Diesel Data: Automotive Repair

Installation








EXTERIOR: FRONT BUMPER (for Sedan): INSTALLATION

INSTALLATION

1. INSTALL FRONT BUMPER ARM SUB-ASSEMBLY LH





(a) Insert the 2 locating pins into the 2 body holes and install the front bumper arm with the 4 bolts.
Torque: 40 Nm (410 kgf-cm, 30 ft-lbf)
2. INSTALL FRONT BUMPER ARM SUB-ASSEMBLY RH
HINT: Use the same procedure as for the LH side.

3. INSTALL WINDSHIELD WASHER JAR ASSEMBLY





(a) Insert the location pin into the body hole and install the windshield washer jar with the 2 bolts.
Torque: 5.5 Nm (55 kgf-cm, 49 in-lbf)
4. INSTALL HEADLIGHT ASSEMBLY RH
HINT: Use the same procedure as for the LH side Installation.

5. INSTALL FRONT BUMPER STONE DEFLECTOR BRACKET





(a) Install the front bumper stone deflector bracket with the 2 nuts.
Torque: 5.5 Nm (55 kgf-cm, 49 in-lbf)
HINT: Use the same procedure as for the opposite side.

6. INSTALL FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY





(a) Install the front bumper reinforcement with the 6 bolts and 4 nuts.
Torque: 40 Nm (410 kgf-cm, 30 ft-lbf)
Torque: 5.5 Nm (55 kgf-cm, 49 in-lbf)
7. CONNECT NO. 2 ENGINE ROOM WIRE (w/ Fog Light)





(a) Install the No. 2 engine room wire with the 7 clamps.
8. CONNECT NO. 2 ENGINE ROOM WIRE (w/o Fog Light)





(a) Install the No. 2 engine room wire with the 6 clamps.
9. INSTALL RADIATOR SUPPORT EXTENSION LH (w/ Energy Absorber)





(a) Engage the 2 claws and install the radiator support extension.
10. INSTALL RADIATOR SUPPORT EXTENSION RH (w/ Energy Absorber)
HINT: Use the same procedure as for the LH side.

11. INSTALL RADIATOR SIDE AIR SEAL LH (w/ Energy Absorber)





(a) Engage the 2 claws and install the radiator side air seal.
12. INSTALL RADIATOR SIDE AIR SEAL RH (w/ Energy Absorber)
HINT: Use the same procedure as for the LH side.

13. INSTALL RADIATOR SIDE AIR SEAL LH (w/o Energy Absorber)





(a) Engage the 4 claws and install the radiator side air seal.
14. INSTALL RADIATOR SIDE AIR SEAL RH (w/o Energy Absorber)
HINT: Use the same procedure as for the LH side.

15. INSTALL THERMISTOR ASSEMBLY (w/ Air Conditioning System)





(a) Install the thermistor with the 2 clamps.
16. INSTALL RADIATOR SUPPORT UPPER ABSORBER





(a) Engage the 6 claws and install the radiator support absorber.
17. INSTALL FRONT BUMPER ENERGY ABSORBER LH (w/ Energy Absorber)





(a) Insert the 2 bosses into the hole of the front bumper reinforcement and install the front bumper energy absorber.
18. INSTALL FRONT BUMPER ENERGY ABSORBER RH (w/ Energy Absorber)
HINT: Use the same procedure as for the LH side.

19. INSTALL FRONT BUMPER SIDE RETAINER LH





(a) Engage the 2 claws and install the front bumper side retainer.
(b) Tighten the screw and the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)for bolt
20. INSTALL FRONT BUMPER SIDE RETAINER RH
HINT: Use the same procedure as for the LH side.

21. INSTALL FRONT BUMPER COVER (w/ Large Front Spoiler)





(a) Install the 2 clips, screw grommet and the 6 spring nuts.





(b) Engage the 6 claws and install the front bumper cover.
(c) Connect the connectors.
HINT: If the vehicle is equipped with fog lights, connect the connector.





(d) Install the 6 clips.
(e) Install the 2 screw grommets.
(f) Tighten the 9 bolts and the 7 screws.





(g) Remove the protective tape.
22. INSTALL FRONT BUMPER COVER (w/ Small Front Spoiler)





(a) Install the 2 clips, the screw grommet and the 10 spring nuts.





(b) Engage the 6 claws and install the front bumper cover.
(c) Connect the connectors.
HINT: If the vehicle is equipped with fog lights, connect the connectors.





(d) Install the 6 clips.
(e) Install the 2 screw grommets.
(f) Tighten the 5 screws and the 3 bolts.





(g) Remove the protective tape.
23. INSTALL FRONT BUMPER COVER (w/o Front Spoiler)





(a) Install the 2 clips and the screw grommet.





(b) Engage the 6 claws and install the front bumper cover.
(c) Connect the connectors.
HINT: If the vehicle is equipped with fog lights, connect the connectors.





(d) Install the 6 clips.
(e) Install the 2 screw grommets.
(f) Tighten the 7 screws and the 3 bolts.





(g) Remove the protective tape.
24. INSTALL FRONT SPOILER COVER (w/ Small Front Spoiler)





(a) Install the front spoiler cover with the 2 screws and the 10 bolts.
25. PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT Headlight Assembly (for Sedan)
26. PREPARE FOR HEADLIGHT AIMING (for Using a Screen) Headlight Assembly (for Sedan)
27. INSPECT HEADLIGHT AIMING Headlight Assembly (for Sedan)
28. ADJUST HEADLIGHT AIMING Headlight Assembly (for Sedan)
29. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT (w/ Fog Light) Fog Light Assembly (for Sedan)
30. PREPARE FOR FOG LIGHT AIMING (w/ Fog Light) Fog Light Assembly (for Sedan)
31. INSPECT FOG LIGHT AIMING (w/ Fog Light) Fog Light Assembly (for Sedan)
32. ADJUST FOG LIGHT AIMING (w/ Fog Light) Fog Light Assembly (for Sedan)