Toyota Corolla Cross Owners & Service Manuals

Toyota Corolla Cross: Installation

Toyota Corolla Cross (2022-2024) Service Manual / Brake / Brake System (other) / Brake Booster (for Hev Model) / Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure

Part Name Code

1

BRAKE BOOSTER GASKET

44785

-

-

-

2

BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

47210L

-

-

3

PUSH ROD PIN

47264A

-

-

4

BRAKE PEDAL RETURN SPRING

47101A

-

-

5

CONNECT BRAKE LINE

-

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

*

For use with a union nut wrench

●

Non-reusable part

Lithium soap base glycol grease

Procedure

Part Name Code

6

NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

55606

-

-

-

Procedure

Part Name Code

7

FRONT NO. 5 BRAKE TUBE

47315

-

-

8

NO. 4 BRAKE TUBE CLAMP

47374B

-

-

9

NO. 3 BRAKE TUBE CLAMP

47373B

-

-

10

ENGINE ROOM MAIN WIRE

82111

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

*

For use with a union nut wrench

●

Non-reusable part

-

-

Procedure

Part Name Code

11

BLEED BRAKE LINE

-

-

-

-

12

OUTER COWL TOP PANEL SUB-ASSEMBLY

55701J

-

-

-

13

WATER GUARD PLATE

55734D

-

-

-

14

NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

55737B

-

-

-

15

WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

-

-

-

-

16

FRONT WHEEL LH

-

-

-

-

17

CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

-

-

-

-

18

UPDATE ECU SECURITY KEY

-

  

-

-

19

INSPECT AND ADJUST BRAKE PEDAL

-

-

-

-

20

PERFORM BRAKE SYSTEM CALIBRATION

-

-

-

-

21

INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

-

-

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

For use with a union nut wrench

CAUTION / NOTICE / HINT

NOTICE:

  • After replacing the brake booster with master cylinder assembly, make sure to perform update ECU security key.
  • After performing the update ECU security key procedure, make sure to perform the initialization procedure for when the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.

PROCEDURE

1. INSTALL BRAKE BOOSTER GASKET

2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(1) Install the brake booster with master cylinder assembly with the 4 nuts.

Torque:

12.7 N·m {130 kgf·cm, 9 ft·lbf}

NOTICE:

  • Tighten the nuts in the order shown in the illustration.
  • Do not kink or damage the brake lines.

  • *a

    Connectors

    *b

    Boot

    *c

    Brake Master Cylinder Push Rod Clevis

    *d

    Brake Master Cylinder Reservoir Assembly
    Do not carry the brake booster with master cylinder assembly by the parts shown in the illustration.
  • Be careful not to allow brake fluid to enter the connector.
  • If installing a new brake booster with master cylinder assembly, do not remove the hole plugs before connecting the brake lines because the brake booster with master cylinder is filled with brake fluid.

3. INSTALL PUSH ROD PIN

Click here

4. INSTALL BRAKE PEDAL RETURN SPRING

Click here

5. CONNECT BRAKE LINE

*a

Torque Wrench Fulcrum Length

-

-

(1) Using a union nut wrench, connect the 2 brake lines to the brake booster with master cylinder assembly.

Torque:

Specified tightening torque :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow the brake lines to twist or interfere with other parts or the vehicle body during tightening.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    17.4 N*m (177 kgf*cm, 13 ft.*lbf)

6. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

7. CONNECT FRONT NO. 5 BRAKE TUBE

*a

Torque Wrench Fulcrum Length

-

-

Connect in this direction

-

-

(1) Using a union nut wrench, connect the front No. 5 brake tube to the brake actuator assembly.

Torque:

Specified tightening torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    13.4 N*m (137 kgf*cm, 10 ft.*lbf)

(2) Connect the front brake tube grommet to the vehicle body.

(3) Using a union nut wrench, connect the front No. 5 brake tube to the front flexible hose LH.

Torque:

Specified tightening torque :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

HINT:

  • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

    Click here

  • When using a union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    13.4 N*m (137 kgf*cm, 10 ft.*lbf)

8. INSTALL NO. 4 BRAKE TUBE CLAMP

NOTICE:

  • Do not damage the No. 4 brake tube clamp.
  • Do not kink or damage the brake lines.

9. INSTALL NO. 3 BRAKE TUBE CLAMP

NOTICE:

  • Do not damage the No. 3 brake tube clamp.
  • Do not kink or damage the brake lines.

10. CONNECT ENGINE ROOM MAIN WIRE

Connect the connector

Lock the lock lever

(1) Connect the connector to the brake booster as shown in the illustration.

NOTICE:

  • Make sure that the connector is locked securely.
  • Make sure that the connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.

Connect the connector in this direction

Connect the connector in this direction

(1) Connect the connector (B) to the brake master cylinder reservoir assembly as shown in the illustration

(2) Engage the clamp to the brake master cylinder reservoir assembly.

(3) Connect the connector (A) to the brake booster.

11. BLEED BRAKE LINE

Click here

12. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

13. INSTALL WATER GUARD PLATE

14. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

15. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

16. INSTALL FRONT WHEEL LH

Click here

17. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here

18. UPDATE ECU SECURITY KEY

HINT:

Perform this procedure only when replacement of the brake booster with master cylinder assembly is necessary.

Click here

19. INSPECT AND ADJUST BRAKE PEDAL

Click here

20. PERFORM BRAKE SYSTEM CALIBRATION

Click here

21. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the battery, there is an automatic learning function that completes learning when the respective system is used.

Click here

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