold the fitting if necessary.
- If removing banjo bolt/hose, remove the banjo bolt and discard old copper crush washers. Keep fittings oriented for routing reference.
- Unbolt any retaining clips/brackets and remove the line from chassis clips. If line is rusty and snaps, be prepared to remove remaining clipped pieces with cutters and replace the clip and line.

4) Prepare replacement line
Option A — Preformed line:
- Match new line to old line by shape and fitting positions. Fit rubber hose ends if included.
Option B — Fabricate new line:
- Cut tubing to length with tubing cutter: rotate cutter around tube, tighten gradually until cut is clean. Do not squeeze; take your time.
- Deburr inside and outside with a deburring tool or file. Internal burrs will cause poor seating and restrict flow.
- Bend tubing using tube bender: make smooth radius bends, avoid kinks. Use appropriate bend radius — don’t overbend.
- Mark and fit to ensure routing clears suspension components, steering, and exhaust.

5) Flare ends (if fabricating)
- Clean tube end, cut square, deburr.
- For double flare (most common):
a) Insert tube into flaring bar so the tube end is flush with the bar’s face slot for the flare thickness specified.
b) Use the pilot cone to form a bubble/flare lip.
c) Switch to the larger cone to compress the bubble into a double flare (the kit instructions show the exact sequence).
d) Inspect flare for even, concentric shape and no cracks. The flare should seat fully against mating surface.
- A single 45° flare is different; confirm the vehicle’s required flare and use the correct adapter in your kit. Wrong flare = leak.

6) Install new line
- Route line as original and secure with clips; use new clips if old ones are corroded/brittle.
- Fit new union/flare nut and hand‑start threads. Use flare‑nut wrench to snug — do not round the nut.
- Tighten to manufacturer torque if available. If torque spec is unknown, snug the nut and then apply a small additional fraction turn — do not over‑tighten.
- For banjo fittings, use new copper crush washers on both sides and torque to spec.

7) Reconnect hoses/calipers and refill
- Reinstall wheel(s) if removed; lower vehicle slightly so wheels touch ground (helps bleeding).
- Fill master cylinder to recommended level with clean brake fluid.
- Bleed brakes starting from the farthest wheel from the master cylinder (usually rear RH -> rear LH -> front RH -> front LH on RHD, but confirm location) until no air and pedal is firm. Use vacuum bleeder or pressure bleeder for single‑person convenience.
- While bleeding, top off master cylinder frequently to avoid introducing air.

8) Leak check and final verification
- With someone holding firm brake pressure, inspect all new fittings and along the line for leaks.
- Pump pedal repeatedly with engine off; then start engine and press again to check pedal firmness. Expect a firm pedal; soft spongy pedal indicates remaining air.
- Torque check flare nuts/banjo bolts after initial road test per manual.
- Clean any spilled fluid and touch up paint where needed.

Common pitfalls & how to avoid them
- Wrong flare type: Inspect old fitting or buy pre‑formed lines. Using a single instead of double flare (or vice versa) causes leaks.
- Poor flare quality: Don’t rush the flaring steps. Cut square, deburr, clamp properly, and follow the double‑flare sequence. Cracked or uneven flares leak.
- Rounding flare nuts: Always use flare‑nut (line) wrenches sized correctly. If stuck, apply penetrating oil and bidirectional rocking; heat as last resort while protecting rubber lines.
- Kinked tubing: Use a proper tube bender to maintain cross‑section. Kinks mean replace line — a kinked line weakens and may fail.
- Not replacing crush washers: Always use new copper crush washers on banjo fittings and unions. Re‑using old washers often leaks.
- Air in system: Bleed thoroughly and keep master cylinder topped off. Use a pressure or vacuum bleeder for best results.
- Incorrect routing: Ensure lines don’t rub, stretch, or contact hot/exhaust parts. Replace any lost chassis clips.
- Corroded mating surfaces: Clean fitting seats with a wire brush; replace severely corroded unions.

When to replace parts rather than repair
- Severely rusty, pitted or cracked hard lines — replace entire section or use preformed replacement lines.
- Old, swollen or cracked flexible hoses — replace with new OEM or OE‑equivalent hoses.
- If unions/caliper threads are damaged, replace the caliper or union fitting as required.
- If uncertain about flare quality or access, buy pre‑flared, pre‑bent replacement lines (these are plug‑and‑play and reduce headache).

Final checks before driving
- Brake pedal should be firm at first press. No leaks at any pressure.
- Do a low‑speed brake test in a safe area to confirm braking performance and ABS operation (if equipped).
- Recheck fittings after first few miles and again after a day of use.

Done correctly, replacement is straightforward; do not compromise on correct flares, new crush washers, secure routing, and thorough bleeding.
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