1997-2001 Lexus ES300 4 Wheel Conversion Kit Installation Manual

1997-2001 Lexus ES300 4 Wheel Conversion Kit Installation Manual

Take a look at our easy-to-follow 1997-2001 Lexus ES300 4 Wheel Conversion Kit Installation Manual to learn how to install your new Strutmasters air suspension conversion kit. Our step-by-step instructions include pictures to help you along the way.

Lexus ES300 parts included in this kit:

  • 4 Coilover Strut Assemblies

Getting Started

  1. Read general service precautions
  2. Wear Eye Protection
  3. Support the vehicle
  4. Remove air suspension parts
  5. Install conversion kit
  6. Disable the ride control light

Tools needed for installation:

  • Metric socket set
  • Floor Jack
  • Jack Stands
  • Metric Wrench Set
  • Wire Cutter/Stripper/Crimping Tool
  • Level Work Surface
  • Spring Compressor (If Applicable)
  • Allen Wrenches
  • Screw Drivers (Phillips and Flat-Head)
  • SST 09817-33190
  • SST 09922-10010

Front Strut Removal and Front Conversion Kit Installation InstructionsStep 1

Caution: A sudden release of pressure may cause personal injury or damage to the vehicle. The air suspension system is under pressure until the air supply lines are disconnected. Use the following precautions when servicing the air suspension system: Wear gloves, ear protection, and eye protection. Wrap a clean cloth around the air supply lines. The vehicle must be raised to perform this conversion! Use proper lifting equipment only! Read instructions carefully before attempting installation, if you have problems during the install then feel free to call our Technical Support Line. Please before calling for technical help, have your invoice handy.

  1. Remove the front wheel. Torque: 103 Nm (1,050 kgf-cm, 76 ft.lbs.).
  2. Remove the flexible hose and ABS speed sensor wire harness and clamp from the shock absorber. Remove the bolt, flexible hose and ABS wire harness clamp. Torque: 29 Nm (300 kgf-cm, 22 ft.lbs.).
  3. Disconnect the stabilizer bar link from the shock absorber.
  4. Disconnect the shock absorber from the steering knuckle.
    • Remove the 2 nuts and bolts on the lower side of the shock absorber. Torque: 211 Nm (2,150 kgf-cm, 156 ft.lbs.)
    • Remove the shock absorber from the steering knuckle. HINT: At the time of the installation, coat the nut's threads with engine oil.
  5. Removing strut for vehicles without Electronic Suspension: Remove the shock absorber with the coil spring. Remove the 3 nuts, suspension support No. 2 and the shock absorber with the coil spring. Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.) HINT: At the time of installation, rotate the suspension support and set it in the direction, see Fig 1.
  6. For Vehicles with Electronic Modulated Suspension: Remove the shock absorber with the coil spring.
    • Disconnect the absorber control actuator sub-wire harness connector.
    • Remove the 3 nuts and shock absorber cap. Torque: 14 Nm (140 kgf-cm, 9 ft.lbs.).
    • Slide the grommet and remove the clip.
    • Disconnect the absorber control actuator connector, see Fig 2.
    • Using SST 09817-33190, loosen the nut in the middle of the suspension support. (See Figure #3)
    • Using SST, torque the nut.
    • Use a torque wrench with a fulcrum length of 345 mm (13.58 inch).
    • Remove the 3 nuts and shock absorber with the coil spring. Torque: 80 Nm (820 kgf- cm, 59 ft.lbs.). Note: At the time of the installation, you can use SST 09922-10010 in direction shown in Fig 3.
  7. Installation is in the reverse order of removal.

Rear Strut Removal and Rear Conversion Kit Installation InstructionsStep 2

  1. Remove rear seat cushions and seatbacks, package tray trim, high mount brake light, and belt hole cover and rear seat belts.
  2. Remove Rear Wheel Torque 103 Nm (1,l500 kgf-cm, 76ft. lbs.), see Fig 1.
  3. Remove the flexible hose and ABS speed sensor wire clamp from the shock absorber. Remove the 2 bolts, flexible hose and ABS wire harness clamp. Torque: Flexible hose: 29 Nm (300 kgf- cm, 22 ft.lbs.). ABS wire: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
  4. Disconnect the stabilizer bar link from the shock absorber, see Fig 2.
  5. Loosen the 2 nuts on the lower side of the shock absorber.
    • Loosen the 2 nuts on the lower side of the shock absorber. Torque: Reused nut: 196 Nm (2,000 kgf-cm, 145 ft. lbs.) New nut: 255 Nm (2,600 kgf-cm, 188 ft. lbs.) HINT: At the time of installation, coat the nut's threads with engine oil.
    • Support the rear axle carrier with a jack.
  6. Remove the shock absorber with the coil spring. For vehicles without Electronic Modulated Suspension:
    • Remove the cap.
    • Loosen the nut in the middle of the suspension support. DO NOT REMOVE IT! Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.).
    • Remove the 3 nuts of the suspension support. Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.).
    • Lower the rear axle carrier and remove the 2 bolts.
    • Remove the shock absorber with the coil spring.
  7. Remove the shock absorber with the coil spring. For vehicles with Electronic Modulated Suspension:
    • Remove the clip and clamp and disconnect the absorber control actuator connector, see Fig 3.
    • Using SST 09817-33190, loosen the nut in the middle of the suspension support. DO NOT REMOVE IT! See Fig 4.
    • Using SST, torque the nut.
    • Use a torque wrench with a fulcrum length of 345 mm (13.58 inch). Torque: 36 Nm (365 kgf-cm, 26 ft. lbs.). At the time of the installation, use SST (09922-10010) in direction shown in Fig 4.
    • Remove the 3 nuts of the suspension support. Torque: 39 Nm (400 kgf-cm, 29 ft.lbs.).
    • Lower the rear axle carrier and remove the 2 bolts.
    • Remove the shock absorber with the coil spring.
  8. Installation is in the reverse order of removal.

Installation now complete.

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