Up to 08/2009

REAR SUSPENSION: REAR PNEUMATIC CYLINDER: INSTALLATION

HINT
* Use the same procedure for the RH side and LH side.
* The procedure listed below is for the LH side.
1. INSTALL REAR PNEUMATIC CYLINDER COVER

(a) Temporarily install the rear pneumatic cylinder cover to the rear pneumatic cylinder.

NOTICE:
If the rear pneumatic cylinder cover is damaged or punctured, replace it with a new one.

(b) Set the rear pneumatic cylinder cover in the installing position as shown in the illustration.

Text in Illustration

NOTICE:
Position the clamping joints between points A and B as shown in the illustration.

(d) Cut the surplus of the rear height control cover bands as shown in the illustration.

(e) Temporarily install the pneumatic chamber bracket to the rear pneumatic cylinder with the 3 nuts.

(f) Using a wooden block, hold the pneumatic chamber bracket between aluminium plates in a vise as shown in the illustration.

Text in Illustration

(g) Fully tighten the 3 nuts.

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf)

(h) Install the bracket cover to the pneumatic chamber bracket with the 4 clips.

(i) Check that the rear pneumatic cylinder cover is not deformed or collapsed inward.

2. INSTALL HEIGHT CONTROL PLUG

(a) Install the height control plug to the rear pneumatic cylinder assembly.

3. INSTALL REAR SPRING SET PLATE

(a) Install the rear spring set plate to the rear No. 2 suspension arm assembly.

NOTICE:
When installing the rear spring set plate, first insert the positioning pin into each hole.

4. INSTALL REAR PNEUMATIC CYLINDER ASSEMBLY

(a) Install 2 new O-ring, a new plate, a new No. 2 connector to the rear pneumatic cylinder assembly.

NOTICE:
Perform this procedure when reusing the rear pneumatic cylinder assembly.

HINT
For the installing procedure of the tube (type 2), refer to Precaution of Suspension Control System Suspension Control System.

(b) Install the rear pneumatic cylinder assembly to the rear No. 2 suspension arm assembly with the nut.

Text in Illustration

Torque : 80 Nm (816 kgf-cm, 59 ft-lbf)

NOTICE:
When installing the rear pneumatic cylinder assembly, first insert the positioning pin into the hole.

(c) Jack up the rear axle assembly to install the rear pneumatic cylinder assembly, placing a wooden block underneath to avoid damage.

Text in Illustration

(d) Temporarily install the rear pneumatic cylinder assembly to the body with the 3 bolts, and then fully tighten the 2 bolt (A).

Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

(e) Using SST and a socket wrench, fully tighten the bolt (B).

Text in Illustration

SST : 09961-00950

without SST - Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

with SST - Torque : 35 Nm (355 kgf-cm, 26 ft-lbf)

NOTICE:
* Use a torque wrench with a fulcrum length of 345 mm (1.13 ft.).
* This torque value is effective when SST is parallel to the torque wrench.
(f) Slowly lower the rear axle assembly.

(g) Connect the air tube to the rear pneumatic cylinder assembly.

HINT
For the connecting procedure of the tube (type 2), refer to Precaution of Suspension Control System Suspension Control System.

5. INSTALL REAR SUSPENSION ARM COVER Installation

6. INSTALL REAR WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

7. INSPECT FOR AIR LEAK

(a) Inspect for air leaks Suspension Control System.