Overhaul - Stabilizer Control W/Bracket Valve Assembly (KDSS)

STABILIZER CONTROL W/BRACKET VALVE ASSEMBLY (KDSS - Kinetic Dynamic Suspension System)
OVERHAUL
1. REMOVE RADIATOR SUPPORT SEAL UPPER
2. REMOVE BATTERY
3. REMOVE STEP SUB-ASSEMBLY LH





4. DRAIN SUSPENSION FLUID
a. Loosen the bleeder plug on the stabilizer control w/ accumulator housing assembly and drain suspension fluid.

HINT:
^ Drain suspension fluid when performing the operations related to the hydraulic circuits.
^ Draining suspension fluid decreases suspension fluid pressure.

b. Tighten the bleeder plug.
Torque: 9.5 Nm (97 kgf-cm, 84 inch lbs.)
5. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
6. SEPARATE STABILIZER BAR FRONT
7. REMOVE SPARE DISC WHEEL
8. SEPARATE STABILIZER BAR REAR
9. REMOVE FRONT DISC WHEEL
10. REMOVE FRONT STABILIZER CONTROL TUBE NO.1 AND NO.2





a. Remove the 2 bolts and front stabilizer tube protector.
b. Using SST, disconnect the front stabilizer control tube No.1 and No.2.
SST 09023-12701





c. Remove the 4 bolts and front stabilizer control tube No. 1 and No.2.

NOTICE:
^ Do not bend the control tubes.
^ Do not damage the control tubes and flare nuts.

11. REMOVE REAR STABILIZER CONTROL TUBE NO.1 AND NO.2





a. Remove the 3 bolts and stabilizer control valve protector.
b. Using SST, disconnect the rear stabilizer control tube No.1.
SST 09023-12701
c. Remove the 2 union bolts of the rear stabilizer control cylinder and the 2 pressure port gaskets.





d. Remove the 4 bolts and rear stabilizer control tube No.1 and No.2.

NOTICE:
^ Do not bend the control tubes.
^ Do not damage the control tubes and flare nuts.

12. REMOVE STABILIZER CONTROL W/BRACKET VALVE ASSEMBLY





a. Disconnect the 2 connectors.





b. Remove the 9 bolts and stabilizer control w/ bracket valve assembly.





13. REMOVE ACCUMULATOR PRESSURE SENSOR WIRE HARNESS
a. Remove the 2 clamps.
b. Disconnect the 2 connectors, disengage the clip and remove the accumulator pressure sensor wire harness.





14. REMOVE STABILIZER CONTROL ACCUMULATOR VALVE TUBE SUB-ASSEMBLY
a. Using SST, disconnect the stabilizer control accumulator valve tube.
SST 09023-00101

NOTICE: Do not damage the accumulator valve tube and flare nuts.

b. Disengage the clip and remove the stabilizer control accumulator valve tube.
15. REMOVE STABILIZER CONTROL ADAPTER SUB-ASSEMBLY





a. Remove the 2 service valve caps and 2 oil nozzle valves.





b. Remove the 2 stabilizer control adapter shutter valves.
c. Remove the O-rings from the stabilizer control adapter shutter valves.





d. Using SST, disconnect the stabilizer control valve to adapter tube.
SST 09023-12701

NOTICE: Do not damage the control valve adapter tube and flare nuts.





e. Remove the 4 bolts and 2 stabilizer control adapters.





16. REMOVE STABILIZER CONTROL VALVE TO ADAPTER TUBE
a. Using SST, disconnect the stabilizer control valve to adapter tube.
SST 09023-12701

NOTICE: Do not damage the control valve adapter tube and flare nuts.

b. Remove the bolt and stabilizer control adapter tube.





17. REMOVE STABILIZER CONTROL VALVE
a. Remove the 3 bolts and stabilizer control valve.
18. REMOVE STABILIZER CONTROL W/ACCUMULATOR HOUSING ASSEMBLY





a. Remove the 2 bleeder plug caps and 2 bleeder plugs.





b. Remove the 3 bolts and stabilizer control w/ accumulator housing.





19. REMOVE ACCUMULATOR PRESSURE SENSOR
a. Secure the stabilizer control w/ accumulator housing in a vise.
b. Using SST, remove the 2 accumulator pressure sensors.
SST 09922-10010

NOTICE: Do not damage the stabilizer control w/ accumulator housing with the SST.





20. INSTALL ACCUMULATOR PRESSURE SENSOR
a. Secure the stabilizer control w/ accumulator housing in a vise.
b. Install the accumulator pressure sensors.
1. Apply suspension fluid to the threads of the accumulator pressure sensors and O-rings.
2. Using SST, install the 2 accumulator pressure sensors to the stabilizer control w/ accumulator housing.
SST 09922-10010
Torque: 75 Nm (762 kgf-cm, 55 ft. lbs.)

NOTICE: Do not damage the stabilizer control w/ accumulator housing with the SST.

21. TEMPORARILY TIGHTEN STABILIZER CONTROL W/ACCUMULATOR HOUSING ASSEMBLY





a. Install the stabilizer control w/ accumulator housing by temporarily tightening the 3 bolts.





b. Install the 2 bleeder plugs and 2 bleeder plug caps.
Torque: 9.5 Nm (97 kgf-cm, 84 inch lbs.)





22. TEMPORARILY TIGHTEN STABILIZER CONTROL VALVE
a. Install the stabilizer control valve by temporarily tightening the 3 bolts.





23. TEMPORARILY TIGHTEN STABILIZER CONTROL VALVE TO ADAPTER TUBE
a. Install the stabilizer control valve to adapter tube.
1. Apply suspension fluid to the threads of the flare nuts.
2. Install the stabilizer control valve to adapter tube to the stabilizer control valve by temporarily tightening the 2 flare nuts.
b. Install the stabilizer control valve to adapter tube by temporarily tightening the bolt.
24. TEMPORARILY TIGHTEN STABILIZER CONTROL ADAPTER SUB-ASSEMBLY





a. Install the 2 stabilizer control adapters by temporarily tightening the 4 bolts.





b. Install the stabilizer control valve to adapter tube.
1. Apply suspension fluid to the threads of the flare nuts.
2. Install the stabilizer control valve to adapter tube to the stabilizer control adapter by temporarily tightening the 2 flare nuts.





c. Install the stabilizer control adapter shutter valves.
1. Apply suspension fluid to 2 new O-rings and install them to the stabilizer control adapter shutter valves.
2. Install the 2 stabilizer control adapter shutter valves to the stabilizer control adapter.
Torque: 14 Nm (140 kgf-cm, 10 ft. lbs.)





d. Install the oil nozzle valve sub-assembly.
1. Apply suspension fluid to the 2 O-rings.
2. Install the 2 oil nozzle valve sub-assembly and 2 service valve caps to the stabilizer control adapter.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





25. TEMPORARILY TIGHTEN STABILIZER CONTROL ACCUMULATOR VALVE TUBE SUB-ASSEMBLY
a. Apply suspension fluid to the threads of the flare nuts.
b. Temporarily tighten the 4 flare nuts on the stabilizer control accumulator valve tube sub-assembly, and engage the clip.
26. FULLY TIGHTEN STABILIZER CONTROL W/BRACKET VALVE ASSEMBLY





a. Fully tighten the 10 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)





b. Fully tighten bolt (A).
Torque: 13 Nm (127 kgf-cm, 9 ft. lbs.)
c. Using SST, fully tighten flare nuts (B).
SST 09023-12701
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)
d. Using SST, fully tighten flare nuts (C).
SST 09023-00101
Torque: 16 Nm (158 kgf-cm, 11 ft. lbs.)
27. INSTALL ACCUMULATOR PRESSURE SENSOR WIRE HARNESS





a. Connect the 2 connectors and engage the clip.





b. Align the left end of the marking tape and the connected part of the accumulator pressure sensor, and install 2 new clamps.

NOTICE: The left end of the marking tape should be positioned within 5 mm (0.20 inch) from the connected part of the accumulator pressure sensor.

28. INSTALL STABILIZER CONTROL W/BRACKET VALVE ASSEMBLY





a. Insert the protrusion on the stabilizer bracket into the frame, and install the stabilizer control w/ bracket valve assembly with the 9 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





b. Connect the 2 connectors.
29. INSTALL FRONT STABILIZER CONTROL TUBE NO.1 AND NO.2
a. Install the front stabilizer control tube No.1 and No.2.
1. Apply suspension fluid to the threads of the flare nuts.
2. Temporarily tighten the 6 flare nuts on the front stabilizer control tube No.1 and No.2.

NOTICE:
^ Do not bend the control tubes.
^ Ensure that the control tubes do not contact other parts.
^ Do not damage the control tubes and flare nuts.

b. Install the 4 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Using SST, fully tighten the 6 flare nuts on the front stabilizer control tube No.1 and No. 2.
SST 09023-12701
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)





d. Install the front stabilizer tube protector with the 2 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
30. INSTALL REAR STABILIZER CONTROL TUBE NO.1 AND NO.2
a. Install the rear stabilizer control tube No. 1 and No.2.
1. Apply suspension fluid to the threads of the flare nuts.
2. Temporarily tighten the 4 flare nuts on the rear stabilizer control tube No. 1.

NOTICE:
^ Ensure that the control tubes of not contact other parts.
^ Do not bend the control tubes.
^ Do not damage the control tubes and flare nuts.

b. Install the 4 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Using SST, fully tighten the 4 flare nuts on the rear stabilizer control tube No.1.
SST 09023-12701
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)








d. Install the rear stabilizer tube No.2 to the rear stabilizer control cylinder with the 2 union bolts and 2 new pressure port gaskets.
Torque: 69 Nm (704 kgf-cm, 51 ft. lbs.)

NOTICE: Insert the stoppers of the rear stabilizer control tube No.2 into the rear stabilizer control cylinder.





e. Install the stabilizer control valve protector with the 3 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
31. BLEED SUSPENSION FLUID
SST 09760-60010
32. CHECK FOR FLUID LEAKS
33. INSTALL FRONT DISC WHEEL
Torque: 112 Nm (1,140 kgf-cm, 83 ft. lbs.)
34. CONNECT STABILIZER BAR FRONT
35. CONNECT STABILIZER BAR REAR
36. STABILIZE SUSPENSION
a. Lower the vehicle.
1. Place the 4 wheels on the ground with the SST connected.

NOTICE:
^ Pay attention to the SST while lowering the vehicle.
^ Ensure that the jack and lift are completely separated from the vehicle.

b. Set charging pressure to within the specified range.
1. Charge suspension fluid with the SST
Specified charging pressure:
2.60 to 3.00 MPa at 20°C (68°F) (Fluid temperature)
2.90 to 3.40 MPa at 35°C (95°F) (Fluid temperature)
c. Stabilize the vehicle.
1. Do not perform any operations on the vehicle for 30 seconds or more after charging suspension fluid. The vehicle will stabilize during this time.

37. CHECK SUSPENSION FLUID PRESSURE
a. Check the suspension fluid pressure.
38. MEASURE VEHICLE HEIGHT
Refer to Alignment; Service and Repair.
39. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1
40. INSTALL SPARE DISC WHEEL
41. INSTALL STEP SUB-ASSEMBLY LH
42. INSTALL BATTERY
43. INSTALL RADIATOR SUPPORT SEAL UPPER