Installation

1UR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the 2 engine mounting insulators with the 2 nuts.

Torque : 70 Nm (714 kgf-cm, 52 ft-lbf)

(b) Install the 2 engine mounting spacers.

2. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the front suspension crossmember sub-assembly with the 2 nuts.

Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.

SST : 09213-54015

90119-08216

SST : 09330-00021

(b) Install the crankshaft angle sensor rotor, drive plate and ring gear sub-assembly and drive plate spacer RR on the crankshaft.

(c) Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.

Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)

NOTICE:
* Do not reuse the drive plate and ring gear sub-assembly installation bolts.
* Do not impact or damage the drive plate and ring gear sub-assembly installation bolts. Be sure to handle them carefully.
(d) Mark the upside of each drive plate and ring gear sub-assembly installation bolt with paint.

(e) Retighten the drive plate and ring gear sub-assembly installation bolts 90° as shown in the illustration.

(f) Check that the painted marks are now at a 90° angle to the upside.

4. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY Installation

5. INSTALL REAR ENGINE MOUNTING MEMBER

(a) Install the rear engine mounting member with the 4 nuts.

Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

6. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Installation

7. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Installation

8. INSTALL STARTER ASSEMBLY Installation

9. INSTALL GENERATOR ASSEMBLY Installation

10. INSTALL COMPRESSOR AND PULLEY

(a) Using an E8 "TORX" socket, install the compressor and pulley with the 2 stud bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Install the compressor and pulley with the 2 bolts and 2nuts.

Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)

11. INSTALL OIL COOLER TUBE SUB-ASSEMBLY Installation

12. INSTALL ENGINE WIRE

13. INSTALL V-RIBBED BELT Installation

14. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR Installation

15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Apply a light coat of engine oil to a new O-ring.

(b) Install the new O-ring to the engine oil level dipstick guide.

(c) Install the engine oil level dipstick guide with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(d) Install the engine oil level dipstick.

20. INSTALL ENGINE AND TRANSMISSION

(a) Place the engine on an engine lifter.

HINT
Place the engine on wooden blocks or an equivalent so that the engine is level.

(b) Remove the 2 bolts and 2 No. 1 engine hangers.

(c) Operate the engine lifter, then install the engine to the vehicle.

NOTICE:
Make sure that the engine is clear of all wiring and hoses.

(d) Install the 10 bolts and 2 nuts.

Bolt A - Torque : 204 Nm (2080 kgf-cm, 150 ft-lbf)

Bolt B - Torque : 50 Nm (510 kgf-cm, 37 ft-lbf)

Bolt C - Torque : 49 Nm (500 kgf-cm, 36 ft-lbf)

Nut - Torque : 167 Nm (1700 kgf-cm, 123 ft-lbf)

(e) Install the engine rear mounting member with the 4 bolts.

Torque : 26 Nm (265 kgf-cm, 19 ft-lbf)

21. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY Installation

22. INSTALL STEERING ACTUATOR ASSEMBLY

(a) Install the steering actuator assembly Installation

23. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY Installation

24. CONNECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY Installation

25. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH Installation

26. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

27. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH Installation

28. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

29. CONNECT FRONT ACTIVE STABILIZER CONTROL ACTUATOR ASSEMBLY (w/ Active Stabilizer System) Installation

30. INSTALL REAR PROPELLER SHAFT ASSEMBLY

(a) Install the rear propeller shaft assembly Installation.

31. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe assembly Installation.

32. CONNECT WIRE HARNESS

(a) Connect the power steering wire harness.

(1) Connect the 2 connectors to the power steering link (A).

(2) Connect the wire harness connector to the power steering link and securely lock the connector (B).

(3) Connect the 2 wire harness clamps.

(4) Connect the ground cable with the bolt (C).

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Install the ground cable with the nut.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(c) Connect the ground cable with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Connect the positive (+) battery cable with the nut.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(e) Connect the clamp.

(f) Connect the wire to the engine room No. 1 junction block.

(g) Install the nut and connect the wire harness clamp.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(h) Install the engine room No. 1 relay block cover.

(i) Connect the 5 connectors to the ECM box.

(j) Connect the No. 4 connector holder.

(k) Connect the 3 connectors and connector clamp.

33. INSTALL ENGINE ROOM ECU COVER Installation

34. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Installation

35. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

36. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the No. 1 fuel pipe sub-assembly until the fuel tube connector makes a "click" sound.

NOTICE:
* Check that there is no damage or foreign objects on the connected part of the fuel pipe.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Push in the fuel tube connector to the No. 1 fuel pipe sub-assembly until the fuel tube connector makes a "click" sound.

(c) Push down on the retainer to lock it in place.

NOTICE:
* Check that there is no damage or foreign objects on the connected part of the fuel pipe.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(d) Install the 2 fuel pipe clamps.

37. CONNECT NO. 3 FUEL HOSE

(a) Push in the fuel tube connector to the No. 3 fuel hose until the fuel tube connector makes a "click" sound.

38. INSTALL NO. 2 FUEL VAPOR FEED HOSE

(a) Connect the No. 2 fuel vapor feed hose.

39. INSTALL HEATER WATER HOSE OUTLET

(a) Connect the heater outlet water hose.

40. INSTALL HEATER WATER HOSE INLET

(a) Connect the heater inlet water hose.

41. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose with the clamp.

42. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose with the clamp.

43. CONNECT NO. 1 OIL COOLER OUTLET HOSE

(a) Connect the No. 1 oil cooler outlet hose with the clamp.

44. CONNECT NO. 1 OIL COOLER INLET HOSE

(a) Connect the No. 1 oil cooler inlet hose with the clamp.

45. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly with the 3 bolts.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

46. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

(a) Install the air cleaner filter element to the air cleaner case sub-assembly.

(b) Align the tab on the throttle body with the groove on the air cleaner hose and tighten the hose clamp bolt and 4 clamps.

(c) Install the bolt and connect the 2 ventilation hoses with the 2 clamps.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

(d) Connect the MAF meter connector.

47. ADD ENGINE OIL Replacement

48. ADD ENGINE COOLANT Service and Repair

49. ADD AUTOMATIC TRANSMISSION FLUID Installation

50. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

51. INSPECT FOR OIL LEAK

52. INSPECT FOR COOLANT LEAK Testing and Inspection

53. INSPECT FOR FUEL LEAK Testing and Inspection

54. INSPECT FOR EXHAUST GAS LEAK

55. INSTALL FRONT WHEEL

56. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

57. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

(a) Check and adjust the front wheel alignment Front Wheel Alignment.

58. CHECK SHIFT LEVER POSITION AA80E Automatic Transmission

59. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

60. INSTALL NO. 2 ENGINE UNDER COVER

61. INSTALL REAR ENGINE UNDER COVER RH

62. INSTALL REAR ENGINE UNDER COVER LH

63. INSTALL ENGINE UNDER COVER

64. CHECK IGNITION TIMING Engine

65. CHECK IDLE SPEED Engine

66. CHECK CO/HC Engine

67. CHECK ENGINE OIL LEVEL Testing and Inspection

68. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No. 1 air cleaner inlet with the bolt.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

69. INSTALL ENGINE ROOM SIDE COVER RH

(a) Install the engine room side cover RH with the 3 clips.

70. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the engine room side cover LH with the 3 clips.

71. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the cool air intake duct seal with the 7 clips.

72. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 4 clips to install the V-bank cover.

NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.