Toyota CH-R Service Manual: Installation

Toyota CH-R Service Manual / Brake System (other) / Brake Master Cylinder / Installation

INSTALLATION

PROCEDURE

1. INSTALL BRAKE MASTER CYLINDER SUB-ASSEMBLY

NOTICE:

When installing a new brake master cylinder sub-assembly, remove the protectors from the master cylinder piston and outlet ports.

(a) Install a new brake master cylinder O-ring to the brake master cylinder sub-assembly.

(b) Using a 13 mm deep socket wrench, install the brake master cylinder sub-assembly to the brake booster assembly with a new nut.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

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.

(c) Using a 13 mm deep socket wrench, install the wire harness bracket to the brake master cylinder sub- assembly with the nut.

Torque:

20 N·m {204 kgf·cm, 15 ft·lbf}

(d) Using a union nut wrench, connect the 2 brake lines to the brake master cylinder sub-assembly.

Torque:

Specified tightening torque :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

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.

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 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a

Torque Wrench Fulcrum Length

(e) Connect the reservoir level switch connector and engage the clamp.

2. INSTALL BATTERY

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3. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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4. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

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5. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

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6. INSTALL WATER GUARD PLATE LH

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

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8. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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9. BLEED BRAKE SYSTEM

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