Installation

SUSPENSION CONTROL: STABILIZER CONTROL VALVE (w/ KDSS):

INSTALLATION

1. INSTALL STABILIZER CONTROL WITH BRACKET VALVE ASSEMBLY






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






(b) Connect the 2 connectors.
2. INSTALL NO. 1 AND NO. 2 FRONT STABILIZER CONTROL TUBE
(a) Install the No. 1 and No. 2 front stabilizer control tubes.
(1) Apply suspension fluid to the threads of the flare nuts.
(2) Temporarily tighten the 6 flare nuts on the No. 1 and No. 2 front stabilizer control tubes.
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-lbf)
(c) Using a union nut wrench, fully tighten the 6 flare nuts on the No. 1 and No. 2 front stabilizer control tubes.
Torque: 44 Nm (450 kgf-cm, 33 ft-lbf)









(d) Install the front stabilizer tube protector with the 2 bolts.
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
3. INSTALL REAR STABILIZER CONTROL TUBE
(a) Install the No. 1 and No. 2 rear stabilizer control tubes.
(1) Apply suspension fluid to the threads of the flare nuts.
(2) Temporarily tighten the 4 flare nuts on the No. 1 rear stabilizer control tube.
NOTICE:
- Ensure that the control tubes do 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-lbf)
(c) Using a union nut wrench, fully tighten the 4 flare nuts on the No. 1 and No. 2 rear stabilizer control tubes.
Torque: 44 Nm (450 kgf-cm, 33 ft-lbf)









(d) Install the No. 2 rear stabilizer tube 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-lbf)
NOTE: Insert the stoppers of the No. 2 rear stabilizer control tube 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-lbf)
4. BLEED SUSPENSION FLUID
(a) Fill the reservoir tank of the SST with suspension fluid.
Fluid:
Suspension fluid AHC
SST: 09760-60010






(b) Connect the SST joints to the oil nozzle valves.
HINT: The SST joints can be connected to either of the oil nozzle valves.





(c) Loosen the 2 stabilizer control adapter shutter valves.
Distance between A and B:
15 to 16.5 mm(0.60 to 0.65 in.) or less
- Do not excessively loosen the valves.
- Ensure that all bleeder plugs are tightened.





(d) Set a wrench, vinyl tube and reservoir tank to the bleeder plug.
HINT: Perform the following refill and air bleeding procedures in the same way for each bleeder plug.

(e) Bleed any air out of the suspension fluid between the SST and stabilizer control with bracket valve assembly.
(1) Boost the fluid pressure to 5 MPa, loosen the bleeder plug, bleed air and tighten the plug.
Torque: 9.5 Nm (97 kgf-cm, 84 in-lbf)





(2) Perform the procedure for A shown in the illustration first, then for B.
(f) Add suspension fluid to each unit.
(1) Loosen the bleeder plug, add suspension fluid until air stops coming out and tighten the bleeder plug.





Torque: 9.5 Nm (97 kgf-cm, 84 in-lbf)
NOTE: Perform the operations in the following order: A, B, C, D, E and F. (Refer to the illustration above.)
(2) Ensure that only 1 bleeder plug is loose when adding suspension fluid.





(3) Perform the procedures with the front and rear cylinders fully stretched downward.
Length of cylinder:
A
411.5 to 417.5 mm (16.20 to 16.44 in.)
B
436.5 to 442.5 mm (17.19 to 17.42 in.)
(g) Bleed any air out of the suspension fluid in each unit.
(1) Boost the fluid pressure to 7 MPa, loosen the bleeder plug, bleed air and tighten the plug. Repeat the procedure until air stops coming out.
Torque: 9.5 Nm (97 kgf-cm, 84 in-lbf)
NOTICE:
- Do not boost the fluid pressure to 8 MPa or more.
- Perform the operations in the following order: A, B, C, D, E and F. (Refer to the illustration above.)
(2) The procedure is complete when air does not come out twice in succession.





(3) Perform the procedures with the front and rear cylinders fully stretched downward.
Length of cylinder:
A
411.5 to 417.5 mm (16.20 to 16.44 in.)
B
436.5 to 442.5 mm (17.19 to 17.42 in.)
5. INSPECT FLUID LEAK Suspension Control System (w/ KDSS)

6. INSTALL FRONT DISC WHEEL
Torque: 112 Nm (1,140 kgf-cm, 83 ft-lbf)
7. CONNECT STABILIZER BAR FRONT Installation

8. CONNECT STABILIZER BAR REAR Installation

9. STABILIZE SUSPENSION
10. INSPECT SUSPENSION FLUID PRESSURE
(a) Check the suspension fluid pressure.
11. MEASURE VEHICLE HEIGHT Service and Repair

12. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
13. INSTALL SPARE DISC WHEEL
14. INSTALL STEP SUB-ASSEMBLY LH Removal

15. INSTALL BATTERY
16. REMOVE UPPER RADIATOR SUPPORT SEAL