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 master cylinder sub-assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced

Replacement Part or Procedure

Necessary Procedures

Effects / Inoperative when not performed

Link

Disconnect cable from negative battery terminal

Memorize steering angle neutral point

Lane departure alert system (w/ Steering Control)

Pre-collision system

Initialize back door lock

Power door lock control system

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 WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

2. REMOVE NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

Click here

3. REMOVE WATER GUARD PLATE LH

Click here

4. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

Click here

5. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

Click here

6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

7. REMOVE BATTERY

Click here

8. DRAIN BRAKE FLUID

NOTICE:

If brake fluid leaks onto any painted surface, immediately wash it off.

9. REMOVE BRAKE MASTER CYLINDER SUB-ASSEMBLY

(a) Disengage the clamp and disconnect the reservoir level switch connector.

(b) Using a union nut wrench, disconnect the 2 brake lines from the brake master cylinder sub-assembly.

NOTICE:

  • Do not damage or deform the brake lines during the removal procedure.
  • Do not allow any foreign matter such as dirt or dust to enter the brake lines from the connecting parts.

(c) Using a 13 mm deep socket wrench, remove the nut and separate the wire harness bracket.

(d) Using a 13 mm deep socket wrench, remove the nut and brake master cylinder sub-assembly from the brake booster assembly.

NOTICE:

  • The brake master cylinder sub-assembly requires careful handling. Do not drop or subject the brake master cylinder sub-assembly to any impact. Do not reuse a brake master cylinder sub-assembly that has been dropped.
  • Do not hold the brake master cylinder sub-assembly by the master cylinder piston. Hold the brake master cylinder sub-assembly by its body or its brake master cylinder reservoir assembly when carrying it.
  • Do not pull out the master cylinder piston.
  • Do not strike or pinch the master cylinder piston, or cause any damage to the master cylinder piston by any other means.
  • When installing the brake master cylinder sub-assembly to the brake booster assembly, or when removing the brake master cylinder sub-assembly from the brake booster assembly, make sure that the brake master cylinder sub-assembly is kept horizontal or with its tip facing downward (the master cylinder piston is facing upward) to prevent the master cylinder piston from falling out.
  • Do not allow any foreign matter to contaminate the master cylinder piston. If any foreign matter gets on the master cylinder piston, remove it by using a piece of cloth and then apply an even layer of lithium soap base glycol grease around the circumference (sliding part) of the master cylinder piston.
  • Do not use any other type of grease or fluid.
  • Make sure to release vacuum from the brake booster assembly before removing the brake master cylinder sub-assembly from the brake booster assembly.

(e) Remove the brake master cylinder O-ring from the brake master cylinder sub-assembly.

    Components
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    Disassembly
    DISASSEMBLY PROCEDURE 1. REMOVE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (a) Mount the brake master cylinder sub-assembly in a vise. NOTICE: Place aluminum plates on the vise to prevent damage to ...

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