Toyota CH-R Service Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE BOOSTER GASKET

(a) Install a new brake booster gasket to the brake booster assembly.

2. INSTALL BRAKE BOOSTER ASSEMBLY

(a) Temporarily install the brake booster assembly to the vehicle body.

NOTICE:

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

(b) Temporarily install the clevis lock nut and brake master cylinder push rod clevis to the brake booster assembly.

NOTICE:

Fully tighten the clevis lock nut when adjusting the brake pedal height.

(c) Install the 4 nuts to secure the brake booster assembly. Torque: 12.7 N·m {130 kgf·cm, 9 ft·lbf} NOTICE: Tighten the 4 nuts in the order shown in the illustration.

(d) Remove the protective tape.

(e) Engage the 2 clamps to install the fuel pipe to the fuel pipe clamp.

(f) Engage the 4 clamps to install the brake tube to the 2 brake tube clamps.

(g) Connect the vacuum warning switch connector.

3. CONNECT CHECK VALVE TO CONNECTOR TUBE HOSE

(a) Connect the check valve to connector tube hose to the brake booster assembly and slide the clip to secure it.

4. INSTALL DASH PANEL HEAT INSULATOR

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

(b) Install the nut (B). Torque: 5.0 N·m {51 kgf·cm, 44 in·lbf}

(c) Tighten the 2 nuts (A).

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

5. INSTALL NO. 1 ENGINE UNDER COVER

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6. INSTALL PUSH ROD PIN

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7. INSTALL BRAKE PEDAL RETURN SPRING

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8. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

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9. INSPECT AND ADJUST BRAKE PEDAL

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