Installation

1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
2. INSTALL SPARK PLUG
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
3. INSTALL IGNITION COIL ASSEMBLY
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
4. INSTALL OIL FILLER CAP HOUSING
(a) Install a new gasket and oil filler cap housing with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
5. INSTALL OIL FILLER CAP SUB-ASSEMBLY
6. INSTALL WATER BY-PASS JOINT RR Installation
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
(a) Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
8. INSTALL INTAKE MANIFOLD Installation
9. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
10. INSTALL WATER INLET Installation
11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation
12. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY Installation
13. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation
14. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install the engine mounting bracket with engine mounting insulator with the 3 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
15. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket with engine mounting insulator with the 4 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation
18. INSTALL NO. 2 VENTILATION HOSE
19. INSTALL VENTILATION HOSE
20. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
21. INSTALL HEATER WATER INLET HOSE A
22. INSTALL RADIATOR OUTLET, NO. 2 HOSE CLAMP OR CLIP
23. INSTALL NO. 1 RADIATOR HOSE
24. INSTALL ENGINE WIRE
25. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY Installation
26. INSTALL ENGINE ASSEMBLY
(a) Attach the engine sling device and hang the engine with the chain block.
(b) Lower the engine into the engine room carefully.
(c) Attach the engine mounting brackets to the frame brackets.
(d) Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts.
Torque: 38 Nm (387 kgf-cm, 28 ft-lbf)
(e) Remove the 4 bolts and 2 engine hangers.
27. INSTALL NO. 2 ENGINE WIRE
(a) Install the ground cable to the cylinder block.
Torque: 13 Nm (133 kgf-cm, 9 ft-lbf)
28. INSTALL ENGINE WIRE
(a) Connect the front differential connector.
(b) Insert the engine wire to the cabin space, and install the grommet.
(c) Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire.
(d) Install the glove compartment door.
(e) Install the cowl side trim board RH.
(f) Install the front door scuff plate RH.
29. INSTALL INTAKE AIR SURGE TANK Installation
30. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
31. CONNECT HEATER WATER INLET HOSE B
32. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Installation
33. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Installation
34. INSTALL COOLER COMPRESSOR Installation
35. INSTALL GENERATOR ASSEMBLY Installation
36. INSTALL VANE PUMP ASSEMBLY Installation
37. INSTALL FAN PULLEY
38. INSTALL FAN WITH FLUID COUPLING
(a) Temporarily install the fan with fluid coupling with the 4 nuts.
39. INSTALL FAN AND GENERATOR V BELT Installation
40. FULLY TIGHTEN FAN WITH FLUID COUPLING Installation
41. INSTALL FAN SHROUD
(a) Put the fan shroud into the engine room.
(b) Connect the 2 oil cooler hoses with the hose clamp.
42. INSTALL RADIATOR ASSEMBLY Installation
43. INSTALL RADIATOR SUPPORT SEAL UPPER
44. INSTALL AIR CLEANER ASSEMBLY Installation
45. CONNECT NO. 2 VENTILATION HOSE
46. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(b) Tighten the 2 hood supports.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
(c) Connect the windshield washer hose.
47. ADJUST HOOD SUB-ASSEMBLY Adjustments
48. INSTALL BATTERY
49. ADD ENGINE OIL Installation
50. ADD ENGINE COOLANT Service and Repair
51. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)

HINT: Installation

52. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)

HINT:

53. CHECK FOR ENGINE COOLANT LEAKAGE Service and Repair
54. CHECK FOR FUEL LEAKAGE Testing and Inspection
55. CHECK FOR ENGINE OIL LEAKAGE
56. INSTALL V-BANK COVER
(a) Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
57. INSPECT IGNITION TIMING Engine
58. INSPECT ENGINE IDLE SPEED Engine
59. INSPECT CO/HC Engine