Installation

2ZR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION

1. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 4 wire harness clamp brackets with the 4 bolts.





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

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

2. INSTALL EXHAUST MANIFOLD

(a) Install a new exhaust manifold gasket and exhaust manifold with the 5 nuts in the sequence shown in the illustration.





Torque : 21 Nm (214 kgf-cm, 16 ft-lbf) for Type A

Torque : 37 Nm (377 kgf-cm, 27 ft-lbf) for Type B

Text in Illustration





3. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the 3 bolts.





Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)

4. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 1 exhaust manifold heat insulator with the 4 bolts.





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

5. INSTALL AIR TUBE ASSEMBLY

(a) Install the air tube assembly with the 2 bolts.





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

6. INSTALL NO. 1 WATER BY-PASS PIPE

(a) Install the water by-pass pipe with the 2 bolts.





Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

(b) Connect the No. 3 water by-pass hose with the clip.

7. INSTALL WATER INLET HOSE

(a) Install the water inlet hose with the 2 clips.





8. INSTALL WATER BY-PASS HOSE

(a) Install the water by-pass hose with the clip.





9. INSTALL OIL LEVEL GAGE GUIDE

(a) Install a new O-ring.





(b) Install the oil level gage guide with the bolt.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

10. INSTALL OIL LEVEL DIPSTICK

11. INSTALL VENTILATION HOSE

(a) Install the ventilation hose.





12. INSTALL FAN BELT ADJUSTING BAR

(a) Install the fan belt adjusting bar with the bolt.





Torque : 19 Nm (189 kgf-cm, 14 ft-lbf)

13. INSTALL GENERATOR ASSEMBLY Installation

14. INSTALL FUEL INJECTOR Installation

15. INSTALL INJECTOR VIBRATION INSULATOR Installation

16. INSTALL NO. 1 DELIVERY PIPE SPACER Installation

17. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

(a) Install the fuel delivery pipe with the 4 fuel injectors, then provisionally install the 3 bolts.





NOTICE:
* Do not drop the fuel injectors when installing the fuel delivery pipe.
* Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.

(b) Tighten the 3 bolts to the specified torque.

Torque : 21 Nm (214 kgf-cm, 16 ft-lbf)

18. INSTALL INTAKE MANIFOLD

(a) Install a new gasket onto the intake manifold.





(b) Provisionally tighten the intake manifold and manifold stay with the 4 bolts and 2 nuts in the order shown in the illustration, and then tighten them to the specified torque.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

(c) Install the wire harness clamp onto the intake manifold.





(d) Install the ventilation hose into the intake manifold.

(e) Install the No. 1 vacuum transmitting hose with the clip.

(f) Install the No. 1 fuel vapor feed hose into the throttle body manifold.





(g) Install the 2 water by-pass hoses with the 2 clips.

19. INSTALL NO. 1 RADIATOR HOSE

(a) Install the No. 1 radiator hose with the clip.





20. INSTALL HEATER WATER HOSE INLET A

(a) Install heater water inlet hose A with the clip.





21. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

(a) Install heater water outlet hose A with the clip.





22. INSTALL NO. 2 VENTILATION HOSE

(a) Install the No. 2 ventilation hose.





23. INSTALL ENGINE WIRE

24. INSTALL RADIO SETTING CONDENSER

(a) Install the radio setting condenser with the bolt.





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

(b) Connect the radio setting condenser connector.

25. INSTALL IGNITION COIL ASSEMBLY

(a) Install the 4 ignition coil assemblies with the 4 bolts.





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

(b) Connect the 4 ignition coil assembly connectors.