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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Reassembly

REASSEMBLY PROCEDURE 1. INSTALL BRAKE MASTER CYLINDER RESERVOIR STRAINER (a) Install the brake master cylinder reservoir strainer to the brake master cylinder reservoir assembly. 2. INSTALL BRAK ...

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Reassembly

Brake Pedal

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