Land Cruiser URJ200 URJ202 GRJ200 VDJ200 - REAR SUSPENSION

INSTALL HOLLOW SPRING SUB-ASSEMBLY

INSTALL REAR COIL SPRING LH

TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY LH

TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY RH

TEMPORARILY INSTALL REAR LATERAL CONTROL ROD ASSEMBLY

CONNECT REAR FLEXIBLE HOSE

STABILIZE SUSPENSION

TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH

TIGHTEN REAR SHOCK ABSORBER ASSEMBLY RH

TIGHTEN REAR LATERAL CONTROL ROD ASSEMBLY

INSTALL REAR STABILIZER END BRACKET (w/ KDSS)

CONNECT REAR STABILIZER LINK ASSEMBLY (w/ KDSS)

INSTALL REAR STABILIZER END BRACKET LH (w/o KDSS)

INSTALL REAR STABILIZER END BRACKET RH (w/o KDSS)

CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY

CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

CONNECT REAR AXLE BREATHER HOSE SUB-ASSEMBLY

BLEED BRAKE LINE

MEASURE VEHICLE HEIGHT (w/ KDSS)

CLOSE STABILIZER CONTROL WITH ACCUMULATOR HOUSING SHUTTER VALVE (w/ KDSS)

INSTALL STABILIZER CONTROL VALVE PROTECTOR (w/ KDSS)

REAR COIL SPRING - INSTALLATION

HINT:

Use the same procedures for the RH side and LH side.

The procedures listed below are for the LH side.

A bolt without a torque specification is shown in the standard bolt chart ().

1. INSTALL HOLLOW SPRING SUB-ASSEMBLY

Install the hollow spring to the frame.

2. INSTALL REAR COIL SPRING LH

Rear Coil Spring - Installation. REAR SUSPENSION. Land Cruiser URJ200 URJ202 GRJ200 VDJ200

Install the coil spring.

HINT:

Before installing the coil spring, check that the coil spring end is in the correct position. If not, reinstall it.

3. TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY LH

Temporarily install the lower side of the shock absorber with the bolt.

4. TEMPORARILY INSTALL REAR SHOCK ABSORBER ASSEMBLY RH

Temporarily install the lower side of the shock absorber with the bolt.

5. TEMPORARILY INSTALL REAR LATERAL CONTROL ROD ASSEMBLY

Temporarily install the lateral control rod with the nut and bolt.

6. CONNECT REAR FLEXIBLE HOSE

Connect the flexible hose to the connecting point with each brake tube, and then install 2 new clips.

Using a union nut wrench, connect each brake tube to the flexible hose while holding the flexible hose with a wrench.

Torque:
without union nut wrench:
15 N*m{ 155 kgf*cm, 11 ft.*lbf}
with union nut wrench:
14 N*m{ 145 kgf*cm, 10 ft.*lbf}

NOTICE:

Do not bend or damage the brake tube.

Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point.

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.

Connect the flexible hose to the connecting point with each brake tube, and then install 2 new clips.

Using a union nut wrench, connect each brake tube to the flexible hose while holding the flexible hose with a wrench.

Torque:
without union nut wrench:
15 N*m{ 155 kgf*cm, 11 ft.*lbf}
with union nut wrench:
14 N*m{ 145 kgf*cm, 10 ft.*lbf}

NOTICE:

Do not bend or damage the brake tube.

Do not allow any foreign matter such as dirt and dust to enter the brake tube from the connecting point.

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.

7. STABILIZE SUSPENSION

Install the rear 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.

8. TIGHTEN REAR SHOCK ABSORBER ASSEMBLY LH

Tighten the bolt.

Torque:
98 N*m{ 999 kgf*cm, 72 ft.*lbf}

NOTICE:

Perform this procedure with all 4 wheels on the ground.

9. TIGHTEN REAR SHOCK ABSORBER ASSEMBLY RH

Tighten the bolt.

Torque:
98 N*m{ 999 kgf*cm, 72 ft.*lbf}

NOTICE:

Perform this procedure with all 4 wheels on the ground.

10. TIGHTEN REAR LATERAL CONTROL ROD ASSEMBLY

Tighten the nut.

Torque:
150 N*m{ 1530 kgf*cm, 111 ft.*lbf}

NOTICE:

Perform this procedure with all 4 wheels on the ground.

11. INSTALL REAR STABILIZER END BRACKET (w/ KDSS)

Install the stabilizer end bracket with the 2 bolts.

Torque:
30 N*m{ 306 kgf*cm, 22 ft.*lbf}

12. CONNECT REAR STABILIZER LINK ASSEMBLY (w/ KDSS)

Install the stabilizer link assembly to the ball joint dust cover protector.

Connect the stabilizer link to the stabilizer bar with the nut.

Torque:
100 N*m{ 1020 kgf*cm, 74 ft.*lbf}

HINT:

If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.

If the rear stabilizer control cylinder extends and it is difficult to temporarily install the stabilizer link to the stabilizer bar, raise the stabilizer control arm with a jack and temporarily install the stabilizer link.

13. INSTALL REAR STABILIZER END BRACKET LH (w/o KDSS)

Connect the stabilizer end bracket with the 2 bolts.

Torque:
36 N*m{ 367 kgf*cm, 27 ft.*lbf}

14. INSTALL REAR STABILIZER END BRACKET RH (w/o KDSS)

Connect the stabilizer end bracket with the 2 bolts.

Torque:
36 N*m{ 367 kgf*cm, 27 ft.*lbf}

15. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY

Connect the No. 3 parking brake cable with the bolt.

Torque:
13 N*m{ 127 kgf*cm, 9 ft.*lbf}

16. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

Connect the No. 2 parking brake cable with the bolt.

Torque:
13 N*m{ 127 kgf*cm, 9 ft.*lbf}

17. CONNECT REAR AXLE BREATHER HOSE SUB-ASSEMBLY

Connect the breather hose to the rear axle housing.

18. BLEED BRAKE LINE

Turn the ignition switch to ON.

Remove the brake master cylinder reservoir filler cap assembly.

Add brake fluid until the fluid level is between the MIN and MAX lines of the reservoir.

Repeatedly depress the brake pedal and bleed air from the bleeder plug of the front disc brake cylinder RH.

Repeat the step above until the air is completely bled, and then tighten the bleeder plug while depressing the brake pedal.

Torque:
11 N*m{ 110 kgf*cm, 8 ft.*lbf}

Bleed the air from the bleeder plug of the front disc brake cylinder LH using the same procedure as for the RH side.

With the brake pedal depressed, loosen the bleeder plug of the rear disc brake cylinder RH, continue to hold the brake pedal and allow brake fluid to be drained from the bleeder plug while the pump motor operates.

HINT:

Air is bled as the pump motor operates while the brake pedal is being depressed.

Be sure to release the brake pedal to stop the motor after approximately 100 seconds of continuous operation.

As brake fluid is continuously drained while the pump operates, it is not necessary to repeatedly depress the brake pedal.

When there is no more air in the brake fluid, tighten the bleeder plug, and then release the brake pedal.

Torque:
11 N*m{ 110 kgf*cm, 8 ft.*lbf}

Bleed the air from the bleeder plug of the rear disc brake cylinder LH using the same procedure as for the RH side.

Turn the ignition switch off.

Inspect for brake fluid leaks.

Check and adjust the brake fluid level ().

Clear the DTCs ().

19. MEASURE VEHICLE HEIGHT (w/ KDSS)

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.

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.