Active Height Control & Adaptive Variable Suspension: Removal & Installation Lexus LX J100

REMOVAL & INSTALLATION

Removal

1. Connect bleeder hose to bleeder screw of height control accumulator and loosen bleeder screw. (Scheme 127)
2. After fluid pressure has dropped and oil has drained out, tighten bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
3. Remove hose and disconnect harness connectors. (Scheme 128)
4. Using special tool (09023-00100), disconnect AHC fluid line from AHC pump and motor. (Scheme 129)
5. Remove bolt, nuts and AHC pump and motor assembly.
6. Remove bolt, collar, cushion, nuts and AHC pump and motor from AHC pump and motor bracket.
7. Remove holders, cushions and cushion bolts from AHC pump and motor.
8. Remove bolt and bracket.

Scheme 127

Scheme 128

Scheme 129

Installation

1. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000) .
2. Fill AHC pump and motor reservoir with suspension fluid AHC and bleed system. See «BLEEDING»(ref-154858-S33064997222003052900000) .
3. Check for leaks.

1. Disconnect harness connector. (Scheme 130)
2. Using special tool (09023-00100), disconnect AHC fluid lines from control valve assembly. (Scheme 131)
3. Remove nuts and control valve assembly.
4. Remove holders, cushions and cushion bolts from control valve assembly.
5. Remove 4 bolts and cover.
6. Remove gasket.

Scheme 130

Scheme 131

1. To install, reverse removal procedure. Install a NEW gasket.
2. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000) .
3. Fill AHC pump motor reservoir with suspension fluid AHC and bleed AHC system. See «BLEEDING»(ref-154858-S33064997222003052900000) .
4. Check for leaks.

1. Connect bleeder hose to bleeder screw of damping force control actuator and loosen bleeder screw. see scheme 25
2. After fluid pressure has dropped and oil has drained out, tighten bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000). Remove hose.
3. Remove bolts and cover. (Scheme 132)
4. Disconnect harness connector.
5. Disconnect fluid lines from damping force control actuator.
6. Remove nut, bolts and damping force control actuator.
7. Place damping force control actuator in vise.
8. Using special tool (09922-10010), remove gas chamber.
9. Remove O-ring and back up ring from gas chamber.
10. If replacing gas chamber, place old gas chamber in a vise and saw a hole in hatched area to discharge gas inside. (Scheme 133) Saw hole while covering saw with a shop rug because chips may fly up. Gas discharging is colorless, odorless and harmless.

Scheme 132

Scheme 133

Note. Be careful to not damage O-ring.

1. Coat O-ring with suspension fluid AHC. Install NEW back up ring and O-ring to gas chamber.
2. Using special tool (09922-10010), install gas chamber in correct direction. (Scheme 134) Use torque wrench with fulcrum length of 13.58 inches (345 mm).
3. Install damping force control actuator and tighten nut and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
4. Connect fluid lines and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
5. Connect harness connector and install cover with bolts. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
6. After installation, fill AHC pump motor reservoir with suspension fluid AHC and bleed AHC system. See «BLEEDING»(ref-154858-S33064997222003052900000).
7. Check for leaks.

Scheme 134

1. Connect bleeder hose to bleeder screw for height control accumulator and loosen screw. (Scheme 127)
2. After fluid pressure has dropped and oil has drained out, tighten bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
3. Remove bleeder hose.
4. Remove front left damping force control actuator. See «DAMPING FORCE CONTROL ACTUATOR»(ref-154858-S00073482572003052900000).
5. Disconnect harness connector. (Scheme 135)
6. Using special tool (09023-38400), disconnect inlet fluid line from height control accumulator. (Scheme 136)
7. Using special tool (09751-36011), disconnect outlet fluid line from height control accumulator. (Scheme 137)
8. Remove nut, bolts and height control accumulator.
9. Before disposing, loosen bleeder screw to bleed high pressure oil. Place accumulator in vise and saw a hole between (A) and (B) to discharge gas inside. (Scheme 138) Saw hole while covering saw with a shop rug because chips may fly up. Gas discharging is colorless, odorless, and harmless.

Scheme 135

Scheme 136

Scheme 137

Scheme 138

1. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000) .
2. Fill AHC pump motor reservoir with suspension fluid AHC and bleed AHC system. See «BLEEDING»(ref-154858-S33064997222003052900000) .
3. Check for leaks.

1. Remove front wheel.
2. Disconnect harness connector. (Scheme 139)
3. Place matchmarks on height control sensor link and front upper suspension arm. Remove nut and disconnect height control sensor link. (Scheme 140)
4. To install, reverse removal procedure. Tighten bolts and nut to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).

Scheme 139

Scheme 140

1. Remove rear wheel.
2. Disconnect harness connector.
3. Place matchmarks on height control sensor link and rear upper control arm. Remove nut and disconnect height control sensor link from rear upper control arm. (Scheme 141)
4. Remove bolts and height control sensor.
5. To install, reverse removal procedure. Tighten bolts and nut to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).

Scheme 141

1. Connect bleeder hose to bleeder screw for height control accumulator and loosen bleeder screw. (Scheme 127)
2. After fluid pressure has dropped and oil has drained out, tighten bleeder screw to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000).
3. Remove bleeder hose.
4. Remove front fender apron.
5. Using special tool (09751-36011), disconnect inlet fluid line from pump attenuator. (Scheme 142)
6. Using special tool (09023-38400), disconnect outlet fluid line from pump attenuator. (Scheme 143)
7. Remove bolts and pump attenuator.
8. Remove collars and cushions.
9. Place pump attenuator in vise and saw a hole between (A) and (B) to discharge gas inside. (Scheme 144) As gas is contained inside a metal bellows, saw up to metal bellows. Saw hole while covering saw with a shop rug because chips may fly up. Gas discharging is colorless, odorless, and harmless.

Scheme 142

Scheme 143

Scheme 144

1. To install, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-154858-S39302085462003052900000) .
2. After installation, fill AHC pump motor reservoir with suspension fluid AHC and bleed AHC system. See «BLEEDING»(ref-154858-S33064997222003052900000) .
3. Check for leaks.