Toyota CH-R Service Manual: Removal

REMOVAL

CAUTION / NOTICE / HINT

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

NOTICE:

Make sure to release vacuum from the brake booster assembly before removing the master cylinder sub-assembly from the brake booster assembly.

PROCEDURE

1. REMOVE NO. 1 AIR DUCT

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2. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

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3. REMOVE BRAKE PEDAL RETURN SPRING

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4. LOOSEN CLEVIS LOCK NUT

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

*1 Clevis Lock Nut *2 Brake Master Cylinder Push Rod Clevis

5. REMOVE PUSH ROD PIN

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6. REMOVE NO. 1 ENGINE UNDER COVER

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7. REMOVE DASH PANEL HEAT INSULATOR

(a) Remove the nut.

(b) Remove the 2 nuts and the dash panel heat insulator.

8. DISCONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Slide the clip and disconnect the check valve to connector tube hose from the brake booster assembly.

9. REMOVE BRAKE BOOSTER ASSEMBLY

(a) Disconnect the vacuum warning switch connector.

(b) Disengage the 5 camps to remove the No. 1 brake tube clamp from the brake tubes.

(c) Disengage the 5 clamps to separate the No. 2 brake tube clamps from the brake tubes.

(d) Disengage the clamp to remove the No. 2 brake tube clamp from the vehicle body.

(e) Disengage the 2 clamps to separate the fuel pipe from the fuel pipe clamp.

(f) Apply protective tape around the vehicle body.

Protective Tape

(g) Remove the 4 nuts and push the brake booster assembly toward the engine compartment. NOTICE: Do not apply excessive force to the brake lines.

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

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

NOTICE:

Do not apply excessive force to the brake lines or refrigerant lines.

10. REMOVE BRAKE BOOSTER GASKET

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