1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of the Cusco Lower Bar Type II Rear, designed specifically for the Toyota MR-S (ZZW30) model. Please read this manual thoroughly before installation to ensure proper fitment and safe operation. This product is intended to enhance chassis rigidity and improve handling characteristics.
2. Safety Information
Always prioritize safety during installation and use. Professional installation is recommended. If you are unsure about any step, consult a qualified mechanic. Ensure the vehicle is securely supported on jack stands or a lift before working underneath it. Wear appropriate personal protective equipment (PPE) such as safety glasses and gloves.
- Do not attempt installation without proper tools and knowledge.
- Ensure all fasteners are tightened to the manufacturer's specified torque values.
- Verify proper clearance with all vehicle components after installation.
- This product is for off-road or competition use only, as per some regional regulations. Check local laws.
3. Package Contents
Before beginning installation, verify that all components are present and undamaged.
- Cusco Lower Bar Type II Rear (Left)
- Cusco Lower Bar Type II Rear (Right)
- Installation Hardware (if included, typically bolts and washers)
Figure 1: Cusco Lower Bar Type II Rear components. The image displays two blue metallic bars, each with a mounting point at both ends. One bar is clearly labeled 'L' for left, and the other 'R' for right, indicating their intended side for installation on the vehicle's rear chassis.
4. Setup and Pre-Installation
4.1 Required Tools
- Socket Wrench Set
- Torque Wrench
- Vehicle Lift or Jack Stands
- Safety Glasses
- Gloves
4.2 Vehicle Preparation
- Park the vehicle on a level surface.
- Engage the parking brake.
- Safely lift the rear of the vehicle using a lift or jack stands, ensuring it is stable and secure.
- Locate the existing mounting points on the rear chassis where the lower bar will be installed. Refer to your vehicle's service manual for specific chassis diagrams if needed.
5. Installation Instructions
Follow these steps carefully for proper installation. It is recommended to have an assistant for certain steps.
- Identify the Left (L) and Right (R) lower bars. These are typically marked on the product itself.
- Position the Left lower bar against the designated mounting points on the left side of the vehicle's rear chassis.
- Insert the provided bolts (or reuse existing factory bolts if specified by Cusco) through the bar's mounting holes and into the chassis. Hand-tighten the nuts.
- Repeat the process for the Right lower bar on the right side of the vehicle.
- Once both bars are loosely installed, ensure they are properly aligned and not binding.
- Using a torque wrench, tighten all bolts to the manufacturer's specified torque settings. Refer to the vehicle's service manual for chassis bolt torque specifications, or Cusco's specific instructions if provided. Do not overtighten.
- Double-check all fasteners to ensure they are securely tightened.
- Carefully lower the vehicle.
After installation, it is advisable to perform a short test drive to ensure no unusual noises or vibrations are present. Re-check bolt tightness after approximately 50-100 miles of driving.
6. Maintenance
The Cusco Lower Bar Type II Rear requires minimal maintenance. Regular inspection is recommended to ensure continued performance and safety.
- Periodic Inspection: Every 3,000-5,000 miles or during routine vehicle service, inspect the lower bars and their mounting points for any signs of damage, corrosion, or loose fasteners.
- Fastener Check: Re-torque all mounting bolts if any looseness is detected.
- Cleaning: Clean the bars with a mild automotive cleaner and soft cloth as needed to remove dirt and road grime. Avoid abrasive cleaners or solvents that could damage the finish.
- Damage: If the lower bar sustains any impact or damage, it should be inspected by a professional and replaced if its structural integrity is compromised.
7. Troubleshooting
This section addresses common issues that may arise during or after installation.
| Issue | Possible Cause | Solution |
|---|---|---|
| Difficulty aligning mounting holes | Vehicle not perfectly level; chassis slightly flexed; incorrect bar orientation. | Ensure vehicle is level. Slightly adjust vehicle height or use a pry bar gently to align holes. Verify 'L' and 'R' markings. |
| Unusual noises (rattling, clunking) after installation | Loose fasteners; contact with other vehicle components. | Re-check and re-torque all mounting bolts. Inspect for any contact points and adjust if possible, or consult a professional. |
| Bar appears bent or damaged | Shipping damage; improper handling; vehicle impact. | Do not install a damaged bar. Contact the retailer or manufacturer for replacement. |
8. Specifications
| Feature | Detail |
|---|---|
| Product Name | Cusco Lower Bar Type II Rear |
| Part Number | 157 478 A |
| Application | Toyota MR-S (ZZW30) |
| Type | Type II Lower Arm Bar |
| Installation Location | Rear Chassis |
| Approximate Item Weight | 2.78 pounds (1.26 kg) |
| Approximate Product Dimensions | 14.8 x 5.7 x 3.7 inches (37.6 x 14.5 x 9.4 cm) |
9. Warranty Information
Cusco products are manufactured to high standards. For specific warranty terms and conditions, please refer to the official Cusco website or contact your authorized dealer. Typically, warranties cover manufacturing defects and do not cover damage due to improper installation, misuse, or normal wear and tear.
10. Customer Support
If you have any questions regarding the installation, operation, or maintenance of your Cusco Lower Bar, please contact your authorized Cusco dealer or visit the official Cusco website for support resources.
Official Cusco Website: www.cusco.co.jp/en/
