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Installation [08/2019 - ]: Procedure

  1. INSTALL HOLE PLUG 
    1. Install the 16 hole plugs to the front frame assembly.

      HINT: 

      There are 3 different shapes of hole plug.

      GTY956690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH 
    1. Align a new front suspension member body mounting rear cushion LH as shown in the illustration and set it to the front frame assembly.
      GTY617950Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      NOTE:
      • Position the front suspension member body mounting rear cushion LH in the correct direction.
      • Do not apply lubricant to the outer sleeve of the front suspension member body mounting rear cushion LH.
    2. Install SST as shown in the illustration.
      GTY672609Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Suspension Member Body Mounting Rear Cushion LH
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Be sure to install SST (09830-01030) in the correct direction.

    3. Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration.
      GTY634929Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:

      Check that there is no clearance between the front frame assembly and the front suspension member body mounting rear cushion LH.

  3. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION 
    1. Align a new front suspension member body mounting rear cushion as shown in the illustration and set it to the front frame assembly.
      GTY630255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      NOTE:
      • Position the front suspension member body mounting rear cushion in the correct direction.
      • Do not apply lubricant to the outer sleeve of the front suspension member body mounting rear cushion.
    2. Install SST using the same procedure as for the front suspension member body mounting rear cushion.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Be sure to install SST (09830-01030) in the correct direction.

    3. Using SST, install the front suspension member body mounting rear cushion.
      NOTE:

      Check that there is no clearance between the front frame assembly and the front suspension member body mounting rear cushion.

      HINT: 

      Perform the same procedure as for the front suspension member body mounting rear cushion LH.

  4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION LH 
    1. Align a new front suspension member body mounting front cushion LH as shown in the illustration and set it to the front frame assembly.
      GTY653800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      NOTE:
      • Position the front suspension member body mounting front cushion LH in the correct direction.
      • Do not apply lubricant to the outer sleeve of the front suspension member body mounting front cushion LH.
    2. Install SST as shown in the illustration.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      GTY613049Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Suspension Member Body Mounting Front Cushion LH
      NOTE:

      Be sure to install SST (09830-01030) in the correct direction.

    3. Using SST, install the front suspension member body mounting front cushion LH as shown in the illustration.
      GTY644065Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:

      Check that there is no clearance between the front frame assembly and the front suspension member body mounting front cushion LH.

  5. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION 
    1. Align a new front suspension member body mounting front cushion as shown in the illustration and set it to the front frame assembly.
      GTY956541Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View from Underneath
      Front of the Vehicle
      NOTE:
      • Position the front suspension member body mounting front cushion in the correct direction.
      • Do not apply lubricant to the outer sleeve of the front suspension member body mounting front cushion.
    2. Install SST using the same procedure as for the front suspension member body mounting front cushion.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

      Be sure to install SST (09830-01030) in the correct direction.

    3. Using SST, install each front suspension member body mounting front cushion as shown in the illustration.
      NOTE:

      Check that there is no clearance between the front frame assembly and the front suspension member body mounting front cushion.

      HINT: 

      Perform the same procedure as for the front suspension member body mounting front cushion LH.

  6. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER 
    1. Install the 2 front suspension member body mounting rear stoppers to the front frame assembly.
  7. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER 
    1. Install the 2 front suspension member body mounting front stoppers to the front frame assembly.
  8. INSTALL FRONT SUSPENSION MEMBER DYNAMIC DAMPER (for 2WD) 
    1. Install the front suspension member dynamic damper to the front frame assembly with the 3 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  9. INSTALL FRONT SUSPENSION MEMBER DUMPER PLATE (for 2WD) 
    1. Install the front suspension member damper plate to the front suspension member dynamic damper with the 2 nuts.

      Torque: 4.9 N*m (50 kgf*cm, 43 in.*lbf) 

  10. INSTALL FRONT NO. 2 SUSPENSION MEMBER DYNAMIC DAMPER (for 2WD) 
    1. Install the front No. 2 suspension member dynamic damper to the front frame assembly with the 2 bolts.

      Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf) 

  11. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 
    1. Install the front lower No. 1 suspension arm sub-assembly to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.
      GTY685334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Bolt (1), (2) 

      Torque: 200 N*m (2039 kgf*cm, 148 ft.*lbf) 

      Bolt (3) 

      Torque: 135 N*m (1377 kgf*cm, 100 ft.*lbf) 

      NOTE:

      Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

  12. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  13. INSTALL FRONT STABILIZER BAR 

    See step  3

  14. INSTALL FRONT FRAME ASSEMBLY 
    1. Slowly jack up the front frame assembly with an engine lifter using 4 attachments or equivalent tools.
      WARNING:
      • The front frame assembly is a very heavy component. Make sure that it is supported securely.
      • If the front frame assembly is not securely supported, it may drop, resulting in serious injury.
      GTY624897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Use attachments to keep the front frame assembly level.

    2. Install the front frame assembly to the vehicle body.
    3. Install the frame side rail plate sub-assembly RH and frame side rail plate sub-assembly LH with the 6 bolts and 2 nuts.

      Bolt (A) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (B) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Nut (C) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      GTY616368Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH with the 6 bolts and 2 nuts.

      Bolt (D) 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      Bolt (E) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

      Nut (F) 

      Torque: 32 N*m (326 kgf*cm, 24 ft.*lbf) 

    5. Lower the engine lifter.
  15. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY 
    1. for AWD:
      1. Connect the No. 1 transmission oil cooler hose assembly to the front frame assembly with the bolt.

        Torque: 19.5 N*m (199 kgf*cm, 14 ft.*lbf) 

    2. for 2WD:
      1. Engage the clamp to connect the No. 1 transmission oil cooler hose assembly to the front No. 2 suspension member dynamic damper.
  16. CONNECT FRONT ENGINE MOUNTING INSULATOR 
    1. Connect the front engine mounting insulator assembly to the front frame assembly with the 3 nuts.

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    2. Install the hole plug to the front frame assembly.
  17. CONNECT REAR ENGINE MOUNTING INSULATOR 
    1. Connect the rear engine mounting insulator assembly to the front frame assembly with the 4 nuts.

      Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) 

    2. Install the 2 hole plugs to the front frame assembly.
  18. REMOVE ENGINE SUPPORT BRIDGE 

    for 2WD: Refer to PROCEDURE - Step 17

    for AWD: Refer to PROCEDURE - Step 19

  19. REMOVE ENGINE HANGERS 

    for 2WD: Refer to PROCEDURE - Step 18

    for AWD: Refer to PROCEDURE - Step 20

  20. INSTALL STEERING LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  21. INSTALL FRONT STABILIZER BAR 

    Refer to PROCEDURE - Step 4

  22. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 

    See step  6

  23. INSTALL FRONT NO. 1 STABILIZER BRACKET RH 

    HINT: 

    Perform the same procedure as for the LH side.

  24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    See step  2

  25. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  26. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  27. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  28. CONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 11

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 13

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 12

  33. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 13

  34. INSTALL SUSPENSION TOWER DAMPER (w/ Suspension Tower Damper) 

    See step  1

  35. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 10

  36. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  37. CONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 12

  38. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 13

  39. INSTALL BATTERY CARRIER SUB-ASSEMBLY 

    for 2WD: Refer to PROCEDURE - Step 40

    for AWD: Refer to PROCEDURE - Step 43

  40. INSTALL BATTERY 

    for 2WD: Refer to PROCEDURE - Step 3

    for AWD: Refer to PROCEDURE - Step 3

  41. INSTALL ECM 

    Refer to PROCEDURE - Step 3

  42. INSTALL AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 41

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 42

  44. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 43

  45. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 3

  46. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 2

  47. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  48. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    See step  12

  49. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 2

  50. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 40

  51. INSTALL FRONT WHEELS 

    Refer to PROCEDURE - Step 1

  52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    NOTE:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Refer to INITIALIZATION [08/2019 - ]

  53. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 10

  54. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 66

  55. INSTALL FRONT LOWER BUMPER ABSORBER 

    Refer to PROCEDURE - Step 68

  56. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 69

  57. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 

    Refer to PROCEDURE - Step 70

  58. INSTALL NO. 3 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 71

  59. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 

    Refer to PROCEDURE - Step 72

  60. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [08/2019 - ]

  61. PERFORM INITIALIZATION 
    • Intelligent Clearance Sonar System
    • Intuitive Parking Assist System (w/ Intelligent Clearance Sonar System)
    		 Refer to CALIBRATION [08/2019 - ]
    Parking Assist Monitor System for Initialization: Refer to INITIALIZATION [08/2019 - ]
    for Calibration: Refer to CALIBRATION [08/2019 - ]
    Panoramic View Monitor System for Initialization: Refer to INITIALIZATION [08/2019 - ]
    for Calibration: Refer to CALIBRATION [08/2019 - ]
    Lighting System (w/ Automatic Headlight Beam Level Control System) Refer to INITIALIZATION [08/2019 - 07/2020] , or refer to INITIALIZATION [07/2020 - ]
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