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Home >> Toyota >> 2017 >> Highlander LE Plus, AWD >> Repair and Diagnosis >> Suspension >> Front Suspension >> Front Suspension (Service Information) (Except Hybrid) >> FRONT SUSPENSION MEMBER (for 1AR-FE) >> Installation [11/2016 - ] >> Procedure

Installation [11/2016 - ]: Procedure

  1. INSTALL HOLE PLUG 
    1. Install the 14 hole plugs to the front frame assembly.

      HINT: 

      There are 4 different shapes of hole plug.

      GTY424304Courtesy 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) 

      GTY425869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. 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.
      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.

  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 
    1. Install the steering link assembly to the front frame assembly with the 2 bolts and 2 nuts.

      Torque: 70 N*m (714 kgf*cm, 52 ft.*lbf) 

      NOTE:
      • Make sure to tighten the bolts starting from the steering link assembly pinion shaft side.
      • Keep the nut from rotating while turning the bolt because the nut has its own stopper.
  11. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY 
    1. Install the front stabilizer bar with 2 front No. 2 stabilizer brackets, 2 front No. 1 stabilizer bar bushings and 2 front stabilizer link assemblies to the front frame assembly.
  12. INSTALL FRONT NO. 1 STABILIZER BRACKET LH 
    1. Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts.

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

  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 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) 

      GTY722867Courtesy 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.
  15. REMOVE BELT 

    Refer to PROCEDURE - Step 16

  16. REMOVE ENGINE SUPPORT BRIDGE 

    Refer to PROCEDURE - Step 19

  17. REMOVE ENGINE HANGERS 

    Refer to PROCEDURE - Step 20

  18. INSTALL NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 35

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

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

    2. Install the hole plug.
  20. 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.
  21. 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.
  22. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 7

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

    Refer to PROCEDURE - Step 8

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

    HINT: 

    Perform the same procedure as for the LH side.

  25. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 12

  26. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  27. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 14

  28. CONNECT FRONT STABILIZER LINK ASSEMBLY LH 

    See step  8

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. CONNECT ENGINE WIRE 
    1. Connect the 3 wire clamps.
      GTY713833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. INSTALL BATTERY 

    Refer to PROCEDURE - Step 46

  32. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 
    1. Move the brake master cylinder reservoir assembly as shown in the illustration to engage the 2 claws.
      GTY426172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Brake Master Cylinder Reservoir Assembly
      *2 Reservoir Bracket
    2. Connect the reservoir level switch connector and install the bolt.

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

  33. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 49

  34. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 50

  35. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 4

  36. INSTALL INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 52

  37. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 67

  38. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 4

  39. INSTALL RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 5

  40. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 6

  41. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY 

    See step  10

  42. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to PROCEDURE - Step 3

  43. 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 [11/2016 - ]

  44. INSPECT FOR EXHAUST GAS LEAK 

    Refer to PROCEDURE - Step 8

  45. INSTALL FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 75

  46. INSTALL FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 76

  47. INSTALL FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 77

  48. INSTALL FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 78

  49. INSTALL FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 8

  50. INSTALL NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 80

  51. INSTALL NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 81

  52. INSTALL FRONT WHEELS 

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

  53. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    Refer to ADJUSTMENT [11/2016 - ]

  54. INSPECT SPEED SENSOR SIGNAL 

    Refer to TEST MODE PROCEDURE [11/2016 - ]

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