Installation

2GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. REMOVE ENGINE STAND

(a) Remove the engine stand.

2. INSTALL FRONT ENGINE MOUNTING INSULATOR LH

(a) Install the front engine mounting insulator LH with the nut.

Torque : 70 Nm (713 kgf-cm, 51 ft-lbf)

3. INSTALL FRONT ENGINE MOUNTING INSULATOR RH

(a) Install the front engine mounting insulator RH with the nut.

Torque : 70 Nm (713 kgf-cm, 51 ft-lbf)

4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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

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

5. INSTALL NO. 1 REAR ENGINE MOUNTING INSULATOR

HINT
Only perform this procedure when replacement of the engine mounting insulator is necessary.

(a) Install the rear No. 1 engine mounting insulator to the automatic transmission assembly with the 4 bolts.

Torque : 12 Nm (120 kgf-cm, 9 ft-lbf)

(b) Install the engine rear mounting member to the automatic transmission assembly with the 4 nuts.

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

6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

7. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY Removal

8. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY Installation

9. CONNECT WIRE HARNESS

(a) Install the wire harness clamp to the automatic transmission assembly with the 2 bolts.

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

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

(b) Connect the park/neutral start switch connector, transmission wire connector, and 2 transmission revolution sensor connectors.

Text in Illustration

HINT
Push up the lever until the claw of the transmission wire connector makes a connection sound.

Text in Illustration

10. INSTALL WATER BY-PASS HOSE

(a) Install the 4 clamps and 2 water by-pass hoses.

(b) Install the bolt and water hose clamp.

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

12. INSTALL FLYWHEEL HOUSING SIDE COVER Installation

13. INSTALL STARTER ASSEMBLY Installation

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Install a new gasket as shown in the illustration.

(b) Install the exhaust manifold with 6 new nuts.

LH:

(b) Install the exhaust manifold with 6 new nuts.

RH:

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

NOTICE:
* Do not damage the stud bolt when installing the exhaust manifold.
* Be sure to tighten either of nuts A first as shown in the illustration.

(c) Connect the air fuel ratio sensor connector.

16. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY

(a) Install a new O-ring to the oil dipstick guide.

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

(c) Push in the oil dipstick guide end into the guide hole.

(d) Install the No. 1 oil dipstick guide with the bolt.

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

(e) Connect the clamp.

(f) Install the No. 2 oil dipstick guide with the bolt.

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

(g) Install the oil dipstick.

17. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH

(a) Install the engine under cover sub-assembly LH.

18. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH

(a) Install the engine under cover sub-assembly RH.

19. INSTALL ENGINE AND TRANSMISSION ASSEMBLY

(a) Set the engine lifter.

(b) Remove the engine hangers.

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

(d) Install the engine and transmission assembly with crossmember with the 14 bolts.

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

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

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

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

Torque : 34 Nm (347 kgf-cm, 24 ft-lbf) for Bolt D

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

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

(f) Install the ground cable with the nut.

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

21. CONNECT POWER STEERING LINK WIRE HARNESS

(a) Install the power steering earth wire to the power steering link assembly with bolt (B).

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

(b) Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.

(c) Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.

(d) Install the 2 wire harness clamps to the power steering link assembly.

(e) Connect the earth wire to the bracket with bolt (A).

Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

22. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

(a) Install the front lower ball joint with the 2 bolts.

Torque : 120 Nm (1224 kgf-cm, 89 ft-lbf)

23. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

HINT
Install the RH side following the same procedure as for the LH side.

24. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH

(a) Install the bolt on the lower side of the front shock absorber while holding the nut.

Torque : 157 Nm (1600 kgf-cm, 116 ft-lbf)

25. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Install the RH side following the same procedure as for the LH side.

26. CONNECT HEIGHT CONTROL SENSOR LINK (w/ HID Headlight System)

(a) Connect the height control sensor link and install it with the nut.

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

27. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY Installation

28. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Install the protector with the 4 new bolts.

Torque : 11 Nm (112 kgf-cm, 8 ft-lbf)

29. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.

HINT
* Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
* Check that the connector and fuel main pipe are securely connected by trying to pull them apart.

(b) Install the fuel pipe clamp.

30. CONNECT NO. 3 FUEL HOSE

(a) Connect the No. 3 fuel hose and clamp.

31. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Observe the following precautions when connecting the fuel tube connectors:

(1) Check that there is no damage or foreign objects on the connector of the pipe.

(2) Match the axis of the connector with the axis of the pipe, and push into the connector until the connector makes a "click" sound. If the connection is tight, apply a small amount of clean engine oil to the tip of the pipe.

(3) After finishing the connection, check if the pipe and the connector are securely connected by pulling on them.

(4) Check for fuel leaks.

(5) Install the No. 1 fuel pipe clamp.

32. CONNECT ENGINE WIRE

(a) Install the bolt, clamp and No. 3 engine wire.

Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)

(b) Connect the ground cable and install it with the bolt.

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

(c) Connect the ground cable and install it with the bolt.

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

(d) Connect the connector and install the 3 clamps.

(e) Connect the No.1 engine wire to the engine room No. 1 junction block. Then, install it with the nut.

Torque : 12 Nm (124 kgf-cm, 9 ft-lbf)

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

(g) Connect the No.2 engine wire and engine room main wire to the positive (+) battery terminal. Then, install it with the nut.

Torque : 7.6 Nm (77 kgf-cm, 67 in-lbf)

(h) Connect the 4 ECM connectors.

(i) Connect the connector holder.

(j) Connect the connector clamp.

(k) Connect the 5connectors.

33. INSTALL ECM COVER Installation

34. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

35. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

36. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

37. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

38. CONNECT RADIATOR RESERVOIR TANK HOSE

(a) Install the clamp and connect the radiator reservoir tank hose.

39. CONNECT NO. 2 RADIATOR HOSE

(a) Install the clamp and connect the No. 2 radiator hose.

40. CONNECT NO. 1 RADIATOR HOSE

(a) Install the clamp and connect the No.1 radiator hose.

41. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 2 fuel vapor feed hose.

42. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the hose to the surge tank.

43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case, clamp and 2 bolts.

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

44. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation

45. INSTALL INLET NO. 1 AIR CLEANER

(a) Install the inlet air cleaner with the bolt and clip.

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

46. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

HINT
Installation.

47. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

48. INSTALL FRONT CENTER FLOOR BRACE Installation

49. INSTALL REAR BODY SUPPORT BRACKET Installation

50. ADD ENGINE OIL Replacement

51. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

52. ADD ENGINE COOLANT Service and Repair

53. CHARGE REFRIGERANT Service and Repair

54. INSPECT FOR FUEL LEAK Fuel System

55. INSPECT FOR COOLANT LEAK Testing and Inspection

56. INSPECT FOR OIL LEAK

57. INSPECT FOR EXHAUST GAS LEAK

58. INSPECT FOR LEAK OF REFRIGERANT Service and Repair

59. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

60. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

61. ADJUST SHIFT LEVER POSITION A760E Automatic Transmission

62. CHECK SHIFT LEVER POSITION Shift Lever Assembly

63. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Installation.

64. CHECK IGNITION TIMING Engine

65. CHECK ENGINE IDLE SPEED Engine

66. CHECK CO / HC Engine

67. CHECK ENGINE OIL LEVEL Testing and Inspection

68. INSTALL REAR ENGINE UNDER COVER LH

(a) Install the rear engine under cover LH with the bolt.

69. INSTALL REAR ENGINE UNDER COVER RH

HINT
Install the RH side following the same procedure as for the LH side.

70. INSTALL NO. 2 ENGINE UNDER COVER

71. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY LH

(a) Install the No. 1 body mounting bracket sub-assembly LH with the 3 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

72. INSTALL NO. 1 BODY MOUNTING BRACKET SUB-ASSEMBLY RH

(a) Install the No. 1 body mounting bracket sub-assembly RH with the 3 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

73. INSTALL NO. 1 FLOOR UNDER COVER

(a) Install the 4 clips and No. 1 floor under cover.

74. INSTALL NO. 2 FLOOR UNDER COVER

(a) Install the 4 clips and No. 2 floor under cover.

75. INSTALL FRONT FLOOR COVER LH

(a) Install the 12 grommets and front floor cover LH.

76. INSTALL FRONT FLOOR COVER RH

(a) Install the 12 grommets and front floor cover RH.

77. INSTALL ENGINE UNDER COVER

78. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 3 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.

79. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the side cover with the 4clips and grommet.

Text in Illustration

80. INSTALL ENGINE ROOM SIDE COVER

(a) Install the side cover with the clip and grommet.

Text in Illustration

81. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 11 clips.