Toyota CH-R Service Manual: Installation

INSTALLATION

PROCEDURE

1. INSTALL HOLE PLUG

(a) Install the 4 hole plugs to the front suspension crossmember sub-assembly.

HINT:

There are 2 different shapes of hole plug.

2. INSTALL FRONT SUSPENSION MEMBER PLATE

(a) Install the 2 front suspension member plates to the front suspension crossmember sub-assembly.

3. INSTALL ENGINE MOVING CONTROL ROD

(a) Install the engine moving control rod to the front suspension crossmember sub-assembly with the bolt.

Torque:

200 N·m {2039 kgf·cm, 148 ft·lbf}

4. TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

(a) Temporarily install the front lower No. 1 suspension arm sub-assembly LH to the front suspension crossmember sub-assembly with the 2 bolts and nut.

5. TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

6. INSTALL FRONT STABILIZER BAR

Click here

7. INSTALL FRONT NO. 1 STABILIZER BRACKET LH

Click here

8. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

HINT:

Perform the same procedure as for the LH side.

9. INSTALL STEERING LINK ASSEMBLY

(a) Install the steering link assembly to the front suspension crossmember sub-assembly with the 2 bolts and 2 new nuts.

Torque:

133 N·m {1356 kgf·cm, 98 ft·lbf}

NOTICE:

  • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.
  • Make sure to tighten the bolts starting from the left side of the vehicle.

10. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

CAUTION:

  • The front suspension crossmember sub-assembly is a very heavy component. Make sure that it is supported securely.
  • If the front suspension crossmember sub-assembly is not securely supported, it may drop, resulting in serious injury.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(b) Install the front suspension crossmember sub-assembly to the vehicle body with the 6 bolts.

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(c) Lower the engine lifter.

(d) Install the engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

(e) Install the 2 wire harness clamp brackets to the front suspension crossmember sub-assembly with the 2 bolts.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

11. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

(a) Install the front lower No. 1 suspension arm sub-assembly LH to the front lower ball joint assembly LH with the bolt and 2 nuts.

Torque:

89 N·m {908 kgf·cm, 66 ft·lbf}

12. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

13. CONNECT TIE ROD END SUB-ASSEMBLY LH

Click here

14. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

15. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

(a) Connect the front stabilizer link assembly LH to the front shock absorber assembly with the nut.

Torque:

74 N·m {755 kgf·cm, 55 ft·lbf}

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.

16. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

17. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

(a) Install the rear side rail reinforcement sub-assembly LH to the front suspension crossmember sub-assembly and vehicle body with the 4 bolts.

Torque:

70 N·m {714 kgf·cm, 52 ft·lbf}

18. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

19. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here

20. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

21. INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here

22. INSTALL FRONT WHEELS

Click here

23. STABILIZE SUSPENSION

Click here

24. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

Click here

25. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

26. INSTALL FRONT FLOOR COVER LH (w/ Cover)

Click here

27. INSTALL FRONT FLOOR COVER RH (w/ Cover)

HINT:

Perform the same procedure as for the LH side.

28. INSTALL REAR ENGINE UNDER COVER LH

Click here

29. INSTALL REAR ENGINE UNDER COVER RH

Click here

30. INSTALL NO. 1 ENGINE UNDER COVER

Click here

31. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here

32. PERFORM INITIALIZATION (w/ Height Control Sensor)

Click here

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