Installation (To 08/2009): Installation

HINT: 

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

1. INSTALL FRONT PNEUMATIC CYLINDER INNER COVER 
   1. Install the front pneumatic cylinder inner cover to the front pneumatic with shock absorber cylinder sub-assembly with 2 new height control cover bands.
      Fig 1: Identifying Fixed Point of Clamping Joint

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1	Fixed Point of Clamping Joint

   2. Cut the surplus of the height control cover bands.
2. INSTALL NO. 4 HEIGHT CONTROL TUBE O-RING 

   HINT: 

   It is unnecessary to perform the following procedures if the front pneumatic with shock absorber cylinder assembly has been replaced with a new one.

   1. Lightly coat 2 new O-rings with MP grease No. 2.
   2. Install the 2 new O-rings to the No. 4 height control tube as shown in the illustration.
      Fig 2: Identifying O-ring

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION
      
      

      *1

      O-Ring

3. INSPECT HEIGHT CONTROL TUBE COVER CUSHION 
   1. Visually check the height control tube cover cushion from above.
      Fig 3: Identifying Height Control Tube Cover Cushion

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      OK

      The height control tube cover cushion is not cracked, pinched or misaligned.

      If any abnormality is found, replace the height control tube cover cushion with a new one.

4. INSTALL FRONT PNEUMATIC WITH SHOCK ABSORBER CYLINDER ASSEMBLY 
   1. Temporarily install the front pneumatic with shock absorber cylinder assembly (upper side) with the 3 nuts as shown in the illustration.
      Fig 4: Identifying Nuts And Front Pneumatic With Shock Absorber Cylinder Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the front shock absorber with coil spring (lower side) to the steering knuckle and insert the 2 bolts and 2 nuts.
      Fig 5: Locating Nuts On Lower Side Of Front Shock Absorber

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf) 

      NOTE:

      When installing the nuts, keep the bolts from rotating.

   3. Fully tighten the front pneumatic with shock absorber cylinder assembly (upper side) with the 3 nuts.
      Fig 6: Identifying Nuts And Front Pneumatic With Shock Absorber Cylinder Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

   4. Install the height control clamp to the front pneumatic with shock absorber cylinder assembly.
      Fig 7: Identifying Height Control Clamp And Front Pneumatic With Shock Absorber Cylinder Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. CONNECT NO. 4 HEIGHT CONTROL TUBE 
   1. Install the No. 4 height control tube and height control tube clamp to the front pneumatic with shock absorber cylinder assembly.
      Fig 8: Holding Pneumatic Cylinder Assembly

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure to hold the front pneumatic with shock absorber cylinder chamber by hand.

   2. Tighten the lock nut.
      Fig 9: Connecting Tube With Lock Nut

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf) 

      NOTE:

      Keep the chamber of the front pneumatic with shock absorber cylinder assembly unmoved by holding it by hand.

      HINT: 

      For the connecting procedure of the height control tube (type 1), refer to Precaution of Suspension Control System. Refer to PRECAUTION .

6. INSTALL FRONT STABILIZER LINK ASSEMBLY  See step  10
7. INSTALL FRONT SPEED SENSOR  See step  11
8. INSTALL FRONT WHEEL 

   Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

9. INSPECT FOR AIR LEAK 
   1. Inspect for air leaks. Refer to PRECAUTION .
10. INSTALL FRONT SHOCK ABSORBER CAP 
    1. Install the front shock absorber cap with the 3 nuts.
       Fig 10: Identifying Nuts And Front Shock Absorber Cap

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

       Torque: 14 N*m (143 kgf*cm, 10 ft.*lbf) 

11. INSTALL COWL TOP SILENCER PAD  See step  13
12. STABILIZE SUSPENSION  See step  15
13. ADJUST VEHICLE HEIGHT 
    1. Adjust the vehicle height. Refer to ON-VEHICLE INSPECTION .
14. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 
    1. Inspect and adjust the front wheel alignment. Refer to ADJUSTMENT .