Installation (To 08/2009): Installation

HINT:

Use the same procedure for the LH side and RH side.
The procedure listed below is for the LH side.

SECURE FRONT SHOCK ABSORBER ASSEMBLY
1. Install the bolt and nut to the front shock absorber assembly as shown in the illustration and secure the front shock absorber assembly in a vise.
  
  Fig 1: Installing Bolt And Nut To Front Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  A
  
  28 mm (1.10 in.)
INSTALL FRONT COIL SPRING LOWER INSULATOR
1. Install the front coil spring lower insulator to the front shock absorber.
  
  Fig 2: Installing Front Coil Spring Lower Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Positioning Pin
  
  NOTE:
  Make sure that the positioning pins on the front coil spring lower insulator are inserted into the holes in the front shock absorber.
INSTALL FRONT SPRING BUMPER
1. Install the front spring bumper to the front shock absorber.
  
  Fig 3: Identifying Front Spring Bumper
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Face the smaller diameter end of the front spring bumper downward.
INSTALL FRONT COIL SPRING
1. Install SST to the front coil spring with the hooks spread as far apart as possible from each other.
  - SST: 09727-00050
  - SST: 09727-30021
    - 09727-00010
    - 09727-00031
  Fig 4: Installing Front Coil Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Make sure that the claws on the hooks are securely engaged to the spring.
  
  HINT:
  
  If the front coil spring is compressed at an angle, using 2 SST will make the work easier.
2. Using SST, compress the front coil spring.
  - SST: 09727-00050
  - SST: 09727-30021
    - 09727-00010
    - 09727-00031
  NOTE:
  Do not use an impact wrench. It will damage SST.
3. Install the front coil spring to the front shock absorber.
  
  Fig 5: Identifying Front Coil Spring & Front Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Make sure that the end of the front coil spring is positioned in the depression of the lower spring seat.
INSTALL FRONT COIL SPRING UPPER INSULATOR
1. Install the front coil spring upper insulator as shown in the illustration.
  
  Fig 6: Identifying Front Coil Spring Upper Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Any misalignment between the front shock absorber lower bracket and the alignment mark must be +/- 5°.
INSTALL FRONT COIL SPRING UPPER SEAT
1. Install the front coil spring upper seat with the mark facing to the outside of the vehicle.
  
  Fig 7: Identifying Front Coil Spring Upper Seat With Mark
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT SUSPENSION SUPPORT BEARING
1. Install the front suspension support bearing as shown in the illustration.
  
  Fig 8: Identifying Front Suspension Support Bearing
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  TEXT IN ILLUSTRATION
  
  *1 Upper Side
  
  NOTE:
  Do not install the bearing upside down.
INSTALL FRONT SUSPENSION SUPPORT SUB-ASSEMBLY
1. Install the front suspension support sub-assembly as shown in the illustration.
  
  Fig 9: Identifying Front Suspension Support Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Check that the slot on the piston rod and the slot on the front suspension support sub-assembly are aligned.
2. Temporarily tighten a new front support to front shock absorber nut.
3. While aligning the stud bolt of the front suspension support and the shock absorber lower bracket, remove SST from the coil spring.
  
  Fig 10: Aligning Stud Bolt Of Front Suspension Support
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - When reassembling the upper support, ensure that any misalignment between the absorber lower bracket and the stud bolt is within +/- 5°. Use the stud bolt that is closest to the outside of the vehicle.
  - Do not use an impact wrench.
INSTALL FRONT SHOCK ABSORBER WITH COIL SPRING
1. Install the front shock absorber with coil spring (upper side) with the 3 nuts as shown in the illustration.
  
  Fig 11: Identifying Front Shock Absorber With Coil Spring
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf)
2. Install the front shock absorber with coil spring (lower side) to the steering knuckle and insert the 2 bolts and 2 nuts.
  
  Fig 12: Locating Nuts On Lower Side Of Front Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 290 N*m (2957 kgf*cm, 214 ft.*lbf)
  
  NOTE:
  When installing the nuts, keep the bolts from rotating.
INSTALL FRONT STABILIZER LINK ASSEMBLY
1. Install the front stabilizer link assembly to the front shock absorber with the nut.
  
  Fig 13: Identifying Front Stabilizer Link Assembly & Front Shock Absorber
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 74 N*m (755 kgf*cm, 55 ft.*lbf)
  
  HINT:
  
  If the ball joint turns together with the nut, use a hexagon wrench (6 mm) to hold the stud bolt.
INSTALL FRONT SPEED SENSOR
1. Install the front speed sensor and front flexible hose with the bolt.
  
  Fig 14: Locating Front Speed Sensor Bolt With Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf)
  
  NOTE:
  Do not twist the front speed sensor when installing it.
2. Install the clamp.
FULLY TIGHTEN FRONT SUPPORT TO FRONT SHOCK ABSORBER NUT
1. Fully tighten the front support to front shock absorber nut.
  
  Fig 15: Identifying Front Shock Absorber Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf)
  
  NOTE:
  Perform this step only when the front shock absorber with coil spring has been disassembled.
INSTALL COWL TOP SILENCER PAD
1. Engage the 3 claws to install the cowl top silencer pad.
  
  Fig 16: Identifying Claws And Cowl Top Silencer Pad
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FRONT WHEEL
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
STABILIZE SUSPENSION
1. Lower the vehicle and bounce it up and down several times to stabilize the front suspension.
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:

Inspect and adjust the front wheel alignment. Refer to ADJUSTMENT .