Front Shock Absorber: Installation

WARNING: This page is about a different car, the 2008 Lexus LS 600hL. However, it is still accessible from the selected car via links, so may be relevant.

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 (see SPECIFIED TORQUE FOR STANDARD BOLTS ).

Fig 1: Identifying Damping Force Control Rod Angle (Hard, Medium And Soft)
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSTALL FRONT PNEUMATIC CYLINDER O-RING LH
HINT:

It is unnecessary to perform the following procedures if the pneumatic cylinder with shock absorber has been replaced with a new one.
1. Lightly coat 2 new O-rings with MP grease.
2. Install the 2 new O-rings and a new plate to a straight tube or equivalent, as shown in the illustration.
  
  Fig 2: Identifying O-Rings And Plate To Straight Tube
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Insert the tube end with the 2 O-rings and plate into the front pneumatic cylinder with shock absorber LH Then, lightly push in the O-rings and plate with a thick piece of paper.
4. While holding the O-rings and plate in place with the paper, slowly pull out the tube.
  
  Fig 3: Inserting Tube With O-Rings
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Install a new tube connector.
  NOTE: Push in the tube connector until a "click" sound is heard.
  
  Fig 4: Pushing Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL LOWER FRONT SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH
1. Install the lower front shock absorber bracket sub-assembly LH to the front pneumatic shock absorber with cylinder assembly LH with the bolt.
  Torque: 48 N.m (489 kgf.cm, 35 ft. lbf.)
  
  Fig 5: Locating Lower Front Shock Absorber Bracket Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT PNEUMATIC SHOCK ABSORBER WITH CYLINDER ASSEMBLY LH
1. Install the front pneumatic shock absorber with cylinder assembly LH on the vehicle by installing the 3 nuts on the suspension support side.
  Torque: 67 N.m (683 kgf.cm, 49 ft. lbf.)
  
  Fig 6: Locating Front Pneumatic Shock Absorber With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL ABSORBER CONTROL ACTUATOR
1. Check that the control rod of the front pneumatic shock absorber with cylinder assembly LH is in the position shown in the illustration
  NOTE: If the control rod is not in the position shown in the illustration, turn the control rod to adjust the position and install the absorber control actuator.
  
  Fig 7: Identifying Control Rod Position
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the absorber control actuator to the actuator support bracket. Turn the actuator clockwise approximately 40° until a click is felt.
  NOTE: Do not excessively turn the actuator.
INSTALL FRONT SHOCK ABSORBER CAP LH
1. Connect the connector to the shock absorber control actuator.
  
  Fig 8: Turning Absorber Control Actuator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the shock absorber cap with the 3 nuts
  Torque: 20 N.m (204 kgf.cm, 15 ft. lbf.)
INSTALL ENGINE ROOM SIDE COVER LH (See INSTALLATION )
INSTALL AIR CLEANER INLET COVER SUB-ASSEMBLY (See INSTALLATION )

Fig 9: Locating Front Shock Absorber Cap Nuts
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
TEMPORARILY INSTALL LOWER FRONT SHOCK ABSORBER BRACKET SUB-ASSEMBLY LH
1. Install the lower front shock absorber bracket sub-assembly LH to the front No. 1 suspension lower arm LH
2. Align the protrusion of the front shock absorber upper bracket plate with the cutout of the lower front shock absorber bracket sub-assembly LH, and temporarily install the nut.
  
  Fig 10: Aligning Front Shock Absorber Upper Bracket Plate With Lower Front Shock Absorber Bracket
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the skid control sensor wire to the front pneumatic shock absorber with cylinder assembly LH with the bolt
  NOTE:
  - Do not twist the skid control sensor wire.
  - When installing the bolt, do not deform the front pneumatic shock absorber with cylinder assembly LH.
CONNECT NO. 4 HEIGHT CONTROL TUBE

Fig 11: Locating Skid Control Sensor Wire Bracket Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Connect the No. 4 height control tube to the cylinder.
2. Connect the No. 1 tube connector
INSTALL AIR CONNECTOR CLIP HOLDER
1. Install the air connector clip holder to the No. 1 tube connector.
  
  Fig 12: Installing Air Connector Clip Holder To No. 1 Tube Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT STABILIZER LINK ASSEMBLY LH
1. Install the front stabilizer link with the 2 nuts.
  Torque: 85 N.m (867 kgf.cm, 63 ft. lbf.)
  
  HINT:
  
  If the ball joint turns together with the nut, use a 6 mm hexagon wrench to hold the stud bolt.
  
  Fig 13: Locating Front Stabilizer Link Assembly Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FRONT HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH
1. Install the bracket of the front height control sensor LH to the front No 1 suspension lower arm LH with the bolt
  Torque: 5.4 N.m (55 kgf.cm, 48 in. lbf.)
INSTALL STEERING KNUCKLE SUB-ASSEMBLY LH (See INSTALLATION )
CONNECT FRONT NO. 1 SUSPENSION UPPER ARM ASSEMBLY LH (See INSTALLATION )

Fig 14: Identifying Front No 1 Suspension Lower Arm With Bolt
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FRONT NO. 2 SUSPENSION UPPER ARM ASSEMBLY LH (See INSTALLATION )
CONNECT TIE ROD ASSEMBLY LH (See INSTALLATION )
INSTALL FRONT SPEED SENSOR LH (See INSTALLATION )
CONNECT SKID CONTROL SENSOR WIRE (See INSTALLATION )
INSTALL FRONT DISC BRAKE DUST COVER LH (See INSTALLATION )
INSTALL FRONT DISC (See INSTALLATION )
CONNECT FRONT DISC BRAKE CALIPER ASSEMBLY LH (See INSTALLATION )
INSTALL FRONT AXLE SHAFT NUT LH (See INSTALLATION )
INSTALL SERVICE PLUG GRIP (See INSTALLATION )
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
NOTE: When disconnecting the cable, some systems need to be initialized after the cable is reconnected (see INITIALIZATION ).
INSTALL BATTERY SERVICE HOLE COVER (See INSTALLATION )
INSTALL BATTERY SERVICE HOLE COVER LH (See INSTALLATION )
INSTALL LUGGAGE COMPARTMENT MAT SUB-ASSEMBLY (See INSTALLATION )
STABILIZE SUSPENSION
1. Install the front wheels.
  Torque: 140 N.m (1428 kgf.cm, 103 ft. lbf.)
2. Lower the vehicle and start the engine Then fill the front pneumatic shock absorber with cylinder assembly LH with air.
  HINT:
  
  If the vehicle height is not restored within 2 minutes, stop the engine and then start the engine again
3. Bounce the vehicle up and down several times to stabilize the front suspension.
  
  Fig 15: View Of Front Suspension And Lower Arm
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Remove the front wheels.
  NOTE: Do not turn the power switch ON (IG).
5. Jack up the front suspension lower arm with a wooden block between the jack and front suspension lower arm Apply a load to the front suspension so that the front suspension lower arm is horizontal.
TIGHTEN FRONT SHOCK ABSORBER BRACKET LOWER SUB-ASSEMBLY LH
1. Tighten the lower side nut of the lower front shock absorber bracket sub-assembly LH.
  Torque: 112 N.m (1142 kgf.cm, 83 ft. lbf.)
INSTALL FRONT WHEEL
Torque: 140 N.m (1428 kgf.cm, 103 ft. lbf.)
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
1. Check and adjust the front wheel alignment (see ADJUSTMENT ).
INSPECT FOR AIR LEAK
1. Inspect for air leaks (see OPERATION CHECK ).
CHECK SUSPENSION CONTROL SYSTEM
1. Check the suspension control system (see ADJUSTMENT ).
ADJUST HEADLIGHT ASSEMBLY
1. For LED headlight: Adjust the headlight (see ADJUSTMENT )
2. For HID headlight: Adjust the headlight (see ADJUSTMENT ).
ADJUST OBJECT RECOGNITION CAMERA
1. Adjust the object recognition camera (see ADJUSTMENT ).