INSTALLATION

PROCEDURE

1. INSTALL FRONT DIFFERENTIAL SUPPORT GUARD LH (w/ Differential Support Guard)

(a) Install the front differential support guard LH to the front suspension crossmember sub-assembly with the 2 bolts.

Torque:

18.5 N·m {189 kgf·cm, 14 ft·lbf}

NOTICE:

Make sure to install the front differential support guard LH with its arrow facing the front of the vehicle.

*a	Arrow
	Front of the Vehicle

2. INSTALL HOLE PLUG (except G16E-GTS)

(a) Install the 4 hole plugs to the front suspension crossmember sub-assembly. HINT: There are 2 different shapes of hole plug.

3. INSTALL FRONT SUSPENSION MEMBER PLATE (except G16E-GTS)

(a) Install the 2 front suspension member plates to the front suspension crossmember sub-assembly.

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

(a) Temporarily install the front lower No. 1 suspension arm sub-assembly LH to the front suspension crossmember sub-assembly with the 2 bolts and nut.

5. TEMPORARILY INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

6. INSTALL ENGINE MOVING CONTROL ROD

(a) Install the engine moving control rod to the front suspension crossmember sub-assembly with the bolt.

Torque:

200 N·m {2039 kgf·cm, 148 ft·lbf}

7. INSTALL FRONT STABILIZER BAR

Click here

8. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (except G16E-GTS)

Click here

9. INSTALL FRONT NO. 1 STABILIZER BRACKET RH (except G16E-GTS)

HINT:

Perform the same procedure as for the LH side.

10. INSTALL FRONT STABILIZER BRACKET (for G16E-GTS)

Click here

11. INSTALL STEERING LINK ASSEMBLY

for G16E-GTS: Click here

except G16E-GTS: Click here

12. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (except G16E-GTS)

(a) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(b) Install the front suspension crossmember sub-assembly to the vehicle body with the 4 bolts.

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(c) Lower the engine lifter.

(d) Install the engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

(e) Install the 2 wire harness clamp brackets to the front suspension crossmember sub-assembly with the 2 bolts.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for G16E-GTS)

(a) Slowly jack up the front suspension crossmember sub-assembly with an engine lifter using 4 attachments or equivalent tools.

NOTICE:

Use attachments to keep the front suspension crossmember sub-assembly level.

(b) Install the front suspension crossmember sub-assembly to the vehicle body with the 4 bolts.

Torque:

141 N·m {1438 kgf·cm, 104 ft·lbf}

(c) Lower the engine lifter.

(d) Install the engine moving control rod with the bolt.

Torque:

170 N·m {1734 kgf·cm, 125 ft·lbf}

(e) Install the wire harness clamp bracket to the front suspension crossmember sub-assembly with the bolt.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(f) Engage the clamp to install the wire harness to the front suspension crossmember sub-assembly.

(g) Engage the 2 clamps to install the wire harness to the No. 2 steering rack housing bracket.

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

for G16E-GTS: Click here

except G16E-GTS: Click here

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

HINT:

Perform the same procedure as for the LH side.

16. CONNECT TIE ROD END SUB-ASSEMBLY LH

Click here

17. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

18. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

(a) Connect the front stabilizer link assembly LH to the front stabilizer bar with the nut.

Torque:

74 N·m {755 kgf·cm, 55 ft·lbf}

NOTICE:

Do not damage the boot of the ball joint.

HINT:

If the ball joint turns together with the nut, use a 6 mm hexagon socket wrench to hold the stud bolt.

19. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

20. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

(a) Install the rear side rail reinforcement sub-assembly LH to the front suspension crossmember sub-assembly and vehicle body with the 4 bolts. Torque: 70 N·m {714 kgf·cm, 52 ft·lbf}

21. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH (except G16E-GTS)

HINT:

Perform the same procedure as for the LH side.

22. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH (for G16E-GTS)

(a) Install the rear side rail reinforcement sub-assembly RH to the front suspension crossmember sub-assembly, the No. 1 air tube and vehicle body with the 6 bolts. Torque: Bolt (A) : 70 N·m {714 kgf·cm, 52 ft·lbf} Bolt (B) : 7.0 N·m {71 kgf·cm, 62 in·lbf}

23. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

Click here

24. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

Click here

25. INSTALL COLUMN HOLE COVER SILENCER SHEET

Click here

26. INSTALL FRONT WHEELS

Click here

27. STABILIZE SUSPENSION

(a) Lower the vehicle.

(b) Bounce the vehicle up and down several times to stabilize the suspension.

28. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

for M20A-FKS: Click here

for ZR Series Engine: Click here

for G16E-GTS: Click here

29. FULLY TIGHTEN FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

for M20A-FKS: Click here

for ZR Series Engine: Click here

for G16E-GTS: Click here

30. INSTALL REAR ENGINE UNDER COVER LH

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for 2ZR-FXE: Click here

for G16E-GTS: Click here

31. INSTALL REAR ENGINE UNDER COVER RH

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for 2ZR-FXE: Click here

for G16E-GTS: Click here

32. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

for M20A-FKS: Click here

for 2ZR-FAE: Click here

for 2ZR-FXE: Click here

for G16E-GTS: Click here

33. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

Click here