Installation

BRAKE SYSTEM (OTHER): BRAKE BOOSTER: INSTALLATION; 2013 MY Corolla [07/2012 -]

1. TEMPORARILY TIGHTEN BRAKE MASTER CYLINDER PUSH ROD CLEVIS

(a) Install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

HINT
Fully tighten the lock nut after adjusting the brake pedal height.

2. INSTALL BRAKE BOOSTER GASKET

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

3. INSTALL BRAKE BOOSTER ASSEMBLY

(a) Install the brake booster assembly to the body with the 4 nuts.





Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

NOTICE:
Do not damage the brake lines or fuel lines.

(b) Engage the 2 clamps to install the brake lines to the body.





4. INSTALL NO. 5 FRONT BRAKE TUBE

(a) Install the No. 5 front brake tube to the body and engage the grommet.





(b) Using a union nut wrench (10 mm), connect the No. 5 front brake tube to the front brake flexible hose LH.





without a union nut wrench - Torque : 15 Nm (155 kgf-cm, 11 ft-lbf)

with a union nut wrench - Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 250 mm (9.84 in.).
* This torque value is effective when the union nut wrench is parallel to the torque wrench.

5. INSTALL CHECK VALVE GROMMET

(a) Install a new check valve grommet to the brake booster assembly.

6. INSTALL BRAKE VACUUM CHECK VALVE ASSEMBLY

(a) Install the vacuum check valve assembly to the brake booster assembly.

7. CONNECT VACUUM HOSE

(a) Connect the vacuum hose and slide the clip.





8. CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS Installation

9. INSTALL BRAKE PEDAL RETURN SPRING Installation

10. INSTALL FRONT WHEEL LH

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY Installation

12. CONNECT CLUTCH TUBE (for Manual Transaxle) Installation

13. FILL RESERVOIR WITH BRAKE FLUID Service and Repair

14. BLEED CLUTCH LINE

15. BLEED BRAKE MASTER CYLINDER Service and Repair

16. BLEED BRAKE LINE Service and Repair

17. BLEED BRAKE ACTUATOR (w/ VSC) Service and Repair

18. INSPECT FOR BRAKE FLUID LEAK

19. INSPECT FLUID LEVEL Testing and Inspection

20. INSPECT AND ADJUST BRAKE PEDAL HEIGHT Adjustments

21. INSPECT BRAKE PEDAL FREE PLAY Adjustments

22. INSPECT BRAKE PEDAL RESERVE DISTANCE Adjustments

23. INSTALL SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar) Installation

24. INSTALL OUTER COWL TOP PANEL (for TMC Made) Installation

25. INSTALL OUTER COWL TOP PANEL (except TMC Made) Installation

26. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

27. INSTALL COWL TOP VENTILATOR LOUVER LH Installation

28. INSTALL CENTER NO. 1 COWL TOP VENTILATOR LOUVER Installation

29. INSTALL HOOD TO COWL TOP SEAL Installation

30. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

31. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

32. INSTALL FRONT WIPER ARM HEAD CAP Installation

33. INSTALL AIR CLEANER CASE (for 2ZR-FE) Installation

34. INSTALL AIR CLEANER CAP SUB-ASSEMBLY (for 2ZR-FE) Installation

35. INSTALL NO. 2 CYLINDER HEAD COVER (for 2ZR-FE) Installation

36. INSTALL AIR CLEANER CASE (for 2AZ-FE) Installation

37. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE (for 2AZ-FE) Installation

38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 2AZ-FE) Installation