BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): INSTALLATION; 2023 MY Corolla Corolla Hatchback GR Corolla [09/2022

Last Modified: 05-13-2024	6.11:8.1.0	Doc ID: RM10000000265ZZ
Model Year Start: 2023	Model: GR Corolla	Prod Date Range: [09/2022 - 11/2022]
Title: BRAKE CONTROL / DYNAMIC CONTROL SYSTEMS: BRAKE ACTUATOR (for Gasoline Model): INSTALLATION; 2023 MY Corolla Corolla Hatchback GR Corolla [09/2022 - 11/2022]

INSTALLATION

CAUTION / NOTICE / HINT

w/ Electric Parking Brake System:

HINT:

The parking brake indicator light blinks (red) when the ignition switch is turned to ON after replacing the brake actuator assembly. Operate the electric parking brake switch assembly to turn off the parking brake indicator light.

PROCEDURE

1. INSTALL BRAKE ACTUATOR BRACKET CUSHION (except G16E-GTS)

(a) Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.

(b) Install the 3 No. 1 brake actuator case collars to the brake actuator bracket cushion.

NOTICE:

Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bracket cushion.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

2. INSTALL BRAKE ACTUATOR ASSEMBLY (except G16E-GTS)

(a) Temporarily install the brake actuator assembly with the 3 bolts.

(b) Fully tighten the 3 bolts in the order shown in the illustration.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

NOTICE:

Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
Do not hold the brake actuator assembly by the connector.
Do not drop the brake actuator assembly when carrying it.

3. INSTALL BRAKE ACTUATOR ASSEMBLY (for G16E-GTS)

(a) Temporarily install the brake actuator assembly with the 3 bolts.

(b) Fully tighten the 3 bolts in the order shown in the illustration.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

NOTICE:

Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
Do not hold the brake actuator assembly by the connector.
Do not drop the brake actuator assembly when carrying it.

4. INSTALL BRAKE ACTUATOR BRACKET CUSHION (for G16E-GTS)

(a) Install the 3 brake actuator bracket cushions to the brake actuator bracket assembly.

(b) Install the 3 No. 1 brake actuator case collars to the brake actuator bracket cushion.

NOTICE:

Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bracket cushion.

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

5. INSTALL BRAKE ACTUATOR WITH BRACKET

(a) Temporarily install the brake actuator with bracket to the vehicle body with the bolt and 2 nuts.

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.
Be careful not to allow any brake fluid to enter the connector.
Do not hold the brake actuator assembly by the connector.
Do not drop the brake actuator with bracket when carrying it.

HINT:

Install the brake actuator with bracket while avoiding the brake lines.

(b) Fully tighten the bolt and 2 nuts in the order shown in the illustration.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

NOTICE:

Do not kink or damage the brake lines.

(d) Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

NOTICE:

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

*a	From 1st Chamber of Brake Master Cylinder Sub-assembly
*b	From 2nd Chamber of Brake Master Cylinder Sub-assembly
*c	To Front Wheel Cylinder Assembly RH
*d	To Rear Wheel Cylinder Assembly LH
*e	To Rear Wheel Cylinder Assembly RH
*f	To Front Wheel Cylinder Assembly LH

(e) Using a union nut wrench, connect the 6 brake lines to the brake actuator assembly.

Torque:

Specified tightening torque (A) :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

Specified tightening torque (B) :

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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
(A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)
When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):
(B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a	Torque Wrench Fulcrum Length
*b	Union Nut Wrench

(f) except G16E-GTS:

(1) Connect the connector to the brake actuator assembly and lock the lock lever.

	Connect the connector
	Lock the lock lever

NOTICE:

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

(g) for G16E-GTS:

(1) Connect the connector to the brake actuator assembly and lock the lock lever.

	Connect the connector
	Lock the lock lever

NOTICE:

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

6. INSTALL DASH PANEL HEAT INSULATOR (for M20A-FKS)

(a) Temporarily install the dash panel heat insulator to the vehicle body with the 2 nuts (A).

(b) Install the nut (B).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

7. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for M20A-FKS)

Click here

8. INSTALL DASH PANEL HEAT INSULATOR (for G16E-GTS)

(a) Temporarily install the dash panel heat insulator to the vehicle body with the 2 nuts (A).

(b) Install the nut (B).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

9. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (for G16E-GTS)

Click here

10. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

except G16E-GTS: Click here

for G16E-GTS: Click here

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

except G16E-GTS: Click here

for G16E-GTS: Click here

12. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

13. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for G16E-GTS: Click here

14. UPDATE ECU SECURITY KEY (for TMC Made)

HINT:

Perform this procedure only when replacement of the brake actuator assembly is necessary.

Click here

15. BLEED BRAKE SYSTEM

Click here

16. ACCELERATION SENSOR ZERO POINT CALIBRATION AND STORE SYSTEM INFORMATION MEMORIZATION

for Gasoline Model with Electric Parking Brake System TMC Made: Click here

for Gasoline Model with Electric Parking Brake System TMMMS Made: Click here

for Gasoline Model without Electric Parking Brake System TMC Made: Click here

for Gasoline Model without Electric Parking Brake System TMMMS Made: Click here

17. PERFORM TEST MODE INSPECTION

for Gasoline Model with Electric Parking Brake System TMC Made: Click here

for Gasoline Model with Electric Parking Brake System TMMMS Made: Click here

for Gasoline Model without Electric Parking Brake System TMC Made: Click here

for Gasoline Model without Electric Parking Brake System TMMMS Made: Click here

18. INSPECT BRAKE ACTUATOR USING TECHSTREAM

Click here

19. CHECK FOR AND CLEAR DTCS

for Gasoline Model with Electric Parking Brake System TMC Made: Click here

for Gasoline Model with Electric Parking Brake System TMMMS Made: Click here

for Gasoline Model without Electric Parking Brake System TMC Made: Click here

for Gasoline Model without Electric Parking Brake System TMMMS Made: Click here