Installation
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
2. INSTALL SPARK PLUG
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
3. INSTALL IGNITION COIL ASSEMBLY Installation
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 REAR Installation
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
8. INSTALL INTAKE MANIFOLD Installation
9. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
(a) Install a new gasket and oil filler bracket with the 3 bolts and 2 nuts.
10. INSTALL WATER INLET Installation
11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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 w/ engine mounting insulator with the 3 bolts.
Torque : 43 Nm (435 kgf-cm, 31 ft-lbf)
15. INSTALL FRONT NO.1 ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket w/ engine mounting insulator with the 4 bolts.
Torque : 43 Nm (435 kgf-cm, 31 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 INLET HOSE
21. INSTALL HEATER WATER OUTLET HOSE
22. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) Installation
23. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transmission) Installation
24. INSTALL ENGINE ASSEMBLY
(a) Attach the engine sling device and hang the engine with the chain block.
(b) Lower the engine into the engine compartment carefully.
(c) Attach the engine mounting brackets to the frame brackets.
(d) Install the engine mounting brackets onto 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.
25. INSTALL NO.2 ENGINE WIRE
(a) Install the ground cable to the cylinder block.
Torque : 13 Nm (133 kgf-cm, 9 ft-lbf)
26. INSTALL ENGINE WIRE
(a) Connect the 3 connectors to the engine room relay box.
(b) Install the nut, then install the engine wire into the engine room relay block.
(c) Connect the front differential connector (4WD only).
(d) Insert the engine wire into the vehicle room, and install the grommet.
(e) Connect the 2 connectors to the four wheel ECU (4WD only).
(f) Connect the 5 connectors to the ECM.
(g) Install the instrument panel finish panel sub-assembly lower RH.
(h) Install the glove compartment door.
27. INSTALL INTAKE AIR SURGE TANK Installation
28. CONNECT HEATER WATER INLET HOSE
29. CONNECT HEATER WATER OUTLET HOSE
30. CONNECT NO.2 FUEL PIPE SUB-ASSEMBLY
31. CONNECT NO.1 FUEL PIPE SUB-ASSEMBLY Installation
32. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
33. INSTALL GENERATOR ASSEMBLY Installation
34. INSTALL VANE PUMP ASSEMBLY
35. INSTALL FAN PULLEY
36. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
37. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)
38. INSTALL TRANSMISSION ASSEMBLY
HINT
Refer to the table below when installing transmission.
39. INSTALL RADIATOR ASSEMBLY Installation
40. INSTALL FAN SHROUD Installation
41. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
42. INSTALL HOOD SUB-ASSEMBLY
Reassembly
43. INSTALL BATTERY
44. ADD ENGINE COOLANT Service and Repair
45. ADD ENGINE OIL Installation
46. PERFORM INITIALIZATION
47. CHECK FOR ENGINE COOLANT LEAKAGE Service and Repair
48. CHECK FOR ENGINE OIL LEAKAGE
49. CHECK FOR FUEL LEAKAGE
50. CHECK FOR EXHAUST GAS LEAKAGE
51. INSTALL V-BANK COVER Installation
52. INSPECT IGNITION TIMING Engine
53. INSPECT ENGINE IDLING SPEED Engine
54. INSPECT CO/HC Engine