STABILIZER CONTROL VALVE (w/ KDSS) INSTALLATION


  1. INSTALL STABILIZER CONTROL WITH ACCUMULATOR HOUSING ASSEMBLY


    1. Install the stabilizer control with accumulator housing with the 3 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    2. Connect the connector, and then attach the clamp to the hole of the bracket.

  2. CONNECT FRONT NO. 1 STABILIZER CONTROL TUBE ASSEMBLY


    1. Temporarily install the 2 flare nuts on the front No. 1 stabilizer control tube assembly.

    2. A01DUNX

      Using a union nut wrench, tighten the 2 flare nuts on the front No. 1 stabilizer control tube assembly.

      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  3. CONNECT REAR NO. 1 STABILIZER CONTROL TUBE ASSEMBLY


    1. Temporarily install the 2 flare nuts on the rear No. 1 stabilizer control tube assembly.

    2. A01DOIH

      Connect the rear No. 1 stabilizer control tube assembly with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    3. Using a union nut wrench, tighten the 2 flare nuts on the rear stabilizer control tubes.

      Torque:
      44 N*m  { 450 kgf*cm, 33 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  4. BLEED AIR FROM SUSPENSION FLUID

    CAUTION:


    • Be sure to check the pipe connections and whether or not any hydraulic circuit parts are damaged before performing work as the hydraulic circuits become highly pressurized during air bleeding.

    • The pipes become highly pressurized when bleeding air. If a fluid leak is discovered, immediately release the pressure and repair the fluid leak as there is danger involved.

    Tech Tips

    When bleeding air, approximately 6 liters of new fluid is needed.


    1. Remove the stabilizer control valve protector Click here.

    2. Check the pipe connections and whether or not any hydraulic circuit parts are damaged.

      A01DME7E01
      Text in Illustration
      *1 Stabilizer Control with Accumulator Housing Bleeder Plug *2 Upper Chamber Stabilizer Control with Accumulator Housing Shutter Valve
      *3 Lower Chamber Stabilizer Control with Accumulator Housing Shutter Valve *4 Stabilizer Control Accumulator Housing Inlet Port
      *5 Front Stabilizer Control Cylinder Upper Chamber Bleeder Plug *6 Front Stabilizer Control Cylinder Lower Chamber Bleeder Plug
      *7 Rear Stabilizer Control Cylinder Upper Chamber Bleeder Plug *8 Rear Stabilizer Control Cylinder Lower Chamber Bleeder Plug

    3. Add new fluid to SST (high pressure oil pump) and bleed air from SST hoses.

      SST
      09760-60020
      Fluid
      Suspension fluid AHC

      Note

      If air is not bled from the hoses, the air will mix into the hydraulic circuit.

    4. Remove the service valve cap. Then put fluid into SST (high pressure oil pump) and connect SST to the suspension fluid inlet port.

    5. Loosen the shutter valves of the stabilizer control with accumulator housing.

      A01DMU0E02
      Text in Illustration
      *1 Stabilizer Control with Accumulator Housing Assembly *2 Upper Chamber Stabilizer Control with Accumulator Housing Shutter Valve
      *3 Lower Chamber Stabilizer Control with Accumulator Housing Shutter Valve *4 Stabilizer Control Accumulator Housing Inlet Port

      Note


      • When loosening a shutter valve, loosen it 1 to 2.5 turns, but do not loosen it any more than that.

      • As air may enter the system or fluid may spray out, do not remove the shutter valves.

    6. Using SST (high pressure oil pump), add fluid.

      CAUTION:

      If a fluid leak is discovered, immediately release the pressure and repair the fluid leak as there is danger involved due to the high pressure.

      Note

      Do not allow the pressure to reach 8 MPa (81.6 kgf/cm2, 1160 psi) or higher as the accumulator may be damaged.


      1. Pump SST (high pressure oil pump) to add fluid until the pressure reaches 5 MPa (51.0 kgf/cm2, 725 psi).*1

      2. Check for fluid leaks from the pipe connections and hydraulic circuit parts.

      3. A01DN0O

        Add fluid to the stabilizer control with accumulator housing.*2


        1. Loosen the bleeder plug of the stabilizer control with accumulator housing.

        2. Pump SST (high pressure oil pump) and maintain a pressure of 5 MPa (51.0 kgf/cm2, 725 psi) until air stops coming out.

        3. Tighten the bleeder plug of the stabilizer control with accumulator housing.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }
      4. A01DM36

        Add fluid to the lower chamber of the front stabilizer control cylinder.*3


        1. Pump SST (high pressure oil pump) to add fluid until the pressure reaches 5 MPa (51.0 kgf/cm2, 725 psi).

        2. Loosen the lower chamber bleeder plug of the front stabilizer control cylinder.

        3. Pump SST (high pressure oil pump) and maintain a pressure of 5 MPa (51.0 kgf/cm2, 725 psi) until air stops coming out.

        4. Tighten the lower chamber bleeder plug of the front stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
      5. A01DPEI

        Add fluid to the upper chamber of the front stabilizer control cylinder.*4


        1. Pump SST (high pressure oil pump) to add fluid until the pressure reaches 5 MPa (51.0 kgf/cm2, 725 psi).

        2. Loosen the upper chamber bleeder plug of the front stabilizer control cylinder.

        3. Pump SST (high pressure oil pump) and maintain a pressure of 5 MPa (51.0 kgf/cm2, 725 psi) until air stops coming out.

        4. Tighten the upper chamber bleeder plug of the front stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
      6. A01DRRZ

        Add fluid to the lower chamber of the rear stabilizer control cylinder.*5


        1. Pump SST (high pressure oil pump) to add fluid until the pressure reaches 5 MPa (51.0 kgf/cm2, 725 psi).

        2. Loosen the lower chamber bleeder plug of the rear stabilizer control cylinder.

        3. Pump SST (high pressure oil pump) and maintain a pressure of 5 MPa (51.0 kgf/cm2, 725 psi) until air stops coming out.

        4. Tighten the lower chamber bleeder plug of the rear stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
      7. A01DQYY

        Add fluid to the upper chamber of the rear stabilizer control cylinder.*6


        1. Pump SST (high pressure oil pump) to add fluid until the pressure reaches 5 MPa (51.0 kgf/cm2, 725 psi).

        2. Loosen the upper chamber bleeder plug of the rear stabilizer control cylinder.

        3. Pump SST (high pressure oil pump) and maintain a pressure of 5 MPa (51.0 kgf/cm2, 725 psi) until air stops coming out.

        4. Tighten the upper chamber bleeder plug of the rear stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

      8. Repeat procedures *1 to *6 until the air in the fluid is gone.

    7. Using SST (high pressure oil pump), bleed the air.

      Note


      • Be sure to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure to all parts. If the pressure is low, the air may not be released.

      • Do not allow the pressure to reach 8 MPa (81.6 kgf/cm2, 1160 psi) or higher as the accumulator may be damaged.


      1. Bleed air from the stabilizer control with accumulator housing.


        1. Pump SST (high pressure oil pump) to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure.

        2. Loosen the bleeder plug of the stabilizer control with accumulator housing to bleed the air.

        3. Tighten the bleeder plug so pressure can be applied. Repeat these steps until the air in the fluid is gone.

        4. Tighten the bleeder plug of the stabilizer control with accumulator housing.

        Torque:
        8.3 N*m  { 85 kgf*cm, 73 in.*lbf }

      2. Bleed air from the upper chamber of the front stabilizer control cylinder.


        1. Pump SST (high pressure oil pump) to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure.

        2. Loosen the upper chamber bleeder plug of the front stabilizer control cylinder to bleed the air.

        3. Tighten the bleeder plug so pressure can be applied. Repeat these steps until the air in the fluid is gone.

        4. Tighten the upper chamber bleeder plug of the front stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

      3. Bleed air from the upper chamber of the rear stabilizer control cylinder.


        1. Pump SST (high pressure oil pump) to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure.

        2. Loosen the upper chamber bleeder plug of the rear stabilizer control cylinder to bleed the air.

        3. Tighten the bleeder plug so pressure can be applied. Repeat these steps until the air in the fluid is gone.

        4. Tighten the upper chamber bleeder plug of the rear stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
    8. A01DP2AE01

      Disconnect the front stabilizer control arm and front stabilizer link, and set the front stabilizer control cylinder to the maximum length.

      Maximum length
      411.5 to 417.5 mm (16.2 to 16.4 in.)

      Note

      Set the front stabilizer control cylinder to the maximum length to completely bleed the air.

      Tech Tips

      Refer to the following procedures to disconnect the front stabilizer control arm and front stabilizer link Click here.

    9. A01DRVRE01

      Disconnect the rear stabilizer bar and rear stabilizer link, and set the rear stabilizer control cylinder to the maximum length.

      Maximum length
      386.5 to 392.5 (15.2 to 15.4 in.)

      Note

      Set the rear stabilizer control cylinder to the maximum length to completely bleed the air.

      Tech Tips

      Refer to the following procedures to disconnect the rear stabilizer bar and rear stabilizer link Click here.

    10. Bleed air from the lower chamber of the front stabilizer control cylinder.


      1. Pump SST (high pressure oil pump) to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure.

      2. Loosen the lower chamber bleeder plug of the front stabilizer control cylinder to bleed the air.

      3. Tighten the bleeder plug so pressure can be applied. Repeat these steps until the air in the fluid is gone.

      4. Tighten the lower chamber bleeder plug of the front stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

    11. Bleed air from the lower chamber of the rear stabilizer control cylinder.


      1. Pump SST (high pressure oil pump) to apply 7 MPa (71.4 kgf/cm2, 1015 psi) of pressure.

      2. Loosen the lower chamber bleeder plug of the rear stabilizer control cylinder to bleed the air.

      3. Tighten the bleeder plug so pressure can be applied. Repeat these steps until the air in the fluid is gone.

      4. Tighten the lower chamber bleeder plug of the rear stabilizer control cylinder.

        Torque:
        7.9 N*m  { 81 kgf*cm, 70 in.*lbf }

    12. Connect the front stabilizer control arm to the front stabilizer link and the rear stabilizer bar to the rear stabilizer link.

      Tech Tips


      • For the front side, refer to the following procedures Click here.

      • For the rear side, refer to the following procedures Click here.

    13. With all wheels on the ground, apply the specified amount of pressure using SST. Maintain this pressure for 2 to 3 minutes to stabilize the pressure.

      Note


      • Refer to the Temperature Management Chart when Filling Fluid as the specified pressure changes according to the fluid temperature.

      • Perform the inspection with the vehicle load completely on the suspension.

      Tech Tips


      • Perform this step with the fuel tank full.

      • If there are any parts installed to the vehicle which place any unbalanced load on the left or right side of the vehicle, remove them.

      Standard Fluid Pressure
      Condition Specified Condition
      Fluid temperature is 20°C (68°F)

      2.6 to 3 MPa (26.6 to 30.5 kgf/cm2, 377 to 435 psi)

    14. Measure vehicle height Click here.

    15. Tighten the shutter valves of the stabilizer control with accumulator housing.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    16. Remove SST (high pressure oil pump) from the suspension fluid inlet port.

      Note

      Make sure that no pressure is applied to SST (high pressure oil pump).

    17. Install the service valve caps to the suspension fluid inlet port.

      Torque:
      0.6 N*m  { 6.0 kgf*cm, 5.0 in.*lbf }

    18. Inspect for suspension fluid leaks Click here.

    19. Install the stabilizer control valve protector Click here.

  5. APPLY PRESSURE ACCORDING TO TEMPERATURE MANAGEMENT CHART WHEN FILLING FLUID

    A01DTBYE01
    Text in Illustration
    *1

    2.42 MPa (24.7 kgf/cm2, 351 psi)

    		 *2

    2.50 MPa (25.5 kgf/cm2, 363 psi)
    *3

    2.59 MPa (26.4 kgf/cm2, 376 psi)

    		 *4

    2.67 MPa (27.2 kgf/cm2, 387 psi)
    *5

    2.76 MPa (28.1 kgf/cm2, 400 psi)

    		 *6

    2.85 MPa (29.1 kgf/cm2, 413 psi)
    *7

    2.95 MPa (30.1 kgf/cm2, 428 psi)

    		 *8

    3.05 MPa (31.1 kgf/cm2, 442 psi)
    *9

    3.27 MPa (33.3 kgf/cm2, 474 psi)

    		 *10

    3.27 MPa (33.3 kgf/cm2, 474 psi)
    *11

    3.38 MPa (34.5 kgf/cm2, 490 psi)

    		 *12

    2.39 MPa (24.4 kgf/cm2, 347 psi)
    *13

    2.46 MPa (25.1 kgf/cm2, 357 psi)

    		 *14

    2.53 MPa (25.8 kgf/cm2, 367 psi)
    *15

    2.60 MPa (26.5 kgf/cm2, 377 psi)

    		 *16

    2.67 MPa (27.2 kgf/cm2, 387 psi)
    *17

    2.75 MPa (28.0 kgf/cm2, 399 psi)

    		 *18

    2.82 MPa (28.8 kgf/cm2, 409 psi)
    *19

    2.90 MPa (29.6 kgf/cm2, 421 psi)

    		 *20

    2.98 MPa (30.4 kgf/cm2, 432 psi)
    *21

    3.06 MPa (31.2 kgf/cm2, 444 psi)

    		 *22

    3.14 MPa (32.0 kgf/cm2, 455 psi)

  6. INSPECT FOR SUSPENSION FLUID LEAK

    CAUTION:

    Fluid is pumped into the system at a high pressure of approximately 3 MPa (30.6 kgf/cm2, 435 psi). If a fluid leak is discovered, immediately release the pressure and repair the fluid leak.


    1. Perform a driving test.

    2. Check for fluid leakage from the parts and connections shown in the illustration.

      A01DNPA
      A01DUP8E01

  7. MEASURE VEHICLE HEIGHT

    Note


    • Perform the inspection on a level surface.

    • Make sure that the wheels are on the ground and facing straight ahead.

    • Perform the inspection with the vehicle load completely on the suspension.

    Tech Tips


    • Perform this step with the fuel tank full.

    • If there are any parts installed to the vehicle which place any unbalanced load on the left or right side of the vehicle, remove them.


    1. Set the tire pressure to the specified value(s) Click here.

    2. Bounce the vehicle to stabilize the suspension.

    3. A01DS6I

      Measure the distance from the ground to the top of the bumper and calculate the difference in the vehicle height between the left and right sides. Perform this procedure for both the front and rear wheels.

      Height difference of left and right sides
      20 mm (0.787 in.) or less

      Tech Tips

      When the difference in vehicle height between the left and right sides is outside of the specification, perform air bleeding Click here.

  8. INSTALL STABILIZER CONTROL VALVE PROTECTOR


    1. Install the stabilizer control valve protector with the 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  9. INSTALL SIDE STEP ASSEMBLY LH


    1. Install the side step with the 6 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. w/ Illumination:

      Connect the 2 connectors.

  10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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