FRONT SUSPENSION MEMBER(When Using the Engine Support Bridge for 2GR-FKS) INSTALLATION

PROCEDURE


  1. INSTALL HOLE PLUG


    1. Install the 10 hole plugs to the front frame assembly.

      Tech Tips

      There are 2 different shapes of hole plug.

      A002CM2N01

  2. INSTALL FRONT SUSPENSION MEMBER BODY MOUNTING REAR CUSHION LH


    1. A0029J9C01
      *a View from Underneath
      B003ZIE 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. A0027WMC01
      *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. A0027N5C05
      *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. A002BBFC01
      *a View from Underneath
      B003ZIE 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 for 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. A002CA3C01
      *a View from Underneath
      B003ZIE 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 for the front suspension member body mounting rear cushion LH.

      SST
      09830-10010   ( 09830-01010, 09830-01020, 09830-01030, 09830-01060 )
    3. A002CJCC05
      *a Hold
      *b Turn

      Using SST, install each 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 NO. 2 FRAME CROSSMEMBER DYNAMIC DAMPER


    1. for 2WD:


      1. A00294E

        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 }

    2. for AWD:


      1. A002AIW

        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 }

  8. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH


    1. A00272BN01

      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

      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

    Tech Tips

    Perform the same procedure as for the LH side.

  10. INSTALL STEERING LINK ASSEMBLY (for 2WD)


    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 (for 2WD)


    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 (for 2WD)


    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 (for 2WD)

    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 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.

      A0027TV

      Note

      Use attachments to keep the front frame assembly level.

    2. Install the front frame assembly to the vehicle body.

    3. A002BMGC02
      B003ZIE Bolt
      B003Z8F Nut

      Install the frame side rail plate sub-assembly RH and frame side rail plate sub-assembly LH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
      Nut (C)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

    4. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (D)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (E)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
      Nut (F)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

    5. Lower the engine lifter.

  15. REMOVE BELT

    for 2WD: Click here

    for AWD: Click here

  16. REMOVE ENGINE SUPPORT BRIDGE

    for 2WD: Click here

    for AWD: Click here

  17. REMOVE ENGINE HANGERS

    for 2WD: Click here

    for AWD: Click here

  18. 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.

  19. 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.

  20. 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.

  21. 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.

  22. CONNECT TRANSMISSION OIL THERMOSTAT


    1. Connect the transmission oil thermostat to the front frame assembly with the 2 bolts.

      Torque:
      19.5 N*m  { 199 kgf*cm, 14 ft.*lbf }

  23. INSTALL STEERING LINK ASSEMBLY (for AWD)

    Click here

  24. INSTALL FRONT STABILIZER BAR WITH FRONT STABILIZER LINK ASSEMBLY (for AWD)

    Click here

  25. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (for AWD)


    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 }

  26. INSTALL FRONT NO. 1 STABILIZER BRACKET RH (for AWD)

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

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

    Tech Tips

    Perform the same procedure as for the LH side.

  29. CONNECT TIE ROD ASSEMBLY LH

    Click here

  30. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  32. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  33. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  34. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  35. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  36. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  37. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

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

    Click here

  39. INSTALL WIRE HARNESS CLAMP BRACKET

    for 2WD: Click here

    for AWD: Click here

  40. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET

    Click here

  41. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  42. CONNECT PURGE VALVE (PURGE VSV)

    Click here

  43. CONNECT VENTILATION HOSE

    Click here

  44. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)

    Click here

  45. CONNECT ENGINE WIRE


    1. A0028QAN02

      Connect the engine wire to the automatic transaxle case sub-assembly with the 2 bolts and nut.

      Torque:
      Bolt (A)
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }
      Bolt (B)
      19.1 N*m  { 195 kgf*cm, 14 ft.*lbf }
      Nut (C)
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  46. INSTALL BATTERY

    Click here

  47. INSTALL THROTTLE BODY GASKET

    Click here

  48. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  49. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE

    Click here

  50. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  51. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  52. INSTALL RADIATOR SIDE SEAL RH

    Click here

  53. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH

    Click here

  54. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

    for LHD: Click here

    for RHD: Click here

  55. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

    Click here

  56. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  57. ADD ENGINE COOLANT

    Click here

  58. INSPECT FOR COOLANT LEAK

    Click here

  59. WARM UP ENGINE

    Click here

  60. INSPECT FOR EXHAUST GAS LEAK

    Click here

  61. INSPECT AND ADJUST TRANSFER OIL (for AWD)

    Click here

  62. INSTALL FRONT FENDER APRON SEAL LH

    Click here

  63. INSTALL FRONT FENDER APRON SEAL RH

    Click here

  64. INSTALL FRONT FENDER LINER LH

    Click here

  65. INSTALL FRONT FENDER LINER RH

    Click here

  66. INSTALL FRONT FLOOR COVER LH

    Click here

  67. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  68. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  69. INSTALL V-BANK COVER SUB-ASSEMBLY

    Click here

  70. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  71. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  72. CHECK FOR SPEED SENSOR SIGNAL

    Click here