Toyota Corolla Cross Owners & Service Manuals

Toyota Corolla Cross: Installation

INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure

Part Name Code

1

BRAKE ACTUATOR BRACKET CUSHION

44547B

-

-

-

2

NO. 1 BRAKE ACTUATOR CASE COLLAR

44521A

-

-

3

BRAKE ACTUATOR ASSEMBLY

44510

-

-

*1

BRAKE ACTUATOR BRACKET ASSEMBLY

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

-

-

Procedure

Part Name Code

4

BRAKE ACTUATOR WITH BRACKET

-

-

-

5

NO. 3 BRAKE TUBE CLAMP

47373B

-

-

6

BRAKE LINE

-

-

-

7

ENGINE ROOM MAIN WIRE

-

-

-

8

AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

88710E

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

*

For use with a union nut wrench

Non-reusable part

ND-OIL 11 or equivalent

-

-

Procedure

Part Name Code

9

DASH PANEL HEAT INSULATOR

-

-

-

10

NO. 1 ENGINE UNDER COVER ASSEMBLY

51410

-

-

-

N*m (kgf*cm, ft.*lbf): Specified torque

-

-

Procedure

Part Name Code

11

OUTER COWL TOP PANEL SUB-ASSEMBLY

55701J

-

-

-

12

WATER GUARD PLATE

55734D

-

-

-

13

NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

55737B

-

-

-

14

WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

-

-

-

-

15

BLEED BRAKE SYSTEM

-

-

-

16

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

-

-

-

-

17

UPDATE ECU SECURITY KEY

-

-

-

18

PERFORM BRAKE SYSTEM CALIBRATION

-

-

-

19

INSPECT BRAKE ACTUATOR USING GTS

-

-

-

20

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

-

-

-

21

WARM UP COMPRESSOR

-

-

-

22

INSPECT FOR REFRIGERANT LEAK

-

-

-

23

PERFORM INITIALIZATION

-

-

-

24

INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

-

-

-

25

CHECK AND CLEAR DTCS

-

-

-

Tightening torque for "Major areas involving basic vehicle performance such as moving/turning/stopping" : N*m (kgf*cm, ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

CAUTION / NOTICE / HINT

NOTICE:

  • After replacing the brake actuator assembly, make sure to perform update ECU security key.
  • After performing the update ECU security key procedure, make sure to perform the initialization procedure for when the cable has been disconnected and reconnected to the negative (-) auxiliary battery terminal.
w/ Electric Parking Brake System:

HINT:

The parking brake indicator light blinks (red) when the ignition switch is turned to ON after replacing the brake actuator assembly. Operate the electric parking brake switch assembly to turn off the parking brake indicator light.

PROCEDURE

1. INSTALL BRAKE ACTUATOR BRACKET CUSHION

2. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR

NOTICE:

Make sure that the No. 1 brake actuator case collar is in full contact with the brake actuator bracket cushion.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

3. INSTALL BRAKE ACTUATOR ASSEMBLY

NOTICE:

  • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
  • Do not hold the brake actuator assembly by the connector.
  • Do not drop the brake actuator assembly when carrying it.

(1) Temporarily install the brake actuator assembly with the 3 bolts.

(2) Fully tighten the 3 bolts in the order shown in the illustration.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

4. INSTALL BRAKE ACTUATOR WITH BRACKET

(1) Temporarily install the brake actuator with bracket to the vehicle body with the 2 nuts.

NOTICE:

  • Do not kink or damage the brake lines.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.
  • Be careful not to allow any brake fluid to enter the connector.
  • Do not hold the brake actuator assembly by the connector.
  • Do not drop the brake actuator with bracket when carrying it.

HINT:

Install the brake actuator with bracket while avoiding the brake lines.

(2) Fully tighten the 2 nuts in the order shown in the illustration.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

5. INSTALL NO. 3 BRAKE TUBE CLAMP

(1) Engage the 5 clamps to install a new No. 3 brake tube clamp to the brake lines.

NOTICE:

Do not kink or damage the brake lines.

6. CONNECT BRAKE LINE

*a

From 1st Chamber of Brake Master Cylinder Sub-assembly

*b

From 2nd Chamber of Brake Master Cylinder Sub-assembly

*c

To Front Wheel Cylinder Assembly RH

*d

To Rear Wheel Cylinder Assembly LH

*e

To Rear Wheel Cylinder Assembly RH

*f

To Front Wheel Cylinder Assembly LH

*g

Torque Wrench Fulcrum Length

-

-

(1) Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

NOTICE:

  • Do not kink or damage the brake line.
  • Do not allow any foreign matter such as dirt or dust to enter the brake line from the connecting parts.

(2) Using a union nut wrench, connect the 6 brake lines to the brake actuator assembly.

Torque:

Specified tightening torque (A) :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

Specified tightening torque (B) :

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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    (A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)):

    (B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

7. CONNECT ENGINE ROOM MAIN WIRE

Lock the lock lever

Connect the connector

(1) Engage the clamp to install the engine room main wire.

(2) Connect the connector to the brake actuator assembly and lock the lock lever.

NOTICE:

  • Make sure that the connector is locked securely.
  • Make sure that the actuator connector can be connected smoothly.
  • Do not allow water, oil or dirt to enter the connector.

8. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY

ND-OIL 11 or equivalent

-

-

(1) Remove the vinyl tape from the air conditioning tube and accessory assembly.

(2) Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube and accessory assembly.

Compressor oil:

ND-OIL 11 or equivalent

(3) Install the 2 O-rings to the air conditioning tube and accessory assembly.

NOTICE:

Keep the O-ring and O-ring fitting surfaces free of foreign matter.

(4) Engage the clamp to install the air conditioning tube and accessory assembly.

(5) Rotate the hook connector as shown in the illustration.

(6) Install the bolt.

Torque:

9.8 N·m {100 kgf·cm, 87 in·lbf}

9. INSTALL DASH PANEL HEAT INSULATOR

(1) Temporarily install the dash panel heat insulator to the vehicle body with the 2 nuts (A).

(2) Install the nut (B).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(3) Tighten the 2 nuts (A).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

10. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Click here

11. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

12. INSTALL WATER GUARD PLATE

13. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

14. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

15. BLEED BRAKE SYSTEM

Click here

16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Click here

17. UPDATE ECU SECURITY KEY

HINT:

Perform this procedure only when replacement of the brake actuator assembly is necessary.

Click here

18. PERFORM BRAKE SYSTEM CALIBRATION

Click here

19. INSPECT BRAKE ACTUATOR USING GTS

Click here

20. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click here

21. WARM UP COMPRESSOR

Click here

22. INSPECT FOR REFRIGERANT LEAK

Click here

23. PERFORM INITIALIZATION

Click here

24. INITIALIZATION AFTER RECONNECTING AUXILIARY BATTERY TERMINAL

HINT:

When disconnecting and reconnecting the auxiliary battery, there is an automatic learning function that completes learning when the respective system is used.

Click here

25. CHECK AND CLEAR DTCS

Click here

    READ NEXT:

     Brake Control Power Supply

     Removal

    REMOVAL CAUTION / NOTICE / HINT COMPONENTS (REMOVAL) Procedure Part Name Code 1 PRECAUTION -

     Installation

    INSTALLATION CAUTION / NOTICE / HINT COMPONENTS (INSTALLATION) Procedure Part Name Code 1 NO. 1 BRAKE CONTROL POWER SUP

    SEE MORE:

     Data List / Active Test

    DATA LIST / ACTIVE TEST DATA LIST NOTICE: In the following table, the values listed under "Normal Condition" are reference values. Do not depend solely on these reference values when deciding whether a part is faulty or not. HINT: Using the GTS to read the Data List allows the values or states of

     Rear Height Sensor Circuit Voltage Out of Range (B241A1C)

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