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 and installed, or replaced during front shock absorber assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure

Necessary Procedure

Effect/Inoperative Function when Necessary Procedure not Performed

Link

Front wheel alignment adjustment

  1. Clear zero point calibration data.
  2. Perform yaw rate and acceleration sensor zero point calibration.
  • DTCs are stored
  • ABS warning light illuminates
  • Slip indicator light illuminates
  • VSC disabled or malfunctions

Suspension, tires, etc.

(The vehicle height changes because of suspension or tire replacement)

Initialize No. 1 headlight ECU sub-assembly LH

Automatic headlight beam level control system

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.

PROCEDURE

1. REMOVE FRONT WHEEL

Click here

2. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

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

(a) Disengage the claw to remove the No. 1 heater air duct splash shield seal from the outer cowl top panel sub-assembly.

4. REMOVE WATER GUARD PLATE LH

(a) Disengage the claw to remove the water guard plate LH.

5. REMOVE COWL BODY MOUNTING REINFORCEMENT LH

(a) Remove the bolt and cowl body mounting reinforcement LH from the vehicle body.

6. REMOVE COWL BODY MOUNTING REINFORCEMENT RH

(a) Remove the 2 bolts and cowl body mounting reinforcement RH from the vehicle body.

7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY

(a) w/ Windshield Deicer:

(1) Disconnect the connector.

(2) Disengage the 2 clamps to separate the wire harness from the outer cowl top panel sub-assembly.

(b) Disengage the 2 clamps to separate the wire harness from the outer cowl top panel sub-assembly.

(c) Remove the 8 bolts, 4 nuts and outer cowl top panel sub-assembly.

8. REMOVE FRONT SUSPENSION SUPPORT DUST COVER

(a) Remove the front suspension support dust cover from the front shock absorber assembly.

9. LOOSEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT

(a) Temporarily install the 2 nuts to the front shock absorber assembly.

(b) Loosen the front support to front shock absorber nut.

CAUTION:

  • Only loosen the front support to front shock absorber nut if the front shock absorber with coil spring needs to be disassembled.
  • Only loosen the front support to front shock absorber nut, do not remove it.
  • If the front support to front shock absorber nut is removed with the front coil spring under tension, components of the front shock absorber with coil spring may fly off.

10. SEPARATE FRONT STABILIZER LINK ASSEMBLY

(a) Remove the nut to separate the front stabilizer link assembly from the front shock absorber assembly.

NOTICE:

Do not damage the boot of the ball joint.

HINT:

If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.

11. SEPARATE FRONT SPEED SENSOR

(a) Disengage the clamp.

(b) Remove the bolt.

(c) Disengage the 2 hooks to separate the front speed sensor and front flexible hose from the front shock absorber assembly.

NOTICE:

Be sure to separate the front speed sensor and front flexible hose from the front shock absorber assembly completely.

12. REMOVE FRONT SHOCK ABSORBER WITH COIL SPRING

(a) Support the front lower No. 1 suspension arm sub-assembly using a jack and wooden block.

*a

Wooden Block

*b

Jack

Front of the Vehicle

Wooden Block Placement Location

NOTICE:

Keep the front lower No. 1 suspension arm sub-assembly supported until installation of the front shock absorber with coil spring is complete.

(b) Remove the 2 bolts and 2 nuts, and separate the front shock absorber with coil spring (lower side) from the steering knuckle.

NOTICE:

  • When removing the nuts, keep the bolts from rotating.
  • Use wire or an equivalent tool to hang the separated steering knuckle.

(c) Remove the 3 nuts, 2 spacers and front shock absorber with coil spring.

13. REMOVE FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT

(a) Secure SST in a vise.

SST: 09727-00051

SST: 09727-30022

09727-00010

09727-00031

(b) Attach the hooks of each SST arm across the diameter of the coil spring.

CAUTION:

  • Make sure that the hooks are securely attached to the coil spring.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.
  • Make sure that the hooks of the upper and lower SST arms are attached to the coil spring so that the distance between the hooks is as large as possible.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.
  • Make sure that the arms of SST are parallel and the number of coils between the arms is the same on each side.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

(c) Install the stopper pins to the hooks of SST.

CAUTION:

  • Make sure that the stopper pins are installed securely.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

(d) Install SST and 2 vehicle nuts to the upper support as shown in the illustration.

SST: 09727-30022

09727-00090

09727-00100

*a

Vehicle Nut

(e) Using SST, compress the coil spring.

CAUTION:

  • If the coil spring starts to bow out while using SST, stop immediately and reattach SST correctly.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.
  • Do not compress the coil spring to the point where the coils touch each other.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.
  • Do not use an impact wrench.
  • If an impact wrench is used, the threads of SST may be damaged, or sudden compression of the coil spring may cause a hook to disengage and the coil spring to fly out, resulting in injury.
  • If a stopper pin touches the coil spring while using SST, remove the stopper pin and continue with the procedure.
  • If a stopper pin is removed, install a coil spring stopper belt as shown in the illustration.
  • If a hook disengages from the coil spring, the coil spring may fly out, resulting in injury.

SST: 09727-00110

(f) Check that the coil spring has become detached, and then remove the front support to front shock absorber nut.

CAUTION:

  • Do not remove the front support to front shock absorber nut while the coil spring is under tension.
  • If the front support to front shock absorber nut is removed with the coil spring under tension, components of the front shock absorber with coil spring may fly off, resulting in injury.

14. REMOVE COLLAR

(a) Remove the collar from the front shock absorber assembly.

15. REMOVE FRONT SUSPENSION SUPPORT SUB-ASSEMBLY

(a) Remove the front suspension support sub-assembly from the front shock absorber assembly.

16. REMOVE FRONT SPRING SEAT SUB-ASSEMBLY WITH INSULATOR

(a) Disengage the front spring seat sub-assembly with insulator from the claws of the front shock absorber assembly.

*1

Front Spring Seat Sub-assembly with Insulator

*a

Claw

(b) Remove the front spring seat sub-assembly with insulator from the front shock absorber assembly.

17. REMOVE FRONT COIL SPRING

(a) Remove the front coil spring and SST.

NOTICE:

Do not use an impact wrench. It will damage SST.

18. REMOVE FRONT SPRING BUMPER

(a) Remove the front spring bumper from the front shock absorber assembly as shown in the illustration.

Remove in this Direction

19. REMOVE FRONT LOWER COIL SPRING INSULATOR

(a) Remove the front lower coil spring insulator from the front shock absorber assembly.

20. REMOVE FRONT SHOCK ABSORBER ASSEMBLY

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