Installation
1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
1. INSTALL OIL LEVEL DIPSTICK 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
7. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY Installation
8. INSTALL INTAKE MANIFOLD
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 Installation
12. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
13. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
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
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
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 AND 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 connector to the four wheel ECU (4WD only).
(f) Connect the 7 connectors to the ECM.
(g) Engage the wire harness clamp.
(h) Install the instrument panel finish panel sub-assembly lower RH.
(i) 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 Installation
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 AIR TUBE ASSEMBLY (w/ Secondary Air Injection System)
(a) Install the air tube assembly with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) Connect the 2 wire harness clamps.
(c) Install the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
40. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)
Installation
41. INSTALL NO. 2 AIR CLEANER HOSE (w/ Secondary Air Injection System)
(a) Install the No. 2 air cleaner hose with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
42. INSTALL AIR PUMP ASSEMBLY (w/ Secondary Air Injection System)
Installation
43. INSTALL AIR CLEANER ASSEMBLY Installation
44. INSTALL RADIATOR ASSEMBLY Installation
45. INSTALL FAN SHROUD Installation
46. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
47. INSTALL HOOD SUB-ASSEMBLY
Reassembly
48. INSTALL BATTERY
49. ADD ENGINE COOLANT Service and Repair
50. ADD ENGINE OIL Installation
51. PERFORM INITIALIZATION
52. CHECK FOR ENGINE COOLANT LEAKAGE Service and Repair
53. CHECK FOR ENGINE OIL LEAKAGE
54. CHECK FOR FUEL LEAKAGE
55. CHECK FOR EXHAUST GAS LEAKAGE
56. INSTALL V-BANK COVER Installation
57. INSPECT IGNITION TIMING Engine
58. INSPECT ENGINE IDLING SPEED Engine
59. INSPECT CO/HC Engine