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Home >> Lexus >> 2012 >> CT 200h L4-1.8L (2ZR-FXE) Hybrid >> Repair and Diagnosis >> Body and Frame >> Frame >> Cross-Member >> Rear Cross-Member >> Service and Repair >> Installation

Installation





REAR SUSPENSION: REAR SUSPENSION MEMBER: INSTALLATION

1. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for LH Side)

(a) Temporarily install the rear suspension member front body mounting cushion so that the holes are positioned longitudinally as shown in the illustration.





Text in Illustration





(b) Install SST as shown in the illustration.





SST : 09570-24011

SST : 09830-10010

09830-01010

09830-01020

09830-01040

09830-01060

NOTICE:
Apply a small amount of grease to the threads of SST (center bolt) before use.

(c) Using SST, install the rear suspension member front body mounting cushion until there is no clearance between the rear suspension member sub-assembly and the rear suspension member front body mounting cushion.





Text in Illustration





SST : 09570-24011

SST : 09830-10010

09830-01010

09830-01020

09830-01040

09830-01060

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

2. INSTALL REAR SUSPENSION MEMBER FRONT BODY MOUNTING CUSHION (for RH Side)

HINT
Perform the same procedure as the LH side.

3. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNTING CUSHION LH

(a) Temporarily install the rear suspension member rear body mounting cushion LH so that the holes are positioned longitudinally as shown in the illustration.





Text in Illustration





(b) Install SST as shown in the illustration.





SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04020

09955-04051

09957-04010

09958-04011

SST : 09950-60020

09951-00890

09952-06010

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

(c) Using SST, install the rear suspension member rear body mounting cushion LH until there is no clearance between the rear suspension member sub-assembly and the rear suspension member rear body mounting cushion LH.





Text in Illustration





SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04020

09955-04051

09957-04010

09958-04011

SST : 09950-60020

09951-00890

09952-06010

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

4. INSTALL REAR SUSPENSION MEMBER REAR BODY MOUNTING CUSHION RH

(a) Temporarily install the rear suspension member rear body mounting cushion RH so that the holes are positioned longitudinally as shown in the illustration.





Text in Illustration





(b) Install SST as shown in the illustration.





SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04020

09955-04051

09957-04010

09958-04011

SST : 09950-60020

09951-00890

09952-06010

NOTICE:
Apply a small amount of grease to the threads and tip of SST (center bolt) before use.

(c) Using SST, install the rear suspension member rear body mounting cushion RH until there is no clearance between the rear suspension member sub-assembly and the rear suspension member rear body mounting cushion RH.





Text in Illustration





SST : 09950-40011

09951-04020

09952-04010

09953-04030

09954-04020

09955-04051

09957-04010

09958-04011

SST : 09950-60020

09951-00890

09952-06010

NOTICE:
If the rear suspension member sub-assembly is scratched, apply paint to the scratched areas of the rear suspension member sub-assembly.

(d) Remove SST from the rear suspension member sub-assembly.

5. INSTALL REAR UPPER CONTROL ARM ASSEMBLY LH

(a) Temporarily install the rear upper control arm assembly LH to the rear suspension member sub-assembly with the bolt and nut.





NOTICE:
* Since a stopper nut is used, turn the bolt.
* Insert the bolt with the threaded end facing the rear of the vehicle.

(b) Set the rear upper control arm assembly LH in the tightening position as shown in the illustration.

Reference length (A):

23.0 mm (0.906 in.)

(c) Fully tighten the bolt in the tightening position.

Torque : 90 Nm (918 kgf-cm, 66 ft-lbf)

NOTICE:
Since a stopper nut is used, turn the bolt.

6. INSTALL REAR UPPER CONTROL ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

7. INSTALL REAR SUSPENSION MEMBER UPPER STOPPER

(a) Install the 2 rear suspension member upper stoppers to the rear suspension member sub-assembly.

NOTICE:
Be sure to install the rear suspension member upper stoppers in the correct direction.

8. INSTALL REAR SUSPENSION MEMBER REAR UPPER STOPPER

(a) Install the 2 rear suspension member rear upper stoppers to the rear suspension member sub-assembly.

NOTICE:
Be sure to install the rear suspension member rear upper stoppers in the correct direction.

9. INSTALL REAR SUSPENSION MEMBER SUB-ASSEMBLY

(a) Support the rear suspension member sub-assembly with an engine lifter using 4 attachments or equivalent tools.

NOTICE:
* Make sure to secure the rear suspension member sub-assembly to prevent it from dropping.
* Use the attachments to keep the rear suspension member sub-assembly level.
* The rear suspension member sub-assembly is a heavy component. Make sure that it is supported securely.

(b) Raise the rear suspension member sub-assembly until there is no clearance between the rear suspension member sub-assembly and the body.

NOTICE:
When raising the rear suspension member sub-assembly, be careful not to damage the vehicle body or other components installed on the vehicle.

(c) Install the rear suspension member sub-assembly with the 2 rear suspension member lower stoppers, 2 rear suspension member rear lower stoppers, 2 bolts, 2 nuts (A) and 2 nuts (B).





Text in Illustration





Bolt - Torque : 125 Nm (1275 kgf-cm, 92 ft-lbf)

Nut (A) - Torque : 125 Nm (1275 kgf-cm, 92 ft-lbf)

Nut (B) - Torque : 61 Nm (620 kgf-cm, 45 ft-lbf)

NOTICE:
Be sure to install the rear suspension member sub-assembly with the rear suspension member rear lower stoppers facing in the correct direction as shown in the illustration.

(d) Lower the engine lifter.

10. INSTALL REAR STABILIZER BAR Installation

11. INSTALL REAR SUSPENSION MEMBER BRACE LH Installation

12. INSTALL REAR SUSPENSION MEMBER BRACE RH

HINT
Perform the same procedure as the LH side.

13. INSTALL REAR UPPER COIL SPRING INSULATOR LH Installation

14. INSTALL REAR UPPER COIL SPRING INSULATOR RH

HINT
Perform the same procedure as the LH side.

15. INSTALL REAR LOWER COIL SPRING INSULATOR LH Installation

16. INSTALL REAR LOWER COIL SPRING INSULATOR RH

HINT
Perform the same procedure as the LH side.

17. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH

(a) Temporarily install the rear No. 2 suspension arm assembly LH to the rear suspension member sub-assembly with the bolt and nut.

NOTICE:
* Since a stopper nut is used, turn the bolt.
* Insert the bolt with the threaded end facing the front of the vehicle.

(b) Set the rear coil spring LH to the rear No. 2 suspension arm assembly LH.





Text in Illustration





NOTICE:
* Set the rear coil spring so that the identification marks are positioned as shown in the illustration.
* Set the rear coil spring so that its lower end is within the range shown in the illustration.

(c) Using a jack and wooden block, slowly jack up the rear No. 2 suspension arm assembly LH.





Text in Illustration





CAUTION:
Do not jack up the rear No. 2 suspension arm assembly too high as the vehicle may fall.

NOTICE:
* When jacking up the rear No. 2 suspension arm assembly, be sure to jack it up slowly.
* Make sure to perform this operation with the vehicle kept as low as possible.

(d) Temporarily install the rear No. 2 suspension arm assembly LH and rear coil spring LH with the bolt and nut.

NOTICE:
* Since a stopper nut is used, turn the bolt.
* Insert the bolt with the threaded end facing the front of the vehicle.

18. TEMPORARILY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

19. INSTALL REAR STABILIZER LINK ASSEMBLY LH Installation

20. INSTALL REAR STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

21. INSTALL REAR AXLE ASSEMBLY (for LH Side)

(a) Use a jack and wooden block to keep the rear No. 2 suspension arm assembly level.

CAUTION:
Do not jack up the rear No. 2 suspension arm assembly too high as the vehicle may fall.

NOTICE:
* When jacking up the rear No. 2 suspension arm assembly, be sure to jack it up slowly.
* Make sure to perform this operation with the vehicle kept as low as possible.

(b) Temporarily install the rear axle assembly to the rear No. 2 suspension arm assembly with the bolt (C) and nut.





Text in Illustration





NOTICE:
* Insert the bolt with the threaded end facing the front of the vehicle.
* Since a stopper nut is used, turn the bolt.

(c) Temporarily install the rear axle assembly and No. 2 flexible hose bracket to the rear upper control arm assembly with the bolt (B) and nut.

NOTICE:
* Insert the bolt with the threaded end facing the rear of the vehicle.
* Since a stopper nut is used, turn the bolt.

(d) Install the rear axle assembly to the rear trailing arm assembly with the 2 bolts (A).

Torque : 200 Nm (2039 kgf-cm, 148 ft-lbf)

(e) Fully tighten the bolt (B) and bolt (C).

Torque : 90 Nm (918 kgf-cm, 66 ft-lbf)

NOTICE:
Since the stopper nuts are used, turn the bolts.

(f) Slowly lower the rear No. 2 suspension arm assembly.

22. INSTALL REAR AXLE ASSEMBLY (for RH Side)

HINT
Perform the same procedure as the LH side.

23. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH Installation

24. TEMPORARILY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

25. INSTALL REAR DISC

(a) Install the 2 rear discs Installation.

26. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY LH Replacement

27. INSTALL REAR DISC BRAKE CALIPER ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

28. CONNECT NO. 3 PARKING BRAKE CABLE ASSEMBLY Installation

29. CONNECT NO. 2 PARKING BRAKE CABLE ASSEMBLY

HINT
Perform the same procedure as for the No. 3 parking brake cable assembly.

30. INSTALL PARKING BRAKE LEVER PROTECTOR (for LH Side) Installation

31. INSTALL PARKING BRAKE LEVER PROTECTOR (for RH Side)

HINT
Perform the same procedure as the LH side.

32. INSTALL REAR HEIGHT CONTROL SENSOR SUB-ASSEMBLY (w/ Height Control Sensor) Installation

33. INSTALL REAR SPEED SENSOR WIRE LH Installation

34. INSTALL REAR SPEED SENSOR WIRE RH

HINT
Perform the same procedure as the LH side.

35. ADJUST PARKING BRAKE

Adjustments

36. STABILIZE SUSPENSION Installation

37. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY LH Installation

38. FULLY TIGHTEN REAR NO. 2 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

39. INSTALL REAR FLOOR SIDE MEMBER COVER (w/ Floor Under Cover)

(a) for LH Side:

(1) Install the rear floor side member cover LH with the 2 bolts, nut and 2 clips.

(b) for RH Side:

(1) Install the rear floor side member cover RH with the bolt, nut and 2 clips.

40. INSTALL REAR SUSPENSION ARM COVER LH Installation

41. INSTALL REAR SUSPENSION ARM COVER RH

HINT
Perform the same procedure as the LH side.

42. INSTALL TAIL EXHAUST PIPE ASSEMBLY

Installation

43. INSTALL REAR WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

44. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY LH Installation

45. FULLY TIGHTEN REAR NO. 1 SUSPENSION ARM ASSEMBLY RH

HINT
Perform the same procedure as the LH side.

46. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY Installation

47. INSTALL INSTRUMENT SIDE PANEL LH Installation

48. INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH Installation

49. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY Installation

50. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

(a) Connect the cable to the negative (-) battery terminal Installation.

(b) Connect the reservoir level switch connector.

(c) Clear the DTCs Reading and Clearing Diagnostic Trouble Codes.

51. INSPECT AND ADJUST REAR WHEEL ALIGNMENT

Rear Wheel Alignment

52. HEIGHT CONTROL SENSOR SIGNAL INITIALIZATION (w/ Height Control Sensor)

Initialization

53. INSPECT AND ADJUST HEADLIGHT AIMING (w/ Height Control Sensor)

(For LED Headlight)

54. CHECK FOR SPEED SENSOR SIGNAL

Test Mode Procedure
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