Installation

2UR-GSE 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 : 09213-38010

SST : 09330-00021

(b) Clean the 10 bolt holes.

(c) Install the crankshaft angle sensor rotor.

HINT
Align the pin hole of the crankshaft angle sensor rotor with the pin of the crankshaft.

(d) Install the drive plate and ring gear sub-assembly and drive plate spacer RR on to the crankshaft.

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

Torque : 30 Nm (301 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.

(f) Mark the upside of each drive plate and ring gear sub-assembly installation bolt with paint.

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

(h) 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 to the automatic transmission assembly 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 2 nuts.

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

HINT
Tighten the bolts and nuts in the order shown in the illustration to install the compressor.

11. INSTALL OIL COOLER TUBE

(a) Install the oil cooler tube with the 2 bolts and nut.

Bolt - Torque : 14 Nm (140 kgf-cm, 10 ft-lbf)

Nut - Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Connect the wire harness clamp.

12. CONNECT WIRE HARNESS AND CONNECTORS Installation

13. CONNECT BREATHER PLUG HOSE Installation

14. INSTALL V-RIBBED BELT Installation

15. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR Installation

16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

19. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

20. INSTALL ENGINE MOUNTING DAMPER

(a) Install the 2 engine mounting dampers with the 2 bolts.

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

21. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH

(a) Install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly with the 2 clamps.

22. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH

(a) Install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly with the 2 clamps.

23. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE Installation

24. INSTALL ENGINE OIL LEVEL DIPSTICK

25. INSTALL ENGINE AND TRANSMISSION

(a) Place the engine on an engine lifter.

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

(b) Remove the 2 bolts and 2 engine hangers.

(c) Operate the engine lifter to install the engine into 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 (1703 kgf-cm, 123 ft-lbf)

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

Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

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

27. INSTALL STEERING COLUMN ASSEMBLY

Installation

28. CONNECT STEERING SLIDING YOKE SUB-ASSEMBLY Installation

29. CONNECT HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY Installation

30. CONNECT STEERING KNUCKLE LH Installation

31. CONNECT STEERING KNUCKLE RH

HINT
Perform the same procedure for the LH side.

32. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH Installation

33. TEMPORARILY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

34. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY Installation

35. FULLY TIGHTEN NO. 1 CENTER SUPPORT BEARING ASSEMBLY Installation

36. INSPECT AND ADJUST BOTH NO. 2 AND NO. 3 JOINT ANGLE Installation

37. INSTALL OUTSIDE AIR GUIDE PLATE RH Installation

38. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR Installation

39. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

40. CONNECT HEATED OXYGEN SENSOR Installation

41. INSTALL FRONT CENTER FLOOR BRACE Installation

42. INSTALL REAR NO. 1 FLOOR PANEL BRACE Installation

43. INSTALL TAIL EXHAUST PIPE ASSEMBLY Installation

44. INSTALL NO. 2 FLOOR UNDER COVER Installation

45. INSTALL NO. 1 FLOOR UNDER COVER Installation

46. CONNECT WIRE HARNESS

(a) Install the ground cable with the nut.

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

(b) Connect the power steering wire harness.

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

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

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

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

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

(c) Connect the ground cable with the bolt and clamp.

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

(d) Connect the ground cable with the bolt.

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

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

(f) Connect the clamp.

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

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

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

(i) Connect the positive (+) battery cable with the nut and clamp.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(j) Connect the 5 connectors and grommet to the ECM box.

(k) Connect the No. 4 connector holder.

(l) Connect the 3 connectors and connector clamp.

47. INSTALL ENGINE ROOM ECU COVER Installation

48. INSTALL WIRE HARNESS CLAMP BRACKET Installation

49. INSTALL BATTERY TRAY Installation

50. INSTALL POWER STEERING ECU ASSEMBLY Installation

51. INSTALL NO. 1 BATTERY TRAY SUPPORT

52. INSTALL BATTERY Installation

53. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Installation

54. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation

55. CONNECT NO. 1 FUEL HOSE

(a) Push in the fuel tube connector to the No. 1 fuel hose until the fuel tube connector makes a "click" sound.

NOTICE:
* Check that there is no damage or foreign objects on the fuel pipe connectors.
* 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 hose 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 fuel pipe connectors.
* 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.

56. 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.

57. INSTALL NO. 2 FUEL VAPOR FEED HOSE

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

58. CONNECT VACUUM HOSE ASSEMBLY

(a) Connect the vacuum hose assembly to the intake air surge tank assembly with the clamp.

(b) Connect the vacuum hose assembly to the hose clamp.

NOTICE:
Align the vacuum hose matchmarks and the hose clamps as shown in the illustration.

59. INSTALL HEATER WATER OUTLET HOSE A

(a) Connect the heater water outlet hose A.

60. INSTALL HEATER WATER HOSE INLET A

(a) Connect the heater water inlet hose A.

61. CONNECT NO. 2 OIL COOLER OUTLET HOSE

(a) Connect the No. 2 oil cooler outlet hose with the clip.

62. CONNECT NO. 2 OIL COOLER INLET HOSE

(a) Connect the No. 2 oil cooler inlet hose with the clip.

63. CONNECT NO. 2 RADIATOR HOSE

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

64. CONNECT NO. 1 RADIATOR HOSE

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

65. CONNECT RESERVE TANK OUTLET HOSE

(a) Connect the reserve tank outlet hose with the clamp.

66. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case sub-assembly with the 2 bolts.

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

(b) Connect the vacuum switching valve connector and clamp.

(c) Connect the vacuum hose and 2 clamps.

67. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Installation

69. ADD ENGINE OIL Replacement

70. ADD ENGINE COOLANT Service and Repair

71. ADD AUTOMATIC TRANSMISSION FLUID

Procedures

72. CHARGE REFRIGERANT Service and Repair

73. INSPECT FOR OIL LEAK

74. INSPECT FOR COOLANT LEAK Testing and Inspection

75. INSPECT FOR FUEL LEAK Fuel System

76. INSPECT FOR EXHAUST GAS LEAK

77. INSTALL FRONT WHEEL

78. STABILIZE SUSPENSION Installation

79. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH Installation

80. FULLY TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

81. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

82. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

Front Wheel Alignment

83. ADJUST SHIFT LEVER POSITION Adjustments

84. INSPECT SHIFT LEVER POSITION Initial Inspection and Diagnostic Overview

85. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET

(a) Install the engine under cover air guide bracket with the 2 bolts.

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

86. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR Installation

87. INSTALL NO. 2 ENGINE UNDER COVER

88. INSTALL REAR ENGINE UNDER COVER RH

89. INSTALL REAR ENGINE UNDER COVER LH

90. INSTALL ENGINE UNDER COVER

91. INSTALL NO. 1 AIR CLEANER INLET

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

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

92. INSTALL ENGINE ROOM SIDE COVER RH

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

93. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the engine room side cover LH with the 5 clips.

94. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the cool air intake duct seal with the 9 clips.

95. INSTALL V-BANK COVER SUB-ASSEMBLY

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

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

96. INSPECT IGNITION TIMING Engine

97. INSPECT ENGINE IDLE SPEED Engine

98. INSPECT CO/HC Engine

99. CHECK AUTOMATIC TRANSMISSION SYSTEM PRECAUTION

Initialization

100. VEHICLE PREPARATION FOR HEADLIGHT AIMING ADJUSTMENT Adjustments

101. PREPARATION FOR HEADLIGHT AIMING (Using a headlight aim test machine) Adjustments

102. PREPARATION FOR HEADLIGHT AIMING (Using a screen) Adjustments

103. INSPECT HEADLIGHT AIMING Adjustments

104. ADJUST HEADLIGHT AIMING Adjustments