TECHNICAL INSTRUCTIONS
FOR
SPECIAL SERVICE CAMPAIGN 30E
2003 MY TOYOTA 4RUNNER
REAR AIR SUSPENSION

Page 1 of 12

I.

OPERATION FLOW CHART
Verify Vehicle Eligibility
1. Check VIN range.
2. Check for SSC Completion
Label.
3. Check TIS/Dealer Daily.

No further action required.

Not Eligible

Applicable

Affix an SSC Completion Label
(from the owner notification) on
the specified location.

II.

LOCATION OF AFFECTED PARTS
Air Tubes

Upper
Clip
Upper
Clip

Pneumatic Cylinder
Assemblies

Rear Axle

Page 2 of 12

III.

AFFECTED VIN RANGE


NOTE:

IV.

Only vehicles on the attached VIN list are involved.
Always consult Dealer Daily or TIS to confirm VIN eligibility and to assure the
SSC is applicable. This will verify the vehicle is involved and has not already
been completed by another dealer. TMS warranty will not reimburse dealers for
repairs conducted on vehicles that are not affected.

PREPARATION

A. PARTS
Part No.
04003-10135

Part Name
Lower Air Suspension Clip Kit

Qty.
1

If the Suspension Clip Kit is no longer available, dealers may order and install the
right and left pneumatic cylinder assemblies. Reference the parts catalog for the
correct part number.

NOTE:

B. TOOLS




Standard Tools
Toyota Scan Tool
SST 09730-00010

Page 3 of 12

V.

WORK PROCEDURE
1. REAR PNEUMATIC CYLINDER
ASSEMBLY REMOVAL
NOTE:
Prior to pneumatic cylinder removal,
the following steps must be
performed before lifting the vehicle to
prevent damage to the pneumatic
cylinders.

A

a. Place vehicle in bay.
b. With engine running. Place height
control to the HI position.
c. The height control indicator light will
stop blinking after the vehicle reaches
maximum height.
d. Measure and record the distance
from the floor to the fender well on
the left and right side of the vehicle.
e. Subtract 10 mm from the lowest
figure.
Measurment A&B
Example
Left
Right
900 mm 890 mm Measurment A
-10 mm
880 mm Measurment B
NOTE:
Measurement B will be used for
vehicle reassembly.
f. Prior to lifting the vehicle turn height
control to normal.
g. Turn height control “OFF”.
h. Turn off vehicle.
i. Raise the vehicle on lift.
NOTE:
Do not lower the rear axle assembly.
Do not perform this repair with the
shock absorber removed from the
vehicle.

Page 4 of 12

c. Disconnect the height control air tube
from the left and right pneumatic
cylinder assembly.
NOTE:
Only disconnect and connect the air
tube by hand to avoid damage and
dirt from entering the air tube.
1). Pinch “A” of the No. 1 connector
and remove it from the housing
as shown.

e. Place the SST on the air tube.

d.

1). Insert the SST into the housing to
expand the claw of the tube
connector.
2). Remove the tube with the SST
inserted.
Release the air from both pneumatic
cylinder assemblies to retract them.
NOTE:
Do not force the removal of the tube.
f. Cover the left and right air tube and
the pneumatic cylinder air tube port
with plastic bags to prevent dirt from
entering air suspension system.

g. Remove the left and right upper clip
on the pneumatic cylinders.
NOTE:
Thread a wire through the hole in
the upper clip to aid in removal.

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h. Rotate the pneumatic cylinder
assembly 90 degrees and remove it
from the rear axle.
NOTE:
Do not extend the pneumatic
cylinder assembly.
Do not deform the rubber bellows.
Be sure to turn the pneumatic
cylinder as one unit so that the
middle does not twist.
Hold the top and bottom during
removal to prevent the cylinder
from extending.
1. REPLACE THE LOWER AIR
SUSPENSION CLIP
a. Remove and discard the old plastic
lower clip from the pneumatic
cylinders.

b. Slide the new metal plug onto the
pneumatic cylinders as shown.

Plug

j.
Clip

Install the new lower clip on to the
plug and center it on the pneumatic
cylinders.
k. Tighten the clip.
Torque:
15 N•m (155 kgf•cm, 11 ft•lbf)
NOTE:
The notches on the clip should
face away from the pneumatic
cylinder.
Placing the pneumatic cylinders in
a vise could damage it.
When installed correctly, the clip
will tighten down the plug on to the
pneumatic cylinder.
Page 6 of 12

l.

Using a hammer and chisel, stake the
holders as shown.
NOTE:
Support the pneumatic cylinder
using a wooden block to prevent
damage to the cylinder.
Do not hold the pneumatic cylinder
in a vice.

j.

Ensure that the pneumatic cylinder
bellows is correctly positioned prior to
reinstallation into the vehicle.
NOTE:
The bellows should not be bent or
twisted.

Retaining ring
(gold)

Bellows

k. The lower part of the bellows needs
to be rolled over the lower chamber.
The gold metal retaining ring should
not be visible.

(rubber)

Lower half of
Pneumatic Cylinder

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3. REINSTALL THE PNEUMATIC
CYLINDER ASSEMBLIES
a. Reinstall the left and right pneumatic
cylinders.
NOTE:
The air tube port faces the rear of
the vehicle.
The left and right pneumatic
cylinders are not interchangeable.
The top of each cylinder is marked
L or R.

Rear

b. Reinstall the left and right upper clip.
NOTE:
Ensure that the upper clip is
properly installed onto the
cylinder.
c.

Retaining ring

Bellows

Inspect and correct the bellows for
proper position. The bellows must
be rolled over the lower chamber
and not be bent or twisted.
NOTE:
Prior to operating the air
suspension system. Inspect the
bellows for proper position by
lifting the pneumatic cylinder dust
cover and ensuring that the
bellows are not twisted or bent.
This should be preformed prior to
any air being pumped into the
pneumatic cylinders.

Lower
chamber

Page 8 of 12

d. Reconnect the height control air
tubes.
1). Reinstall connector No. 1 into the
housing until a “click” is heard.
NOTE:
After installing connector No. 1
carefully tug on the air tube to
ensure that the connector is
properly engaged.
e. Lower the vehicle until the tires touch
the ground.
f. Continue lowering the vehicle until
the bottom of the pneumatic cylinders
touches the rear axle.
g. Align the seating pin on the
pneumatic cylinders with the rear axle
and install the cylinders onto the rear
axle.
h. Lower the vehicle to measurement B
(taken in Step 1).
NOTE:
Do not extend the pneumatic
cylinders to engage the cylinder
onto the rear axle.
That will damage the cylinders.
Ensure that the pneumatic cylinder
diaphragm has not been deformed
or wrinkled.
Ensure that the seating pin is
correctly seated into the rear axle.
i.
j.

Start the vehicle.
Switch the vehicle height control
“ON”.
k. Set vehicle height control to the “HI”
position.
l. After the compressor has stopped
switch the height control “OFF”.
m. Turn vehicle “OFF”.

Page 9 of 12

4. CHECK AIR TUBE CONNECTIONS
AND BELLOWS
a. Raise the vehicle.
b. Apply soapy water to the connections
shown and check for any leakage.
c. Carefully inspect the bellows to
ensure they are not twisted, bent or
wrinkled.

Front

NOTE:
The bellows are under pressure and
you could be injured if the bellows
tears or the retaining ring disengages.
If the bellows are twisted, bent or
wrinkled release the air pressure and
reposition the bellows and repeat
steps 3i to 3m.
d. Lower the lift clear of the vehicle. Be
careful as the pneumatic cylinder
assemblies could be damaged if not
aligned correctly.

5. ADJUST VEHICLE HEIGHT
a. Place the vehicle on a level surface.
b. Place the height control switch to
NORMAL.
c. Turn the height control to the “OFF”
position.
d. Turn the vehicle OFF.
e. Measure the vehicle height as shown
on the left and right sides. (C-D
measurement).
NOTE:
When adjusting the vehicle height
do not load and unload the vehicle
this will cause the vehicle height to
change.
The maximum allowable difference
between the left and right is
10mm (0.39 in).

R ear
C - D
4 X 2

4 X 4

8 1 . 4 m m ( 3 . 2 0 in . )

7 8 . 9 m m ( 3 . 1 1 in )
Page 10 of 12

e. If the vehicle height is not with in
specifications lift the frame of the
vehicle.
f. Using the Toyota Scan Tool.
1). Turn the ignition switch to the
“ON” position.
2). Measure the left and right vehicle
height sensor values.
NOTE:
Maximum difference between
measurement C – D and the sensor
values can not exceed 5 mm (0.20 in).
Maximum difference between the left
and right is 5 mm (0.20).
f. If the vehicle height differs beyond
the specifications, the height control
sensor needs to be adjusted.
1). Loosen the nut.
2). Slide the height control sensor up
and down.
3). Adjust the vehicle height (C – D
measurement) while monitoring
the scan tool values.
4). Tighten the nut.
Torque:
5.4 N•m (55 kgf•cm, 48 in•lbf)
g. If the vehicle height cannot be
corrected as outlined in step f. Adjust
the height control sensor link.
1). Loosen the 2 lock nuts for the
height control link
2). Adjust the vehicle height (C – D
measurement) by turning the link
while monitoring the scan tool
values.
3). Tighten the 2 lock nuts.
Torque:
5.4 N•m (55 kgf•cm, 48 in•lbf)

Page 11 of 12

4). Check that measurement “A” is
within the standard value.
Standard Length:
6.5 – 15.0 mm (0.26 – 0.59 in.)

h. Operate the vehicle height control
system:

Normal to High
then

High to Normal
i. Measure the left and right vehicle
height again (C – D measurement)
j. Check that vehicle height and left &
right measurements are with in
specifications.
NOTE:
If the values are still out of
specifications repeat steps e to i.

VI.

SSC COMPLETION LABEL INSTALLATION
1. After completing the repair and before returning the vehicle to the owner, an
SSC completion label that is enclosed in the owner’s notification letter must
be affixed to the left front door hinge post near the check strap.
2. The label is to be filled out as follows:
 Write in SSC 30E.
 Write in the date the repair was performed.
 Write in your dealer code.
3. Additional SSC completion labels, in sheets of 50 (P/N 00410-01917), may be
ordered through the non-parts system on a 1450 order form or through the
TDN system.

Page 12 of 12