Toyota CH-R Service Manual: Installation

Toyota CH-R Service Manual / Brake Control / Dynamic Control Systems / Brake Actuator / Installation

INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL BRAKE ACTUATOR BRACKET CUSHION

(a) Install the brake actuator bracket cushion to the brake actuator bracket assembly.

2. INSTALL NO. 1 BRAKE ACTUATOR CASE COLLAR

(a) Install the No. 1 brake actuator case collar to the brake actuator bracket cushion.

3. INSTALL BRAKE ACTUATOR ASSEMBLY

(a) Temporarily install the brake actuator assembly with the 2 nuts and bolt.

(b) Fully tighten the 2 nuts and bolt in the order shown in the illustration.

Torque:

6.5 N·m {66 kgf·cm, 58 in·lbf}

NOTICE:

  • Do not remove the hole plugs of a new brake actuator assembly before connecting the brake tubes because the brake actuator assembly is filled with brake fluid.
  • Do not hold the brake actuator assembly by the connector.

4. INSTALL BRAKE ACTUATOR WITH BRACKET

(a) Temporarily install the brake actuator with bracket to the vehicle body with the bolt and 2 nuts.

(b) Fully tighten the bolt and 2 nuts in the order shown in the illustration.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

NOTICE:

Do not damage the brake tubes.

(c) Temporarily tighten each brake line to the correct position on the brake actuator assembly as shown in the illustration.

*a

From 1st Chamber of Brake Booster with Master Cylinder Assembly

*b

From 2nd Chamber of Brake Booster with Master Cylinder Assembly

*c

To Front Wheel Cylinder Assembly LH

*d

To Rear Wheel Cylinder Assembly RH

*e

To Rear Wheel Cylinder Assembly LH

*f

To Front Wheel Cylinder Assembly RH

(d) Using a 10 mm and 12 mm union nut wrench, connect the 6 brake tubes to the brake actuator assembly.

Torque:

Specified tightening torque (A) :

15.2 N·m {155 kgf·cm, 11 ft·lbf}

Specified tightening torque (B) :

19.5 N·m {199 kgf·cm, 14 ft·lbf}

NOTICE:

  • Do not kink or damage the brake tubes.
  • Do not allow the brake tubes to twist or interfere with other parts or the vehicle body during tightening.
  • Do not allow any foreign matter such as dirt or dust to enter the brake tubes 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 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (A): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)
  • When using a union nut wrench (fulcrum length of 20 mm (0.787 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)) (B): 17.4 N*m (177 kgf*cm, 13 ft.*lbf)

*a

Torque Wrench Fulcrum Length

(e) Connect the connector to the brake actuator assembly and lock the lock lever.

NOTICE:

  • Make sure that the actuator connector can be connected smoothly. Do not allow water, oil or dirt to enter the connector.
  • Make sure that the connector is locked securely.

Connect the connector

Lock the lock lever

5. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

Click here

6. INSTALL BATTERY

Click here

7. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

Click here

8. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

Click here

9. INSTALL WATER GUARD PLATE LH

Click here

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

Click here

11. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

Click here

12. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Click here

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

Click here

13. BLEED BRAKE SYSTEM

Click here

14. INSPECT BRAKE ACTUATOR USING TECHSTREAM

Click here

15. PERFORM SYSTEM VARIANT LEARNING

Click here

16. CHECK FOR AND CLEAR DTCS

Click here

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