Brake Booster (For Hatchback) Installation

Brake. Yaris. Ncp93, 131
Brake System (Other). Yaris. Ncp93, 131

  1. INSTALL BRAKE BOOSTER ASSEMBLY

  2. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

  3. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS

  4. INSTALL OUTER COWL TOP PANEL

  5. INSTALL INNER COWL TOP TO COWL BRACE

  6. INSTALL FRONT NO. 1 VENTILATOR SEAL

  7. INSTALL FRONT AIR SHUTTER SEAL RH

  8. INSTALL PROPORTIONING VALVE ASSEMBLY (w/o ABS,VSC)

  9. INSTALL BRAKE ACTUATOR ASSEMBLY (w/ ABS,VSC)

  10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

  11. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

  12. INSPECT AND ADJUST BRAKE PEDAL HEIGHT

  13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

  14. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY (w/ Knee Airbag)

  15. INSTALL LOWER NO. 2 INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

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

Brake Booster (For Hatchback) -- Installation



1. INSTALL BRAKE BOOSTER ASSEMBLY

  1. Install a new gasket onto the brake booster assembly.

  1. Temporarily install the brake booster assembly with the 4 nuts.



    Yaris. Ncp93, 131.Brake System (Other).Brake System (For Sedan).Brake Booster (For Hatchback) Installation

  1. Tighten the 4 nuts in the order shown in the illustration.

    Torque:
    9.0 N*m{92 kgf*cm, 80 in.*lbf}

  1. Connect the vacuum hose to the vacuum check valve with the clip.



2. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY


    Yaris. Ncp93, 131.Brake System (Other).Brake System (For Sedan).Brake Booster (For Hatchback) Installation

  1. Align the matchmarks on the No. 2 steering intermediate shaft assembly and the steering column assembly and provisionally install them with the bolt.

    Text in Illustration
    *a
    		Matchmark
    *b
    		Front of the Vehicle

  1. Tighten the bolt B while aligning the No. 2 steering intermediate shaft assembly with the position C as shown in the illustration.

    Standard C:
    18.5 to 19.7 mm
    Torque:
    35 N*m{360 kgf*cm, 26 ft.*lbf}

  1. Tighten bolt A.

    Torque:
    35 N*m{360 kgf*cm, 26 ft.*lbf}


3. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS

  1. Apply lithium soap base glycol grease to the push rod pin.



    Yaris. Ncp93, 131

  1. Install the push rod clevis with the push rod pin and a new clip.

    Text in Illustration
    Yaris. Ncp93, 131
    		Apply Lithium Soap Base Glycol Grease

  1. Install the brake pedal return spring.



4. INSTALL OUTER COWL TOP PANEL

  1. Install the outer cowl top panel with the 8 bolts.

    Torque:
    7.0 N*m{71 kgf*cm, 62 in.*lbf}

  1. Engage the 2 clamps and install the wire harness.



5. INSTALL INNER COWL TOP TO COWL BRACE

  1. Install the cowl top to cowl brace with the 2 bolts.

    Torque:
    7.0 N*m{71 kgf*cm, 62 in.*lbf}


6. INSTALL FRONT NO. 1 VENTILATOR SEAL

  1. Engage the clip and install the front No. 1 ventilator seal.



7. INSTALL FRONT AIR SHUTTER SEAL RH
HINT:
Use the same procedure for the RH and LH sides.


8. INSTALL PROPORTIONING VALVE ASSEMBLY (w/o ABS,VSC)
(YARIS_NCP93 RM000001LWT00YX.html)


9. INSTALL BRAKE ACTUATOR ASSEMBLY (w/ ABS,VSC)
(YARIS_NCP93 RM000001BXN02KX.html)


10. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY
(YARIS_NCP93 RM000000CIB02OX.html)


11. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
(YARIS_NCP93 RM000001OV1024X.html)


12. INSPECT AND ADJUST BRAKE PEDAL HEIGHT
(YARIS_NCP93 RM000000ORB01UX.html)


13. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

  1. Engage the 5 claws and 2 clips and install the instrument panel finish panel.



14. INSTALL LOWER NO. 1 INSTRUMENT PANEL AIR BAG ASSEMBLY (w/ Knee Airbag)
(YARIS_NCP93 RM000003SR900DX.html)


15. INSTALL LOWER NO. 2 INSTRUMENT PANEL FINISH PANEL (w/o Knee Airbag)

  1. Engage the 2 claws and 5 clips and install the instrument panel finish panel.



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

  1. Engage the guide and the claw.

  1. Install the instrument panel under cover with the 2 <A> screws.