Toyota Yaris: Brake Booster / Removal

Toyota Yaris XP210 (2020-2022) Reapir and Service Manual / Brake / Brake System (other) / Brake Booster / Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during brake booster assembly removal/installation are shown below.

HINT:

When the cable is disconnected / reconnected to the auxiliary battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

  • Learning completes when vehicle is driven

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Lane tracing assist system

    Drive the vehicle straight ahead at 35 km/h (22 mph) or more for 5 second or more.

    Pre-collision system

    Parking support brake system

    Stop and start system

    Drive the vehicle until stop and start control is permitted (approximately 5 to 60 minutes)

  • Learning completes when vehicle is operated normally

    Effect/Inoperative Function When Necessary Procedures are not Performed

    Necessary Procedures

    Link

    Power door lock control system

    • Back door opener

    Perform door unlock operation with door control switch or electrical key transmitter sub-assembly switch.

    Air conditioning system

    After the ignition switch is turned to ON, the servo motor standard position is recognized.

    -

PROCEDURE

1. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

Click here

2. REMOVE NO. 1 ENGINE UNDER COVER ASSEMBLY

Click here

3. REMOVE DASH PANEL HEAT INSULATOR

(a) Remove the nut.

(b) Remove the nut, clamp and dash panel heat insulator.

4. DISCONNECT VACUUM HOSE ASSEMBLY

(a) Slide the clip and disconnect the vacuum hose assembly from the brake booster assembly.

5. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

Click here

6. REMOVE COLUMN HOLE COVER SILENCER SHEET

Click here

7. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

8. LOOSEN CLEVIS LOCK NUT

(a) Loosen the lock nut of the brake master cylinder push rod clevis.

*1

Lock Nut

*2

Brake Master Cylinder Push Rod Clevis

9. REMOVE BRAKE PEDAL RETURN SPRING

Click here

10. REMOVE PUSH ROD PIN

Click here

11. REMOVE BRAKE BOOSTER ASSEMBLY

(a) Remove the bolt to separate the engine room main wire.

(b) Disengage the clamp.

(c) Disconnect the vacuum sensor connector.

(d) Apply protective tape to the vehicle body as shown in the illustration.

Protective Tape

(e) Disengage the 5 clamps to separate the brake lines from the No. 2 brake tube clamp.

(f) Disengage the clamp and remove the No. 2 brake tube clamp from the vehicle body.

(g) Disengage the 5 clamps to remove the No. 1 brake tube clamp from the brake lines.

(h) Using a union nut wrench, disconnect the 2 brake lines from the brake actuator assembly.

(i) Remove the 4 nuts.

(j) Remove the brake master cylinder push rod clevis and lock nut from the brake booster assembly.

(k) Remove the brake booster assembly from the vehicle body.

NOTICE:

Do not apply excessive force to the brake lines.

12. REMOVE BRAKE BOOSTER GASKET

(a) Remove the brake booster gasket from the brake booster assembly.

    Disassembly

    DISASSEMBLY PROCEDURE 1. REMOVE BRAKE VACUUM CHECK VALVE ASSEMBLY (a) Remove the brake vacuum check valve assembly from the brake booster assembly. (b) Remove the check valve grommet from the brake booster assembly...

    Inspection

    INSPECTION PROCEDURE 1. INSPECT BRAKE VACUUM CHECK VALVE ASSEMBLY (a) Check that there is ventilation from the booster side to the engine side, and no ventilation from the engine side to the booster side of the brake vacuum check valve assembly...

    Other information:

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Problem Symptoms Table


    PROBLEM SYMPTOMS TABLE NOTICE: Before replacing the main body ECU (multiplex network body ECU) or certification ECU (smart key ECU assembly), refer to Registration. Click here HINT: Use the table below to help determine the cause of problem symptoms...

    Toyota Yaris XP210 (2020-2022) Reapir and Service Manual: Fail-safe Chart


    FAIL-SAFE CHART If any of the following DTCs are stored, the ECM enters fail-safe mode to allow the vehicle to be driven temporarily. DTC No. Fail-safe Operation Fail-safe Deactivation Condition P058A01 P062049 P065C07 P160200 P161A87 P162B87 Generator command is fixed...

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