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

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

Click here

3. REMOVE WATER GUARD PLATE LH

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4. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

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5. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

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6. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

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7. REMOVE BATTERY

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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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