Toyota Yaris: Brake Booster / Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE BOOSTER GASKET

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

2. INSTALL BRAKE BOOSTER ASSEMBLY

(a) Temporarily install the brake booster assembly to the vehicle body.

NOTICE:

Do not apply excessive force to the brake lines.

(b) Temporarily install the lock nut and brake master cylinder push rod clevis to the brake booster assembly.

NOTICE:

Fully tighten the lock nut when adjusting the brake pedal height.

(c) Install the 4 nuts to secure the brake booster assembly. Torque: 12.7 N·m {130 kgf·cm, 9 ft·lbf} NOTICE: Tighten the 4 nuts in the order shown in the illustration.

(d) Using a union nut wrench, connect the 2 brake lines to the brake actuator 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)

*a Torque Wrench Fulcrum Length

(e) Engage the 5 clamps to install a new No. 1 brake tube clamp to the brake lines.

(f) Engage the clamp and install a new No. 2 brake tube clamp to the vehicle body.

(g) Engage the 5 clamps to install the brake lines to the No. 2 brake tube clamp.

(h) Remove the protective tape.

(i) Connect the vacuum sensor connector.

(j) Engage the clamp.

(k) Install the engine room main wire with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

3. INSTALL PUSH ROD PIN

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4. INSTALL BRAKE PEDAL RETURN SPRING

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5. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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6. INSTALL COLUMN HOLE COVER SILENCER SHEET

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

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8. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the brake booster assembly and slide the clip to secure it. NOTICE: When connecting the vacuum hose assembly, face the paint mark up. Make sure that the tabs of the clip are facing upward.

*a Paint Mark

9. INSTALL DASH PANEL HEAT INSULATOR

(a) Temporarily install the dash panel heat insulator to the vehicle body with the nut (A) and clamp.

(b) Install the nut (B). Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(c) Tighten the nut (A).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

10. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

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11. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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12. INSPECT AND ADJUST BRAKE PEDAL

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