Toyota Corolla (E120) 2002–2008 Repair Manual / Brake / Brake booster assy / Replacement

Toyota Corolla (E120): Replacement

1. Drain brake fluid

Notice

: wash the brake fluid off immediately if it comes into contact with any painted surface.

2. Remove air cleaner cap sub–assy

3. Remove air cleaner case sub–assy

1.  remove the air cleaner element, then remove the 3 bolts and air cleaner case sub–assy.

4. Remove brake master cylinder sub–assy

5. Disconnect brake master cylinder push rod clevis

1.  loosen the push rod clevis lock nut.
2.  remove the clip, clevis pin and wave washer.

6. Remove cruise control actuator assy (w/ cruise control)

1. Remove the 2 nuts and bolt from the cruise control actuator and bracket, and move cruise control actuator aside.

7. Remove front wheel lh

8. Remove brake booster assy

1. Using sst and spanner, disconnect the brake tube from the flexible hose, and remove the brake tube from the body.

   Sst 09023–00100

2.  slide the clip, disconnect the vacuum hose from the brake booster assy.

3. Disconnect the 2 or 3 brake tubes from the clamp, and move brake tubes aside.

4. Remove the 4 nuts and clevis.
5.  pull out the brake booster and gasket.

9. Install brake booster assy

1.  install the clevis to the booster push rod.

2. Install a new gasket and brake booster with the 4 nuts.

   Torque: 12.7 Nvm (130 Kgf·cm, 9 ft·lbf)

2. Connect the 2 or 3 brake tubes to the clamp.
3.  connect the vacuum hose to the brake booster.

5. Using sst and spanner, connect the brake tube to the flexible hose.

   Sst 09023–00100 torque: 15.2 Nvm (155 Kgf·cm, 11 ft·lbf)

10. Install front wheel lh

torque: 103 nvm (1,050 Kgf·cm, 76 ft·lbf)

11. Install cruise control actuator assy (w/ cruise control)

1. Install the cruise control actuator and bracket with 2 nuts and bolt.

   Torque: 43 nvm (438 Kgf·cm, 32 ft·lbf)

12. Connect brake master cylinder push rod clevis

1.  apply the lithium soap base glycol grease to the push rod clevis pin.
2.  connect the brake master cylinder push rod clevis with the push rod clevis pin, wave washer and clip.

13. Install brake master cylinder sub–assy

14. Install air cleaner case sub–assy

1.  install the air cleaner case with 3 bolts, then install the air cleaner element to the air cleaner case sub– assy.

15. Install air cleaner cap sub–assy

16. Fill reservoir with brake fluid

17. Bleed master cylinder 

sst 09023–00100

18. Bleed brake line

19. Check and adjust brake pedal height

20. Check pedal free play

21. Check pedal reserve distance

22. Check fluid level in reservoir

23. Check brake fluid leakage