Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - FRONT SUSPENSION

FRONT STABILIZER BAR (w/ KDSS) - INSTALLATION

1. INSTALL FRONT NO. 1 SUSPENSION CONTROL BLEEDER PLUG
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the 2 suspension control bleeder plugs to the front stabilizer control cylinder.

  • Torque:
  • 8.3 N*m{ 85 kgf*cm, 73 in.*lbf}
2. INSTALL FRONT STABILIZER CONTROL CYLINDER
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the front stabilizer control cylinder to the frame with the bolt, washer and nut.

  • Torque:
  • 275 N*m{ 2804 kgf*cm, 203 ft.*lbf}
3. CONNECT FRONT NO. 1 STABILIZER CONTROL TUBE ASSEMBLY
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install 2 new gaskets and the front stabilizer control cylinder to the front stabilizer control cylinder with the 2 union bolts.

  • Torque:
  • 69 N*m{ 704 kgf*cm, 51 ft.*lbf}
4. INSTALL EXHAUST CENTER PIPE ASSEMBLY

for 1GR-FE:


Install the center exhaust pipe ().

for 1UR-FE:


Install the center exhaust pipe ().

for 3UR-FE:


Install the center exhaust pipe ().

for 1VD-FTV (w/ DPF):


Install the center exhaust pipe ().

for 1VD-FTV (w/o DPF):


Install the center exhaust pipe ().

5. INSTALL TAILPIPE ASSEMBLY

for 1GR-FE:


Install the tailpipe ().

for 1UR-FE:


Install the tailpipe ().

for 3UR-FE:


Install the tailpipe ().

for 1VD-FTV (w/ DPF):


Install the tailpipe ().

for 1VD-FTV (w/o DPF):


Install the tailpipe ().

6. INSTALL STABILIZER CONTROL TUBE PROTECTOR

Install the tube protector with the 2 bolts.

  • Torque:
  • 15 N*m{ 152 kgf*cm, 11 ft.*lbf}
7. TEMPORARILY INSTALL FRONT STABILIZER CONTROL ARM ASSEMBLY
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the stabilizer control arm to the front stabilizer control cylinder with the nut and bolt.

8. BLEED AIR FROM SUSPENSION FLUID

Bleed the air from the suspension fluid ().

9. INSTALL FRONT NO. 1 STABILIZER BAR BUSH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the 2 bushes to the outer side of the bush stoppers on the front stabilizer bar as shown in the illustration.

  • NOTICE:
  • Be sure to install the front No. 1 stabilizer bar bushes so that the bump of each bush faces the inside of the vehicle.
10. TEMPORARILY INSTALL FRONT STABILIZER BAR
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Set the stabilizer bracket so that the arrow mark is facing the front side of the vehicle.

Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the 2 stabilizer brackets and front stabilizer bar with the 4 bolts.

Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the front stabilizer bar to the stabilizer control arm with the bolt and nut.

11. TEMPORARILY INSTALL FRONT STABILIZER LINK ASSEMBLY RH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the stabilizer link with the bolt.

Temporarily install the stabilizer link with the nut.

Tighten the nut.

  • Torque:
  • 128 N*m{ 1305 kgf*cm, 94 ft.*lbf}
  • HINT:
  • If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.
12. TEMPORARILY INSTALL FRONT STABILIZER LINK ASSEMBLY LH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the stabilizer link to the lower arm with the bolt.

Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Temporarily install the stabilizer link to the stabilizer control arm with the bolt and nut.

  • HINT:
  • If the front stabilizer control cylinder extends and it is difficult to temporarily install the stabilizer link to the stabilizer control arm, raise the stabilizer control arm with a jack and temporarily install the stabilizer link.
13. TIGHTEN FRONT NO. 1 STABILIZER BRACKET LH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the 2 bolts of the front stabilizer brackets.

  • Torque:
  • 87 N*m{ 887 kgf*cm, 64 ft.*lbf}
  • NOTICE:
  • Tighten the bolts in 3 steps, in the order shown in the illustration.
14. TIGHTEN FRONT NO. 1 STABILIZER BRACKET RH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the 2 bolts of the front stabilizer brackets.

  • Torque:
  • 87 N*m{ 887 kgf*cm, 64 ft.*lbf}
  • NOTICE:
  • Tighten the bolts in 3 steps, in the order shown in the illustration.
15. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

Install the No. 1 engine under cover sub-assembly with the 10 bolts.

  • Torque:
  • 29 N*m{ 296 kgf*cm, 21 ft.*lbf}
16. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

Push in the clip to install the front fender splash shield sub-assembly LH.

Install the 3 bolts and screw.

17. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

Push in the clip to install the front fender splash shield sub-assembly RH.

Install the 3 bolts and 2 screws.

18. STABILIZE SUSPENSION

Install the front wheels.

  • Torque:
  • for aluminum wheel:
  • 131 N*m{ 1336 kgf*cm, 97 ft.*lbf}
  • for steel wheel:
  • 209 N*m{ 2131 kgf*cm, 154 ft.*lbf}

Lower the vehicle.

Press down on the vehicle several times to stabilize the suspension.

19. TIGHTEN FRONT STABILIZER LINK ASSEMBLY LH
  • NOTICE:
  • Perform this procedure with all 4 wheels on the ground.
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the bolt.

  • Torque:
  • 135 N*m{ 1377 kgf*cm, 100 ft.*lbf}

Tighten the nut.

  • Torque:
  • 140 N*m{ 1428 kgf*cm, 103 ft.*lbf}
20. TIGHTEN FRONT STABILIZER LINK ASSEMBLY RH
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the bolt.

  • Torque:
  • 135 N*m{ 1376 kgf*cm, 100 ft.*lbf}
  • NOTICE:
  • Perform this procedure with all 4 wheels on the ground.
21. TIGHTEN FRONT STABILIZER CONTROL ARM ASSEMBLY
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the nut.

  • Torque:
  • 190 N*m{ 1937 kgf*cm, 140 ft.*lbf}
  • NOTICE:
  • Perform this procedure with all 4 wheels on the ground.
22. TIGHTEN FRONT STABILIZER BAR
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Tighten the nut.

  • Torque:
  • 230 N*m{ 2345 kgf*cm, 170 ft.*lbf}
  • NOTICE:
  • Perform this procedure with all 4 wheels on the ground.
23. INSTALL FRONT FENDER APRON TRIM PACKING D
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the apron trim packing with the 4 clips.

24. INSTALL FRONT FENDER APRON TRIM PACKING B
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the apron trim packing with the 3 clips.

25. INSPECT FOR SUSPENSION FLUID LEAK

Check that the union nuts shown in the illustration are tightened to the specified torque.

  • Torque:
  • without union nut wrench:
  • 15 N*m{ 155 kgf*cm, 11 ft.*lbf}
  • with union nut wrench:
  • 14 N*m{ 143 kgf*cm, 10 ft.*lbf}
  • HINT:
Use a torque wrench with a fulcrum length of 300 mm (11.8 in.).
The torque value for use with a union nut wrench is effective when the union nut wrench is parallel to the torque wrench.

Check for fluid leakage from the parts and connections.

Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

  • HINT:
  • For union nuts and union bolts not shown in the illustration, refer to the installation procedures for each title.
26. MEASURE VEHICLE HEIGHT
  • NOTICE:
Perform the inspection on a level surface.
Ensure that the wheels are on the ground and facing straight ahead.
Perform the inspection with the vehicle load completely on the suspension.
  • HINT:
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.

Set the tire pressure to the specified value(s) ().

Bounce the vehicle to stabilize the suspension.

Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

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

  • Height difference of left and right sides:
  • 15 mm (0.591 in.) or less
  • HINT:
  • If not as specified, perform the vehicle tilt calibration.
27. CLOSE STABILIZER CONTROL WITH ACCUMULATOR HOUSING SHUTTER VALVE
  • NOTICE:
Perform the inspection on a level surface.
Ensure that the wheels are on the ground and facing straight ahead.
Perform the inspection with the vehicle load completely on the suspension.
  • HINT:
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.

Using a 5 mm hexagon socket wrench, tighten the lower and upper chamber shutter valves of the stabilizer control with accumulator housing.

  • Torque:
  • 14 N*m{ 143 kgf*cm, 10 ft.*lbf}
28. INSTALL STABILIZER CONTROL VALVE PROTECTOR
Front Stabilizer Bar (W/ Kdss) - Installation. FRONT SUSPENSION. Land Cruiser URJ200  URJ202 GRJ200 VDJ200

Install the valve protector with the 3 bolts.

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

Attach the clamp, and connect the connector to the valve protector.

29. INSPECT FOR EXHAUST GAS LEAK

If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.