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Installation [11/2016 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.
  1. INSTALL HOLE PLUG 
    1. Install the 10 hole plugs to the front frame assembly.

      HINT: 

      There are 2 different shapes of hole plug.

      GTY446224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      GTY443041Courtesy 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.

    2. Install SST as shown in the illustration.
      GTY435175Courtesy 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
    3. Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration.
      GTY445738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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.
      GTY432844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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 for 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.
      GTY436274Courtesy 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.

    2. Install SST using the same procedure as for 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 each front suspension member body mounting front cushion as shown in the illustration.
      GTY451690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *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) 

      GTY436494Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSTALL NO. 2 FRAME CROSSMEMBER DYNAMIC DAMPER 
    1. Install the No. 2 frame crossmember dynamic damper to the front frame assembly with the 2 bolts.

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

  9. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 
    1. 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: Tightening Sequence Of Front Lower No. 1 Suspension Arm Sub-Assembly LH
      GTY443164Courtesy 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.

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

    HINT: 

    Perform the same procedure as for the LH side.

  11. INSTALL STEERING LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  12. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY 

    Refer to PROCEDURE - Step 4

  13. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 

    See step  5

  14. INSTALL FRONT NO. 1 STABILIZER BRACKET RH 

    HINT: 

    Perform the same procedure as for the LH side.

  15. 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 RH and frame side rail plate 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) 

      GTY695038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Install the front suspension member rear brace RH and front suspension member rear brace 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.
  16. REMOVE BELT 

    Refer to PROCEDURE - Step 20

  17. REMOVE ENGINE SUPPORT BRIDGE 

    Refer to PROCEDURE - Step 21

  18. REMOVE ENGINE HANGERS 

    Refer to PROCEDURE - Step 22

  19. INSTALL WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 14

  20. CONNECT FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Connect the front engine mounting insulator assembly to the front frame assembly with the 3 nuts.

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

    2. Install the hole plug.
  21. CONNECT ENGINE MOUNTING INSULATOR LH 
    1. Connect the engine mounting insulator LH to the front frame assembly with the 3 nuts.

      Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf) 

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

      Torque: 99 N*m (1010 kgf*cm, 73 ft.*lbf) 

    2. Install the 2 hole plugs.
  23. CONNECT REAR ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Connect the rear engine mounting insulator assembly to the front frame assembly with the 2 nuts.

      Torque: 58 N*m (591 kgf*cm, 43 ft.*lbf) 

    2. Install the 2 hole plugs.
  24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  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 8

  27. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  28. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 10

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    See step  8

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 19

  33. INSTALL ENGINE WIRE 
    1. Engage the 2 clamps.
      GTY713693Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the engine wire with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

    3. Install the No. 3 earth wire with the bolt.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  34. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 15

  35. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  36. CONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 17

  37. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 18

  38. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  39. INSTALL INVERTER TRAY BRACKET SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 50

  40. INSTALL INVERTER WITH CONVERTER ASSEMBLY 

    Refer to PROCEDURE - Step 6

  41. INSTALL V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 74

  42. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 10

  43. INSTALL FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 78

  44. INSTALL FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 79

  45. INSTALL FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 80

  46. INSTALL FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 81

  47. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 82

  48. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 83

  49. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 84

  50. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf) 

  51. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2016 - ]

  52. CHECK FOR SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2016 - ]

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