Installation

1GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE HANGER

(a) Install 2 engine hangers with 4 bolts as shown in the illustration.

Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)

2. REMOVE ENGINE STAND

(a) Attach an engine sling device and hang the engine with a chain block.

(b) Lift the engine and remove it from the engine stand.

(c) Place the engine onto a work bench.

3. INSTALL ENGINE ASSEMBLY

(a) Attach an engine sling device and hang the engine with a chain block.

(b) Slowly lower the engine into the engine compartment.

(c) Install the front engine mounting insulator LH with the 3 nuts.

for nut A - Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)

for nut B - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

(d) Install the front engine mounting insulator RH with the 3 nuts.

for nut A - Torque : 72 Nm (734 kgf-cm, 53 ft-lbf)

for nut B - Torque : 40 Nm (408 kgf-cm, 30 ft-lbf)

(e) Remove the 4 bolts and 2 engine hangers.

4. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.

SST : 09213-54015

91651-60855

SST : 09330-00021

(b) Install the front spacer, drive plate and rear spacer to the crankshaft.

HINT
As the front spacer, drive plate and ring gear and rear spacer are not reversible, be sure to install it in the direction shown in the illustration.

(c) Apply adhesive to 2 or 3 threads at the end of the 8 bolts.

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

(d) Uniformly install and tighten the 8 bolts in several steps in the sequence shown in the illustration.

Torque : 83 Nm (846 kgf-cm, 61 ft-lbf)

NOTICE:
Do not start the engine for at least 1 hour after installing.

5. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (for Automatic Transmission)

(a) Connect the oil cooler tube with the bolt.

Torque : 14 Nm (143 kgf-cm, 10 ft-lbf)

6. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Connect the suction hose with the bolt.

Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)

7. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for 4WD)

8. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR (for 2WD) Installation

9. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) for 4WD:

Install the automatic transmission to the vehicle .

(b) for 2WD:

Install the automatic transmission to the vehicle Installation.

10. INSTALL PROPELLER SHAFT ASSEMBLY (for 4WD) Installation

11. INSTALL PROPELLER SHAFT ASSEMBLY (for 2WD) Installation

12. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD) Installation

13. CONNECT NO. 1 AND NO. 2 FUEL PIPES

(a) Connect the No. 1 and No. 2 fuel pipes Service Precautions.

(b) Install the fuel pipe clamp to the connector.

14. CONNECT HEATER WATER HOSE ASSEMBLY

(a) Connect the 2 hoses and heater water hose.

HINT
The direction of the hose clamp is indicated in the illustration.

15. CONNECT ENGINE WIRE

(a) Connect the ECM connector.

(1) Attach the grommet to the wire harness support.

(2) Pass the wire harness into the vehicle and install the wire harness support.

(3) Connect the 6 connectors and attach the clamp.

(b) Install the lower instrument panel Installation.

(d) Connect the connector and install the bolt.

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

16. INSTALL FLYWHEEL HOUSING SIDE COVER

17. INSTALL STARTER ASSEMBLY Installation

18. INSTALL STARTER COVER Installation

19. INSTALL GENERATOR ASSEMBLY Installation

20. INSTALL WIRING HARNESS CLAMP BRACKET Installation

21. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH Installation

22. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation

23. INSTALL MANIFOLD STAY Installation

24. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH Installation

25. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation

26. INSTALL NO. 2 MANIFOLD STAY Installation

27. INSTALL FRONT EXHAUST PIPE ASSEMBLY

(a) Install the front exhaust pipe Installation.

28. INSTALL COOLER COMPRESSOR ASSEMBLY Installation

29. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation

30. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation

31. CONNECT VANE PUMP ASSEMBLY Installation

32. INSTALL FAN AND GENERATOR V BELT Installation

33. INSTALL INTAKE AIR SURGE TANK Installation

34. INSTALL RADIATOR ASSEMBLY Installation

35. INSTALL FAN SHROUD Installation

36. CONNECT OIL COOLER TUBE Installation

37. INSTALL RADIATOR RESERVOIR Installation

38. INSTALL NO. 2 RADIATOR HOSE Installation

39. INSTALL NO. 1 RADIATOR HOSE Installation

40. INSTALL RADIATOR SIDE DEFLECTOR LH Installation

41. INSTALL RADIATOR SIDE DEFLECTOR RH Installation

42. INSTALL UPPER FRONT BUMPER RETAINER Installation

43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case with the 3 bolts.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(b) Attach the wire harness clamp.

(c) Install the air cleaner filter element.

44. INSTALL AIR CLEANER CAP AND HOSE Installation

45. INSTALL FRONT BUMPER COVER

(a) Install the front bumper cover Installation.

46. INSTALL V-BANK COVER Installation

47. INSTALL BATTERY TRAY

48. INSTALL BATTERY

49. INSTALL BATTERY HOLD DOWN CLAMP Installation

50. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

51. ADD ENGINE COOLANT Service and Repair

52. ADD ENGINE OIL Replacement

53. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

(a) Install the cowl top ventilator louver Installation.

54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

55. INSPECT FOR FUEL LEAK Installation

56. INSPECT FOR ENGINE OIL LEAK Replacement

57. INSPECT FOR EXHAUST GAS LEAK

58. CHECK ENGINE OIL LEVEL Testing and Inspection

59. INSTALL UPPER RADIATOR SUPPORT SEAL

(a) Install the upper radiator support seal with the 13 clips.

60. INSTALL NO. 1 FRONT FENDER APRON TO FRAME SEAL RH

(a) Install the No. 1 front fender apron to frame seal with the 5 clips.

61. INSTALL NO. 1 FRONT FENDER APRON TO FRAME SEAL LH

(a) Install the No. 1 front fender apron to frame seal with the 5 clips.

62. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal with the 5 clips.

63. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal with the 5 clips.

64. INSTALL REAR ENGINE UNDER COVER ASSEMBLY

(a) Install the rear engine under cover with the 4 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

65. INSTALL TRANSMISSION UNDER COVER

(a) Install the transmission under cover with the 2 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

66. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

(a) Hook the engine under cover to the vehicle body as shown in the illustration.

(b) Install the 4 bolts.

Torque : 29 Nm (296 kgf-cm, 21 ft-lbf)

67. INSTALL FRONT BUMPER COVER LOWER

(a) Install the front bumper cover lower with the 5 bolts and clip.

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

68. PERFORM RESET MEMORY

(a) for 2WD:

Perform the Reset Memory procedures Programming and Relearning.

(b) for 4WD:

Perform the Reset Memory procedures .

69. INSPECT IGNITION TIMING Engine

70. INSPECT ENGINE IDLE SPEED Engine

71. INSPECT CO/HC Engine

72. INSTALL HOOD SUB-ASSEMBLY

(a) Install the hood with the 8 bolts.

for bolt A - Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)

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

(b) Connect the washer nozzle hose.

73. ADJUST HOOD SUB-ASSEMBLY Adjustments

74. CHARGE REFRIGERANT Service and Repair

75. WARM UP ENGINE Service and Repair

76. CHECK FOR REFRIGERANT GAS LEAK Service and Repair