Last Modified: 05-13-2024 6.11:8.1.0 Doc ID: RM100000001GOQM
Model Year Start: 2020 Model: Corolla Prod Date Range: [01/2019 - 09/2022]
Title: BRAKE SYSTEM (OTHER): BRAKE BOOSTER (for HV Model): INSTALLATION; 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]

INSTALLATION

PROCEDURE

1. INSTALL BRAKE BOOSTER GASKET

(a) Install a new brake booster gasket to the brake booster with master cylinder assembly.

2. INSTALL BRAKE BOOSTER WITH MASTER CYLINDER ASSEMBLY

(a) 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.
  • 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.

*a

Skid Control ECU

*b

No. 1 Reservoir Hose

*c

Brake Master Cylinder Push Rod Clevis

*d

Boot

*e

Master Cylinder Reservoir Assembly

*f

Brake Actuator Bracket

3. INSTALL PUSH ROD PIN

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (for HV Model): INSTALLATION+

4. INSTALL BRAKE PEDAL RETURN SPRING

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (for HV Model): INSTALLATION+

5. CONNECT BRAKE LINE

(a) Engage the 6 clamps to install a new No. 2 brake tube clamp to the brake lines.

NOTICE:

  • Do not damage the No. 2 brake tube clamp.
  • Do not kink or damage the brake lines.

(b) Using a union nut wrench, connect the 3 brake lines to the brake booster with master cylinder 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 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 2019 - 2025 MY Corolla Corolla Hatchback Corolla HV GR Corolla [06/2018 -        ]; INTRODUCTION: REPAIR INSTRUCTION: PRECAUTION

  • 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)

*a

Torque Wrench Fulcrum Length

*b

Union Nut Wrench

6. CONNECT NO. 2 BRAKE ACTUATOR HOSE

(a) Connect the No. 2 brake actuator hose to the brake booster with master cylinder assembly, and slide the clip to secure it.

*a

Identification Mark

Front of the vehicle

NOTICE:

  • Make sure to connect the No. 2 brake actuator hose with its identification mark facing the front of the vehicle.
  • Install the clip within the range shown in the illustration.

7. CONNECT ENGINE ROOM MAIN WIRE

(a) Connect the connector to the brake booster with master cylinder assembly and lock the lock lever as shown in the illustration.

Connect the connector

Lock the lock lever

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.

(b) Engage the clamp to install the engine room main wire.

(c) Connect the connector to the brake booster with master cylinder assembly.

8. BLEED NO. 1 BRAKE ACTUATOR TUBE

NOTICE:

Make sure to bleed the air from the No. 1 brake actuator tube. If the air remains in the No. 1 brake actuator tube, the air will enter the brake booster pump assembly and may damage the brake booster pump assembly.

(a) Remove the brake master cylinder reservoir filler cap assembly.

(b) Add brake fluid to the reservoir until the fluid level is between the MAX and MIN lines on the brake fluid reservoir.

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT3

SAE J1704 or FMVSS No. 116 DOT4

(c) Remove the nut to separate the No. 1 brake actuator tube.

HINT:

If the No. 1 brake actuator tube has already been separated, it is not necessary to perform this step.

(d) Set SST to the brake master cylinder reservoir assembly.

SST: 09992-00242

SST: 09992-00350

(e) Using SST, increase and then maintain the pressure in the brake master cylinder reservoir assembly for 60 seconds.(*1)

Standard Pressure:

50 to 80 kPa (0.6 to 0.8 kgf/cm2, 7.3 to 11.6 psi)

(f) Release the pressure in the brake master cylinder reservoir assembly and wait for 30 seconds.(*2)

(g) Repeat steps *1 to *2, 3 times.

(h) Remove SST.

(i) Pull up the No. 1 brake actuator tube as shown in the illustration as high as possible for 10 seconds without damaging the bracket of the No. 1 brake actuator tube.(*3)

Pull up

NOTICE:

Do not damage the hoses.

HINT:

Elevating the No. 2 brake actuator hose causes any air in the horizontal portion of the hose to flow to the brake master cylinder reservoir assembly side.

(j) Repeat step *3, 5 times.

(k) Elevate the No. 1 brake actuator tube for 10 seconds by lifting the No. 1 brake actuator tube as shown in the illustration.(*4)

NOTICE:

Do not damage the hoses.

HINT:

Elevating the No. 1 brake actuator tube causes any air in the horizontal portion of the tube to flow to the brake master cylinder reservoir assembly side.

Pull up

(l) Lower the No. 1 brake actuator tube for 10 seconds as shown in the illustration.(*5)

NOTICE:

Do not damage the hoses.

HINT:

Lowering the No. 1 brake actuator tube causes any air in the No. 1 brake actuator tube to flow to the brake master cylinder reservoir assembly side.

Press down

(m) Repeat steps *4 to *5, 5 times.

(n) Install the No. 1 brake actuator tube with the nut.

Torque:

8.5 N·m {87 kgf·cm, 75 in·lbf}

9. CONNECT BRAKE BOOSTER PUMP CONNECTOR

HINT:

Perform this operation only when the accumulator pressure zero down could not be performed using the Techstream.

(a) Connect the connector to the brake booster pump assembly and lock the lock lever as shown in the illustration.

Connect the connector

Lock the lock lever

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.

10. FILL RESERVOIR WITH BRAKE FLUID

11. CONNECT CABLE TO NEGATIVE AUXILIARY BATTERY TERMINAL

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; MAINTENANCE: 2ZR-FXE AUXILIARY BATTERY: INSTALLATION

12. BLEED BRAKE SYSTEM

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE FLUID (for HV Model): BLEEDING+

13. INSPECT AND ADJUST BRAKE PEDAL

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE SYSTEM (OTHER): BRAKE PEDAL (for HV Model): ADJUSTMENT

14. OBTAIN ZERO POINT OF YAW RATE AND ACCELERATION SENSOR

Click here 2020 - 2022 MY Corolla Corolla HV [01/2019 - 09/2022]; BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: ELECTRONICALLY CONTROLLED BRAKE SYSTEM (for HV Model): CALIBRATION

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

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV [01/2019 - 09/2022]; INTERIOR PANELS / TRIM: FRONT CONSOLE BOX (except G16E-GTS): INSTALLATION+

16. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV [01/2019 - 09/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): INSTALLATION+

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

Click here 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV [01/2019 - 09/2022]; FRONT SUSPENSION: FRONT SHOCK ABSORBER (except G16E-GTS): INSTALLATION+

18. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here 2020 MY Corolla Corolla Hatchback Corolla HV GR Corolla [01/2019 - 09/2019]; WIPER / WASHER: FRONT WIPER MOTOR: INSTALLATION 2020 - 2022 MY Corolla Corolla Hatchback Corolla HV GR Corolla [09/2019 - 09/2022]; WIPER / WASHER: FRONT WIPER MOTOR: INSTALLATION