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Installation





1NR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION

1. INSTALL WIRING HARNESS CLAMP BRACKET

(a) Install the wiring harness clamp bracket to the cylinder head cover with the bolt.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

(b) Install the wiring harness clamp bracket to the cylinder head with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(c) Install the wiring harness clamp bracket to the cylinder block with the bolt.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY





(a) Install the V-ribbed belt tensioner and engine cover bracket with the 2 bolts.

Text in Illustration





NOTICE:
Attach stopper of the bracket to the belt tensioner.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

3. INSTALL NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET





(a) Temporarily install the No. 2 idle pulley with bracket with the 4 bolts.

(b) Fully tighten the 4 bolts in the order shown in the illustration.

Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)

4. INSTALL NO. 1 WATER BY-PASS PIPE





(a) Connect the water by-pass hose to the water inlet with the clip.

Text in Illustration





NOTICE:
Install the clip so that its claws face away from the engine.

(b) Temporarily install the No. 1 water by-pass pipe with the 3 bolts.

(c) Fully tighten the 3 bolts in the order shown in the illustration.

Torque : 22 Nm (224 kgf-cm, 16 ft-lbf)

(d) Engage the No. 2 water by-pass hose to the 3 clamps as shown in the illustration.

5. INSTALL NO. 2 VENTILATION HOSE





(a) Install the ventilation hose to the cylinder head with the clip.

Text in Illustration





NOTICE:
* Install the clip so that its claws are within the clip center installation range.
* The protrusion of the head cover should overlap the paint mark of the hose.

6. INSTALL VENTILATION HOSE





(a) Install the ventilation hose to the cylinder head with the clip.

Text in Illustration





NOTICE:
Install the clip so that its claws are within the clip center installation range.

7. INSTALL NO. 1 IGNITION COIL

(a) Install the 4 ignition coils with the 4 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

8. INSTALL INJECTOR VIBRATION INSULATOR Installation

9. INSTALL NO. 1 DELIVERY PIPE SPACER Installation

10. INSTALL FUEL INJECTOR ASSEMBLY Installation

11. INSTALL FUEL DELIVERY PIPE Installation

12. INSTALL EGR HOLE COVER PLATE

(a) Install a new EGR valve gasket onto the cylinder head.

(b) Install the EGR hole cover plate with the 3 nuts.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

13. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the oil level dipstick guide.

HINT
Apply engine oil to the O-ring and install the oil level dipstick guide into the oil pan.

(b) Temporarily install the engine oil level dipstick guide with the 2 bolts.





(c) Fully tighten the 2 bolts in the order shown in the illustration.

Torque : 18 Nm (184 kgf-cm, 13 ft-lbf)

14. INSTALL ENGINE OIL LEVEL DIPSTICK

15. INSTALL NO. 4 ENGINE WIRE

(a) Engage the 7 clamps and install the No. 4 engine wire.

(b) Install the ground bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(c) Connect the 4 fuel injector connectors.

(d) Connect the 4 ignition coil connectors.

(e) Connect the 2 camshaft timing oil control valve connectors.

16. INSTALL INTAKE MANIFOLD ASSEMBLY

(a) Install a new No. 2 intake manifold to head gasket onto the cylinder head.

(b) Temporarily install the intake manifold with the 3 bolts and 2 nuts.





(c) Fully tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

17. INSTALL INTAKE MANIFOLD STAY





(a) Temporarily install the intake manifold stay with the 2 bolts.

(b) Fully tighten the 2 bolts in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

18. CONNECT NO. 4 WATER BY-PASS HOSE





(a) Connect the No. 4 water by-pass hose to the EGR hole cover plate with the clip.

Text in Illustration





NOTICE:
Install the clip so that its claws are within the clip center installation range.

19. CONNECT NO. 2 WATER BY-PASS HOSE





(a) Connect the No. 2 water by-pass hose to the throttle body with the clip.

Text in Illustration





NOTICE:
* Install the clip so that its claws are within the clip installation range.
* Line up the rib of the throttle with motor body assembly with the center of the paint mark.

20. CONNECT VENTILATION HOSE





(a) Connect the ventilation hose to the intake manifold with the clip.

Text in Illustration





NOTICE:
Install the clip so that its claws are within the clip center installation range.

21. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

(a) Install the new exhaust manifold to head gasket onto the cylinder head.

(b) Temporarily install the exhaust manifold converter with the 3 new bolts and 2 new nuts.





(c) Fully tighten the 3 bolts and 2 nuts in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

22. INSTALL MANIFOLD STAY





(a) Temporarily install the manifold stay with the new bolt and new nut.

(b) Fully tighten the bolt and nut in the order shown in the illustration.

Torque : 28 Nm (286 kgf-cm, 21 ft-lbf)

23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR





(a) Temporarily install the exhaust manifold heat insulator with the bolt and 2 nuts.

(b) Fully tighten the bolt and 2 nuts in the order shown in the illustration.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

24. INSTALL GENERATOR ASSEMBLY





(a) Install the generator with the 2 bolts.

Bolt A - Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)

Bolt B - Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
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