Toyota CH-R Service Manual: Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

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

PROCEDURE

1. INSTALL REAR DISC

(a) Align the matchmarks of the rear disc and rear axle hub and bearing assembly, and install the rear disc.

NOTICE:

When replacing the rear disc with a new one, select the installation position where the rear disc has minimal runout.

*a

Matchmark

2. INSTALL REAR DISC BRAKE CYLINDER MOUNTING

(a) Install the rear disc brake cylinder mounting to the rear axle carrier sub-assembly with the 2 bolts.

Torque:

107 N·m {1091 kgf·cm, 79 ft·lbf}

3. INSTALL REAR DISC BRAKE BUSHING DUST BOOT

(a) Apply a light layer of lithium soap base glycol grease to the entire circumference of 2 new rear disc brake bushing dust boots.

HINT:

Apply more than 0.3 g (0.01 oz.) of lithium soap base glycol grease to each rear disc brake bushing dust boot.

Lithium Soap Base Glycol Grease

(b) Install the 2 rear disc brake bushing dust boots to the rear disc brake cylinder mounting.

4. INSTALL REAR DISC BRAKE CYLINDER SLIDE PIN

Lithium Soap Base Glycol Grease

(a) Apply a light layer of lithium soap base glycol grease to the contact surface of the rear No. 1 disc brake cylinder slide pin.

(b) Install a new rear disc brake cylinder slide bushing to the rear No. 1 disc brake cylinder slide pin.

Lithium Soap Base Glycol Grease

(c) Apply a light layer of lithium soap base glycol grease to the sliding part and the sealing surfaces of the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin.

(d) Install the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin to the rear disc brake cylinder mounting.

*1

Rear No. 1 Disc Brake Cylinder Slide Pin

*2

Rear No. 2 Disc Brake Cylinder Slide Pin

(e) Push the rear No. 1 disc brake cylinder slide pin and rear No. 2 disc brake cylinder slide pin into each rear disc brake bushing dust boot to engage the pins to the boots.

5. INSTALL REAR DISC BRAKE PAD SUPPORT PLATE

(a) Install the 4 rear disc brake pad support plates to the rear disc brake cylinder mounting.

NOTICE:

Be sure to install each rear disc brake pad support plate in the correct position and direction.

6. INSTALL REAR DISC BRAKE ANTI-SQUEAL SHIM

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7. INSTALL REAR DISC BRAKE PAD

(a) Install the 2 rear disc brake pads to the rear disc brake cylinder mounting.

NOTICE:

Install the rear disc brake pad so that the rear disc brake pad wear indicator plate is mounted on the lower side of the vehicle.

8. INSTALL REAR DISC BRAKE CYLINDER ASSEMBLY

(a) Hold the 2 rear disc brake cylinder slide pins, and install the rear disc brake cylinder assembly to the rear disc brake cylinder mounting with the 2 new bolts in the order shown in the illustration.

Torque:

34.5 N·m {352 kgf·cm, 25 ft·lbf}

*a

Hold

*b

Turn

9. INSTALL PARKING BRAKE ACTUATOR ASSEMBLY

(a) Apply a light coat of lithium soap base glycol grease to a new O-ring.

(b) Install the O-ring to the rear disc brake cylinder assembly.

NOTICE:

Make sure to replace the O-ring with a new one when installing the parking brake actuator assembly.

(c) Using a 5 mm hexagon socket wrench, install the parking brake actuator assembly to the rear disc brake cylinder assembly with the 2 bolts.

Torque:

11.5 N·m {117 kgf·cm, 8 ft·lbf}

10. CONNECT NO. 2 PARKING BRAKE WIRE ASSEMBLY

(a) Connect the No. 2 parking brake wire assembly connector to the parking brake actuator assembly.

11. CONNECT REAR FLEXIBLE HOSE

(a) Connect the rear flexible hose to the rear disc brake cylinder assembly with a new union bolt and a new gasket.

Torque:

30.4 N·m {310 kgf·cm, 22 ft·lbf}

NOTICE:

Install the rear flexible hose lock securely into the lock hole in the rear disc brake cylinder assembly.

12. BLEED BRAKE LINE

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13. BLEED REAR DISC BRAKE CYLINDER ASSEMBLY

CAUTION:

If the rear disc brake cylinder assembly has been disassembled, perform air bleeding for the rear disc brake cylinder.

NOTICE:

  • Perform air bleeding while maintaining the brake fluid level between the MAX and MIN lines on the brake fluid reservoir.
  • Do not allow brake fluid to contact any painted surface. If brake fluid leaks onto any painted surface, immediately wash it off.

HINT:

  • Use the same procedure for the RH side and LH side.
  • The following procedure is for the LH side.
  • While performing air bleeding of the rear disc brake assembly, the bolt can be reused during the bleeding procedure. After air bleeding is complete, replace the bolt with a new one.

(a) Perform the procedure to enter rear disc brake pad replacement mode 5 times.

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(b) Release the parking brake.

(c) Disconnect the No. 2 parking brake wire assembly connector from the parking brake actuator assembly.

(d) Remove the center No. 1 cowl top ventilator louver.

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(e) Remove the brake master cylinder reservoir filler cap.

(f) Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

NOTICE:

  • Make sure that there is sufficient brake fluid in the reservoir.
  • If brake fluid leaks onto any painted surface, immediately wash it off.
  • Do not remove the filter from the brake master cylinder reservoir and be sure to fill the brake master cylinder reservoir with new brake fluid to avoid any potential contamination of the brake system. Contamination, for example by dirt particles or mineral oil, could lead to functional brake problems.

(g) Remove the bolt and separate the rear disc brake cylinder assembly.(*1)

NOTICE:

Keep the rear no. 2 disc brake cylinder slide pin free of foreign matter.

*a

Turn

*b

Hold

(h) Hold the rear disc brake cylinder assembly horizontally, then tilt it 45° toward the bleeder plug side as shown in the illustration.(*2)

(i) Temporarily install the rear disc brake cylinder assembly with the bolt.(*3)

*a

Turn

*b

Hold

(j) Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.(*4)

(k) When fluid stops coming out, tighten the bleeder plug and release the brake pedal.(*5)

(l) Repeat steps (*1) through (*5) 3 times.

NOTICE:

If there is still air in the system after performing steps (*1) through (*5) 3 times, repeat the steps (*1) through (*5) until the air has been bled.

(m) Tighten the bleeder plug completely.

Torque:

11 N·m {112 kgf·cm, 8 ft·lbf}

(n) Install the rear disc brake cylinder assembly with a new bolt.

Torque:

34.5 N·m {352 kgf·cm, 25 ft·lbf}

(o) Connect the No. 2 parking brake wire assembly connector to the parking brake actuator assembly.

(p) Inspect for brake fluid leaks.

(q) Inspect the brake fluid level in the reservoir.

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(r) Install the brake master cylinder reservoir filler cap assembly.

(s) Install the center No. 1 cowl top ventilator louver.

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14. INSTALL REAR WHEEL

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15. NORMAL CONDITION RECOVERY

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