Part 1

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.
Torque: 20 Nm (200 kgf-cm, 14 ft-lbf)
2. INSTALL KNOCK CONTROL SENSOR Installation

3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.

4. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

(a) Install the bolt and No. 1 vacuum switching valve.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL RADIO SETTING CONDENSER

(a) Install the 2 bolts and 2 radio setting condensers.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL NO. 1 ENGINE FRONT MOUNTING BRACKET LH

(a) Install the No. 1 engine front mounting bracket LH with the 6 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
7. INSTALL WATER PUMP PULLEY Installation

8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
9. INSTALL NO. 2 TIMING GEAR COVER

(a) Install the No. 2 timing gear cover with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
HINT: Each bolt length is as follows:
A: 70 mm (2.76 in.)
B: 33 mm (1.30 in.)

(b) Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
(c) Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
11. INSTALL GENERATOR ASSEMBLY

12. INSTALL COOLER COMPRESSOR ASSEMBLY

13. INSTALL ENGINE MOUNTING BRACKET RR (for 4WD)

(a) Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
14. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)

(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
15. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
16. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Install a new gasket as shown in the illustration.

(b) Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
17. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 insulator with the 3 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
18. INSTALL NO. 2 MANIFOLD STAY

(a) Install the No. 2 manifold stay with the bolt and nut in the order shown in the illustration.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
19. INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY

(a) Install 2 new O-rings to the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the oil level gauge guide end into the guide hole.
(d) Install the No. 1 oil level gauge guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(e) Install the No. 2 oil level gauge guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(f) Install the oil level gauge.
20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Install a new gasket as shown in the illustration.

(b) Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
21. INSTALL INTAKE MANIFOLD
NOTE: DO NOT apply oil to the bolts listed below:

(a) Set a new gasket on each cylinder head.
- Align the port holes of the gasket and cylinder head.
- Make sure that the gasket is installed in the correct direction.

(b) Set the intake manifold on the cylinder heads.
(c) Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
22. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 mounting stay RH with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
23. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
24. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
NOTE: DO NOT apply oil to the bolts listed below:

(a) Install a new gasket to the intake air surge tank.

(b) Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.
Bolt - Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
Nut - Torque: 16 Nm (163 kgf-cm, 12 ft-lbf)
(c) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)

(d) Connect the connector.
(e) Connect the No. 1 ventilation hose.

(f) Install the clamp and connect the throttle with motor body assembly connector.
(g) Connect the vapor feed hose.
(h) Connect the 2 water by-pass hoses to the throttle with motor body assembly.
25. INSTALL VENTILATION HOSE

(a) Using pliers, grip the claws of the 2 clips and slide the 2 clips to the intake air surge tank assembly and ventilation valve.
26. INSTALL ENGINE HANGERS

(a) Install the 4 bolts, and 2 engine hangers.
27. REMOVE ENGINE STAND
28. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

29. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) .

30. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD) Installation.

31. INSTALL TRANSFER STIFFENER PLATE RH Installation

32. INSTALL MANIFOLD STAY

(a) Install the bolt, nut, and manifold stay.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)
33. INSTALL ENGINE FRONT MOUNTING BRACKET

34. INSTALL STARTER ASSEMBLY

35. INSTALL ENGINE WIRE
36. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

37. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation

38. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation

39. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)

(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft-lbf)

(d) Connect the connector and clamp.
40. INSTALL POWER STEERING LINK

41. INSTALL FRONT STABILIZER BAR

42. REMOVE ENGINE HANGERS

(a) Remove the 4 bolts and 2 engine hangers.
43. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump with the 2 bolts and nut.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

(b) Install the 2 pressure feed tube clamp nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
(c) Connect the power steering oil pressure switch connector.
44. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.

(c) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.
A - Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
B - Torque: 32 Nm (329 kgf-cm, 24 ft-lbf)

(d) Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
A - Torque: 85 Nm (867 kgf-cm, 63 ft-lbf)
B - Torque: 32 Nm (329 kgf-cm, 24 ft-lbf)
45. RECONNECT SUCTION HOSE SUB-ASSEMBLY

46. RECONNECT DISCHARGE HOSE SUB-ASSEMBLY

47. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY

48. INSTALL FRONT AXLE ASSEMBLY LH Installation

49. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

50. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation

51. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedures described for the LH side.

52. INSTALL TIE ROD ASSEMBLY LH Installation

53. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

54. INSTALL FRONT SPEED SENSOR LH Installation

55. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedures described for the LH side.

56. INSTALL FRONT AXLE HUB NUT LH Installation

57. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedures described for the LH side.

58. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

59. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedures described for the LH side.

60. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY Installation