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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 2GR-FKS) >> Removal [11/2016 - ] >> Procedure

Removal [11/2016 - ]: Procedure

  1. PRECAUTION 
    NOTE:

    After turning the engine switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

    Refer to PRECAUTION [11/2016 - ]

  2. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD 
  3. SECURE STEERING WHEEL 

    Refer to PROCEDURE - Step 2

  4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    NOTE:

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

    Refer to INITIALIZATION [11/2016 - ]

  5. REMOVE FRONT WHEELS 
  6. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY 

    Refer to REMOVAL [12/2013 - ]

  7. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 

    See step  4

  8. REMOVE NO. 1 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 8

  9. REMOVE NO. 2 ENGINE UNDER COVER 

    Refer to PROCEDURE - Step 9

  10. REMOVE FRONT FLOOR COVER LH 

    Refer to PROCEDURE - Step 10

  11. SEPARATE FRONT FENDER LINER LH 

    Refer to PROCEDURE - Step 11

  12. SEPARATE FRONT FENDER LINER RH 

    Refer to PROCEDURE - Step 12

  13. REMOVE FRONT FENDER APRON SEAL LH 

    Refer to PROCEDURE - Step 13

  14. REMOVE FRONT FENDER APRON SEAL RH 

    Refer to PROCEDURE - Step 14

  15. REMOVE RADIATOR SIDE DEFLECTOR SEAL LH 

    Refer to PROCEDURE - Step 1

  16. REMOVE RADIATOR SIDE SEAL RH 

    Refer to PROCEDURE - Step 2

  17. REMOVE COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3

  18. REMOVE V-BANK COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 25

  19. REMOVE INLET AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 27

  20. DRAIN ENGINE COOLANT 

    Refer to PROCEDURE - Step 1

  21. REMOVE AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE 

    Refer to PROCEDURE - Step 28

  22. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 3

  23. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 4

  24. REMOVE BATTERY 

    Refer to PROCEDURE - Step 26

  25. DISCONNECT ENGINE WIRE 
    1. Remove the 2 bolts and nut, disconnect the engine wire from the automatic transaxle case sub-assembly.
      GTY738391Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. SEPARATE BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY 

    Refer to PROCEDURE - Step 29

  27. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 8

  28. DISCONNECT PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 9

  29. REMOVE NO. 2 SURGE TANK STAY 

    Refer to PROCEDURE - Step 10

  30. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 11

  31. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 12

  32. REMOVE WIRE HARNESS CLAMP BRACKET 

    for 2WD: Refer to PROCEDURE - Step 34

    for AWD: Refer to PROCEDURE - Step 35

  33. REMOVE FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  34. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side) 

    Refer to PROCEDURE - Step 9

  35. REMOVE FRONT EXHAUST PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 10

  36. REMOVE PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) 

    Refer to REMOVAL [11/2016 - ]

  37. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH 

    See step  7

  38. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  39. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 5

  40. SEPARATE TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 6

  41. SEPARATE TIE ROD ASSEMBLY RH 

    HINT: 

    Use the same procedure described for the LH side.

  42. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  43. SEPARATE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  44. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for AWD) 
    1. Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.
      GTY729826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for AWD) 

    HINT: 

    Perform the same procedure as for the LH side.

  46. SEPARATE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 12

  47. SEPARATE STEERING LINK ASSEMBLY (for AWD) 

    Refer to PROCEDURE - Step 13

  48. SEPARATE TRANSMISSION OIL THERMOSTAT 
    1. Remove the 2 bolts and separate the transmission oil thermostat from the front frame assembly.
      GTY729827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. SEPARATE FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Remove the hole plug.
    2. Remove the 3 nuts and separate the front engine mounting insulator assembly.
      GTY737731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. SEPARATE ENGINE MOUNTING INSULATOR LH 
    1. Remove the 2 hole plugs.
    2. Remove the 3 nuts and separate the engine mounting insulator LH from the front frame assembly.
      GTY717466Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. SEPARATE ENGINE MOUNTING INSULATOR RH 
    1. Remove the 2 hole plugs.
    2. Remove the 3 nuts and separate the engine mounting insulator RH from the front frame assembly.
      GTY717459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. SEPARATE REAR ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Remove the 2 hole plugs.
    2. Remove the 2 nuts and separate the rear engine mounting insulator assembly from the front frame assembly.
      GTY717460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. INSTALL ENGINE HANGERS 

    for 2WD: Refer to PROCEDURE - Step 59

    for AWD: Refer to PROCEDURE - Step 65

  54. INSTALL ENGINE SUPPORT BRIDGE 

    for 2WD: Refer to PROCEDURE - Step 60

    for AWD: Refer to PROCEDURE - Step 66

  55. INSTALL BELT 

    for 2WD: Refer to PROCEDURE - Step 63

    for AWD: Refer to PROCEDURE - Step 69

  56. REMOVE FRONT FRAME ASSEMBLY 
    1. Using the chain block assembly, lift the engine with automatic transaxle assembly until the engine is slightly raised off the front frame assembly.
      GTY723623Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Chain Block Assembly
      Turn
      NOTE:
      • When suspending the engine with automatic transaxle assembly, do not tighten the chain block assembly more than 41 N*m (418 kgf*cm, 30 ft.*lbf).
      • Lift the engine with automatic transaxle assembly until the engine is slightly raised off the front frame assembly.
      • Do not lift the engine with automatic transaxle assembly excessively.
      • Do not shake the engine with automatic transaxle assembly excessively while it is suspended.
    2. Support the front frame assembly with an engine lifter using 4 attachments or equivalent tools as shown in the illustration.
      GTY716163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Engine Lifter
      *b Attachment
      Attachment Placement Location
      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.

    3. Remove the 6 bolts, 2 nuts and frame side rail plate RH and frame side rail plate LH.
      GTY709614Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut
    4. Remove the 6 bolts, 2 nuts and front suspension member rear brace RH and front suspension member rear brace LH.
    5. Slowly lower the front frame assembly.
      NOTE:

      When lowering the front frame assembly, be careful not to damage the vehicle body or other components installed to the vehicle.

  57. REMOVE FRONT NO. 1 STABILIZER BRACKET LH (for 2WD) 
    1. Remove the 2 bolts and front No. 1 stabilizer bracket LH from the front frame assembly.
      GTY425867Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE FRONT NO. 1 STABILIZER BRACKET RH (for 2WD) 

    HINT: 

    Perform the same procedure as for the LH side.

  59. REMOVE FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY (for 2WD) 
    1. Remove the front stabilizer bar with 2 front No. 2 stabilizer brackets, 2 front No. 1 stabilizer bar bushings and 2 front stabilizer link assemblies from the front frame assembly.
  60. REMOVE STEERING LINK ASSEMBLY (for 2WD) 
    1. Remove the 2 bolts, 2 nuts and steering link assembly from the front frame assembly.
      GTY718512Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Keep the nut from rotating while turning the bolt because the nut has its own stopper.

  61. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 
    1. Remove the 3 bolts, nut and front lower No. 1 suspension arm sub-assembly LH from the front frame assembly.
      GTY428667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

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

  62. REMOVE FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  63. REMOVE NO. 2 FRAME CROSSMEMBER DYNAMIC DAMPER 
    1. for 2WD:
      1. Remove the 2 bolts and No. 2 frame crossmember dynamic damper from the front frame assembly.
        GTY450851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. for AWD:
      1. Remove the 2 bolts and No. 2 frame crossmember dynamic damper from the front frame assembly.
        GTY425871Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT STOPPER 
    1. Remove the 2 front suspension member body mounting front stoppers from the front frame assembly.
  65. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR STOPPER 
    1. Remove the 2 front suspension member body mounting rear stoppers from the front frame assembly.
  66. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION 
    1. Install SST as shown in the illustration.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01040
        3. 09830-01050
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09954-04010
        4. 09955-04011
        5. 09958-04011
      GTY432828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Suspension Member Body Mounting Front Cushion
    2. Using SST, remove each front suspension member body mounting front cushion from the front frame assembly.
      GTY448204Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      NOTE:
      • Make sure that the claws of SST are securely engaged to the mounting cushion.
      • Tighten SST slowly and evenly.
      • Be careful as the mounting cushion may fly out.
      • The mounting cushion cannot be reused.
  67. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH 
    1. Install SST as shown in the illustration.
      • SST: 09830-10010 
        1. 09830-01010
        2. 09830-01040
        3. 09830-01050
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09954-04010
        4. 09955-04011
        5. 09958-04011
      GTY438194Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Front Suspension Member Body Mounting Rear Cushion LH
    2. Using SST, remove the front suspension member body mounting rear cushion LH from the front frame assembly.
      GTY447868Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      NOTE:
      • Make sure that the claws of SST are securely engaged to the mounting cushion.
      • Tighten SST slowly and evenly.
      • Be careful as the mounting cushion may fly out.
      • The mounting cushion cannot be reused.
  68. REMOVE FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION RH 

    HINT: 

    Perform the same procedure as for the LH side.

  69. REMOVE HOLE PLUG 
    1. Remove the 10 hole plugs from the front frame assembly.

      HINT: 

      There are 2 different shapes of hole plug.

      GTY446224Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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