FRONT SUSPENSION MEMBER (When Using the Engine Support Bridge for 2AR-FE) INSTALLATION


  1. INSTALL HOLE PLUG


    1. Install each hole plug to the front frame assembly.

  2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH


    1. A01HXV4E01
      Text in Illustration
      *a View from Underneath
      A01I0B8 Front of the Vehicle

      Temporarily install a new front suspension member body mounting rear cushion LH while confirming the installation direction.

      Note

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

    2. A01I0M9E01
      Text in Illustration
      *1 Front Suspension Member Body Mounting Rear Cushion LH

      Install SST as shown in the illustration.

      SST
      09830-10010   ( 09830-01010, 09830-01020, 09830-01030, 09830-01060 )
    3. A01I20ME05
      Text in Illustration
      *a Hold
      *b Turn

      Using SST, install the front suspension member body mounting rear cushion LH as shown in the illustration.

      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. A01I0PEE01
      Text in Illustration
      *a View from Underneath
      A01I0B8 Front of the Vehicle

      Temporarily install a new front suspension member body mounting rear cushion RH while confirming the installation direction.

      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   ( 09830-01010, 09830-01020, 09830-01030, 09830-01060 )

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

      SST
      09830-10010   ( 09830-01010, 09830-01020, 09830-01030, 09830-01060 )

      Tech Tips

      Perform the same procedure as for the LH side.

  4. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING FRONT CUSHION


    1. A01HZ4ZE01
      Text in Illustration
      *a View from Underneath
      A01I0B8 Front of the Vehicle

      Temporarily install a new front suspension member body mounting front cushion while confirming the installation direction.

      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   ( 09830-01010, 09830-01020, 09830-01030, 09830-01060 )
    3. A01HYM1E05
      Text in Illustration
      *a Hold
      *b Turn

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

      SST
      09830-10010   ( 09830-01010, 09830-01020, 09830-01030, 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. A01I27R

      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. A01HY1QE01

      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.

      Torque:
      Bolt 1, 2
      200 N*m  { 2039 kgf*cm, 148 ft.*lbf }
      Bolt 3
      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

    Tech Tips

    Perform the same procedure as for the LH side.

  10. INSTALL STEERING LINK ASSEMBLY


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

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

      Note


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

      • Make sure to tighten the bolts starting from the pinion shaft side.

  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


    1. Install the front No. 1 stabilizer bracket LH to the front frame assembly with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  13. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    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.

      CAUTION:


      • 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. A01I1GQE02

      Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

      Torque:
      A
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      B
      32 N*m  { 329 kgf*cm, 24 ft.*lbf }

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

      Torque:
      C
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      D
      32 N*m  { 329 kgf*cm, 24 ft.*lbf }

  15. REMOVE BELT


    1. Install SST to the vehicle body as shown in the illustration.

      A01HYX6E01
      SST
      09727-00110

    2. Using the SST ratchet buckle, tighten the SST belt until there is no slack.

      A01I1LBE01
      Text in Illustration
      *a Ratchet Buckle - -

  16. REMOVE ENGINE SUPPORT BRIDGE


    1. Remove SST from the vehicle body.

      Note

      Prevent SST from contacting the vehicle body or windshield.

    2. Install the 2 hood support assemblies.

      Click here

  17. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts and No. 1 and No. 2 engine hangers from the engine assembly.

  18. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  19. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

  20. INSTALL ENGINE MOUNTING INSULATOR LH


    1. Install 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. INSTALL ENGINE MOUNTING INSULATOR RH


    1. Install 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. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY


    1. A01HY0XE02
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the steering intermediate shaft to the steering link assembly.

    2. Install the bolt.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH


    1. A01I0AWE01
      Text in Illustration
      *a Matchmark

      Align the matchmarks and install the front drive shaft assembly to the front axle hub sub-assembly.

      Note

      Be careful not to damage the drive shaft boot or speed sensor rotor.

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

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


    1. A01HY44E01
      Text in Illustration
      *A Type A Nut
      *B Type B Nut
      *a 20 mm (0.787 in.)
      *b 22 mm (0.866 in.)
      A01I0B8 Bolt
      A01HZQC Nut

      Connect the front lower No. 1 suspension arm sub-assembly to the front lower ball joint assembly with the bolt and 2 nuts.

      Torque:
      Type A Nut and Bolt
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Type B Nut and Bolt
      92 N*m  { 938 kgf*cm, 68 ft.*lbf }

      Note


      • The tightening torque for the bolt differs depending on the type of nut.

      • Make sure to tighten the bolt to the same torque as the nuts.

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

    Tech Tips

    Perform the same procedure as for the LH side.

  27. CONNECT TIE ROD ASSEMBLY LH


    1. Connect the tie rod assembly LH to the steering knuckle with the nut.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    2. Install a new cotter pin.

      Note

      Further tighten the nut up to 60° if the holes for the cotter pin are not aligned.

  28. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. INSTALL FRONT STABILIZER LINK ASSEMBLY LH


    1. Install the front stabilizer link assembly to the front shock absorber assembly with the nut.

      Torque:
      125 N*m  { 1275 kgf*cm, 92 ft.*lbf }

      If the ball joint turns together with the nut, use a wrench to hold the stud bolt.

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH


    1. Clean the threaded parts on the front drive shaft assembly and a new axle shaft nut using a non-residue solvent.

      Note


      • Be sure to perform this work even when using a new drive shaft.

      • Keep the threaded parts free of oil and foreign matter.

    2. A01HXRR

      Using a socket wrench (30 mm), install the front axle shaft nut.

      Torque:
      294 N*m  { 2998 kgf*cm, 217 ft.*lbf }

    3. Using a chisel and hammer, stake the front axle shaft nut.

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01HXZOE03

      Using a vernier caliper, measure the free length of the compression spring.

      Minimum Free Length 40.5 mm (1.60 in.)

      Tech Tips

      If the length is less than the minimum, replace the compression spring.

    2. Temporarily install a new gasket to the exhaust manifold converter sub-assembly.

    3. A01I0DFE40
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Gasket
      *a Wooden Block

      Using a plastic hammer and wooden block, tap in the gasket until its surface is flush with the exhaust manifold converter sub-assembly.

      Note


      • Be sure to install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket.

      • Do not push in the gasket by using the exhaust pipe when connecting it.

    4. Install a new gasket to the front exhaust pipe assembly.

    5. Connect the front exhaust pipe assembly to the exhaust pipe support.

    6. Install the front exhaust pipe assembly with the 2 compression springs, 2 bolts and 2 nuts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    7. Connect the heated oxygen sensor connector.

  34. INSTALL NO. 1 AIR CLEANER BRACKET


    1. Install the No. 1 air cleaner bracket with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 2 wire clamps.

  35. CONNECT ENGINE WIRE


    1. A01HY1Z

      Connect the 2 wire clamps.

    2. Connect the ECM connector with the lock lever.

    3. Connect the engine wire to the engine room relay block.

    4. Connect the 4 connectors.

    5. A01HYSI

      Connect the engine wire to the engine room relay block with the clamp.

    6. Connect the wire clamp and install the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    7. Install the No. 1 relay block cover.

  36. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. Install the battery clamp with the bolt and nut.

      Torque:
      Bolt
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Connect the cable to the positive (+) battery terminal with the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

  37. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A01I0FIE01
      Text in Illustration
      *a Hole
      *b Projection

      Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

    2. Tighten the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Connect the wire harness clamp.

  38. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly.

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  39. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner cap sub-assembly with the 2 clamps.

    2. Install the air cleaner hose with the hose clamp.

    3. Connect the ventilation hose to the cylinder head cover.

    4. Install the fuel vapor feed hose to the air cleaner hose.

    5. Connect the mass air flow meter connector and 2 wire harness clamps to the air cleaner cap sub-assembly.

    6. Connect the vacuum switching valve assembly to the air cleaner hose.

  40. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the negative (-) cable to the negative (-) battery terminal.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

      Note

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

  42. INSPECT FOR EXHAUST GAS LEAK

  43. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Fit the 3 pins and install the No. 1 engine cover sub-assembly.

  44. INSTALL COOL AIR INTAKE DUCT SEAL


    1. Install the cool air intake duct seal with the 9 clips.

  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 WHEEL

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  52. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  53. CHECK FOR SPEED SENSOR SIGNAL

    Click here