Installation

1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL ENGINE WIRE
(a) Connect the connectors to the engine.
(b) Engage the clamps to the engine.
(c) Connect the connector to the knock sensor sub wire.
(d) Install the ground wire onto the bank 2 cylinder head with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Install the ground wire onto the bank 1 cylinder head with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
2. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
3. INSTALL OIL FILLER CAP HOUSING
(a) Install a new gasket.
(b) Install the oil filler cap housing with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
4. INSTALL OIL FILLER CAP SUB-ASSEMBLY
5. INSTALL IGNITION COIL ASSEMBLY Installation

6. INSTALL INTAKE MANIFOLD Installation

7. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY Installation

8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY Installation

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY Installation

10. 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 (435 kgf-cm, 31 ft-lbf)

11. 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 (435 kgf-cm, 31 ft-lbf)
12. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

13. INSTALL NO. 2 MANIFOLD STAY Installation

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

15. INSTALL MANIFOLD STAY Installation

16. INSTALL NO. 2 VENTILATION HOSE

17. INSTALL VENTILATION HOSE

18. INSTALL HEATER OUTLET WATER HOSE

19. INSTALL HEATER INLET WATER HOSE
20. INSTALL ENGINE ASSEMBLY

(a) Attach the engine sling device and hang the engine with a 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.
21. INSTALL ENGINE WIRE
(a) Connect the front differential connector (for Automatic Transmission 4WD).

(b) Install the ground wire with the bolt and engage the clamp.
Torque: 8.4 Nm (85 kgf-cm, 74 in-lbf)
(c) Connect the 2 connectors to the A/C unit.
(d) Connect the 3 connectors to the ECM.
(e) Connect the connector to the four wheel drive ECU (for Automatic Transmission 4WD).
(f) Install the glove compartment door Installation.
22. INSTALL NO. 2 ENGINE WIRE

(a) Install the engine wire onto the engine room relay block with the nut.
Torque: 10 Nm (102 kgf-cm, 7.4 ft-lbf)

(b) Connect the connector to the engine room relay block.

(d) Install the ground wire onto the body with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 7.4 in-lbf)

23. CONNECT HEATER WATER OUTLET HOSE

24. CONNECT HEATER INLET WATER HOSE

25. CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
(a) Connect the No. 2 fuel tube connector and fuel pipe, and install the No. 2 fuel pipe clamp.
NOTE: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

26. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
(a) Connect the No. 1 fuel tube connector and fuel pipe, and install the No. 2 fuel pipe clamp.
NOTE: Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a click sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

27. INSTALL VANE PUMP ASSEMBLY Installation

28. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

29. INSTALL GENERATOR ASSEMBLY Installation

30. INSTALL INTAKE AIR SURGE TANK Installation

31. INSTALL NO. 2 SURGE TANK STAY Installation

32. INSTALL NO. 1 SURGE TANK STAY Installation

33. INSTALL OIL BAFFLE PLATE Installation

34. INSTALL THROTTLE BODY BRACKET Installation

35. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Apply adhesive to the 2 or 3 end threads of the bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent.

(c) Install the flywheel and 2 spacers onto the crankshaft.
(d) Install the flywheel with the 6 bolts in the order shown in the illustration.
Torque: 83 Nm (846 kgf-cm, 61 ft-lbf)
36. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

(a) Using SST, hold the crankshaft.
SST: 09213-54015
91651-60855
SST: 09330-00021

(b) Apply adhesive to the 2 or 3 end threads of the bolts.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or the equivalent.

(c) Install the drive plate and 2 spacers onto the crankshaft.
(d) Install the drive plate with the 6 bolts in the order shown in the illustration.
Torque: 83 Nm (846 kgf-cm, 61 ft-lbf)
37. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)
Refer to the procedures up to "INSTALL CLUTCH DISC ASSEMBLY" Installation.
38. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)
Refer to the procedures up to "INSTALL MANUAL TRANSMISSION" Installation.
39. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
Refer to the procedures up to "INSTALL AUTOMATIC TRANSMISSION" Installation or Installation).
40. INSTALL RADIATOR ASSEMBLY
Refer to the procedures up to "INSTALL RADIATOR ASSEMBLY" Installation.

41. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
(b) Connect the windshield washer hose.
42. INSTALL HOOD SUPPORT Installation

43. INSTALL BATTERY
44. ADD ENGINE COOLANT Service and Repair

45. ADD ENGINE OIL Replacement

46. PERFORM INITIALIZATION (for Automatic Transmission) Programming and Relearning

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. INSPECT IGNITION TIMING Engine

52. INSPECT ENGINE IDLING SPEED Engine

53. INSPECT COMPRESSION Engine

54. INSPECT CO/HC Engine

55. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Refer to the procedures up to "INSPECT AND ADJUST FRONT WHEEL ALIGNMENT" Service and Repair.