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Home >> Toyota >> 2015 >> Avalon Hybrid Limited >> Repair and Diagnosis >> Suspension >> Front Suspension >> Front Suspension (Service Information) (Hybrid) >> FRONT SUSPENSION MEMBER (When Using the Engine Support Bridge) >> Installation [10/2014 - ] >> Procedure

Installation [10/2014 - ]: Procedure

  1. INSTALL HOLE PLUG 
    1. Install 12 hole plugs to the front frame assembly.

      HINT: 

      There are 4 different shapes of hole plug.

  2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH 
    1. Temporarily install a new front suspension member body mounting rear cushion LH while confirming the installation direction.
      GTY317767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View from Underneath
      Front of the Vehicle
      NOTE:

      Position the front suspension member body mounting rear cushion LH in the correct direction.

    2. Install SST as shown in the illustration.
      GTY373991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Suspension Member Body Mounting Rear Cushion LH
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
    3. Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration.
      GTY549051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b 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 RH 
    1. Temporarily install a new front suspension member body mounting rear cushion RH while confirming the installation direction.
      GTY318192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View from Underneath
      Front of the Vehicle
      NOTE:

      Position the front suspension member body mounting rear cushion RH in the correct direction.

    2. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
    3. Using SST, install the front suspension member body mounting rear cushion RH.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060

      HINT: 

      Perform the same procedure as for the LH side.

  4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION 
    1. Temporarily install a new front suspension member body mounting front cushion while confirming the installation direction.
      GTY321763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a View from Underneath
      Front of the Vehicle
      NOTE:

      Position the front suspension member body mounting front cushion in the correct direction.

    2. Install SST using the same procedure as the front suspension member body mounting rear cushion LH.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
    3. Using SST, install the front suspension member body mounting front cushion as shown in the illustration.
      GTY540438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
      *b Turn
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01020
        3. 09830-01030
        4. 09830-01060
      NOTE:

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

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

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

  8. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 
    1. Install the front lower arm bushing stopper to the front lower No. 1 suspension arm sub-assembly LH.
    2. Install the front lower No. 1 suspension arm sub-assembly LH to the front frame assembly with the 3 bolts and nut in the order shown in the illustration.
      Fig 1: Front Lower No. 1 Suspension Arm Sub-Assembly LH Tightening Sequence
      GTY250359Courtesy 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:

      While keeping the nut from rotating, tighten the bolt.

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

    HINT: 

    Perform the same procedure as for the LH side.

  10. INSTALL STEERING LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY 
    1. Install the front stabilizer bar with 2 front stabilizer link assemblies to the front frame assembly.
  12. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 

    See step  3

  13. INSTALL FRONT NO. 1 STABILIZER BRACKET RH 

    HINT: 

    Perform the same procedure as for the LH side.

  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 heavy component. Make sure that it is supported securely.
      • Make sure to secure the front frame assembly to prevent it from dropping.
      NOTE:

      Use the attachments to keep the front frame assembly level.

    2. Install the frame side rail plate RH and frame side rail plate LH with the 4 bolts and 2 nuts.
      GTY559179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A 

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

      B 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

    3. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 4 bolts and 2 nuts.

      C 

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

      D 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

    4. Connect the 2 clamps.
  15. REMOVE BELT 

    Refer to PROCEDURE - Step 18

  16. REMOVE ENGINE SUPPORT BRIDGE 

    Refer to PROCEDURE - Step 19

  17. REMOVE ENGINE HANGERS 

    Refer to PROCEDURE - Step 1

  18. INSTALL NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 36

  19. CONNECT WIRE HARNESS 

    Refer to PROCEDURE - Step 44

  20. INSTALL FRONT ENGINE MOUNTING INSULATOR 
    1. Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

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

  21. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Install the engine mounting insulator LH to the front frame assembly with the 3 nuts.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

    2. Install the 2 hole plugs.
  22. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Install the engine mounting insulator RH to the front frame assembly with the 3 nuts.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

    2. Install the 2 hole plugs.
  23. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 7

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

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

    Refer to PROCEDURE - Step 8

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

    HINT: 

    Perform the same procedure as for the LH side.

  28. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  29. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 

    See step  5

  31. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  32. INSTALL FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 12

  33. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 9

  35. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  36. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    (Refer to PROCEDURE - Step 12 )

  37. INSPECT FOR EXHAUST GAS LEAK 
  38. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 85

  39. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  40. REMOVE FRONT FENDER TO COWL SIDE SEAL LH 

    Refer to PROCEDURE - Step 4

  41. REMOVE FRONT FENDER TO COWL SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  42. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  43. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH 

    Refer to PROCEDURE - Step 7

  44. REMOVE FRONT WIPER ARM HEAD CAP 

    Refer to PROCEDURE - Step 8

  45. INSTALL FRONT FENDER APRON SEAL LH 
  46. INSTALL FRONT FENDER APRON SEAL RH 
  47. INSTALL ENGINE UNDER COVER LH 
  48. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
  49. INSTALL ENGINE UNDER COVER RH 
  50. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
  51. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1049 kgf*cm, 73 ft.*lbf) 

  52. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [10/2014 - 10/2015] or ADJUSTMENT [10/2015 - ] )

  53. CHECK FOR SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [10/2014 - 10/2015] or TEST MODE PROCEDURE [10/2015 - ] )

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