Engine Mechanical (1GR-FE): Removal & Installation — Engine Mechanical (1GR-FE) — Mechanical

INSTALLATION

INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
INSTALL SPARK PLUG Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
INSTALL IGNITION COIL ASSEMBLY (See «INSTALLATION»(ref-263622-S40530376892007091100000) )
INSTALL OIL FILLER CAP HOUSING Install a new gasket and oil filler cap housing with the 2 nuts. Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
INSTALL OIL FILLER CAP SUB-ASSEMBLY
INSTALL WATER BY-PASS JOINT RR (See «INSTALLATION»(ref-263620-S21477777982007091100000) )
INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See «INSTALLATION»(ref-281736-S25029447432008031900000) )
INSTALL INTAKE MANIFOLD (See «INSTALLATION»(ref-263620-S21477777982007091100000) )
INSTALL OIL FILTER BRACKET SUB-ASSEMBLY Install a new gasket and oil filler bracket with the 3 bolts and 2 nuts.
INSTALL WATER INLET (See «INSTALLATION»(ref-263626-S28996822532007091100000) )
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (See «INSTALLATION»(ref-263620-S01802223722007091100000) )
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-263620-S03930477642007091100000) )
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY (See «INSTALLATION»(ref-263620-S03930477642007091100000) )
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH Install the engine mounting bracket w/ engine mounting insulator with the 3 bolts. Torque: 43 N*m (435 kgf*cm, 31 ft.*lbf)
INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH Install the engine mounting bracket w/ engine mounting insulator with the 4 bolts. Torque: 43 N*m (435 kgf*cm, 31 ft.*lbf)
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (See «INSTALLATION»(ref-263620-S38449452742007091100000) )
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (See «INSTALLATION»(ref-263620-S21477777982007091100000) )
INSTALL NO. 2 VENTILATION HOSE
INSTALL VENTILATION HOSE
INSTALL HEATER WATER INLET HOSE
INSTALL HEATER WATER OUTLET HOSE
INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission) (See «INSTALLATION»(ref-263620-S27364259222007091100000) )
INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY (for Automatic Transmission) (See «INSTALLATION»(ref-263620-S27364259222007091100000) )
INSTALL ENGINE ASSEMBLY Attach the engine sling device and hang the engine with the chain block. Lower the engine into the engine compartment carefully. Attach the engine mounting brackets to the frame brackets. Install the engine mounting brackets onto the frame brackets with the 4 bolts and 4 nuts. Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) Remove the 4 bolts and 2 engine hangers.
INSTALL NO. 2 ENGINE WIRE Install the ground cable to the cylinder block. Torque: 13 N*m (133 kgf*cm, 9 ft.*lbf)
INSTALL ENGINE WIRE Connect the 3 connectors to the engine room relay box. Install the nut, then install the engine wire into the engine room relay block. Connect the front differential connector (4WD only). Insert the engine wire into the vehicle room, and install the grommet. Connect the 2 connectors to the four wheel ECU (4WD only). Connect the 5 connectors to the ECM. Install the instrument panel finish panel subassembly lower RH. Install the glove compartment door.
INSTALL INTAKE AIR SURGE TANK (See «INSTALLATION»(ref-263620-S05240243742007091100000) )
CONNECT HEATER WATER INLET HOSE
CONNECT HEATER WATER OUTLET HOSE
CONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY
CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-263638-S09800470222007091100000) )
INSTALL COOLER COMPRESSOR ASSEMBLY (See «INSTALLATION»(ref-281736-S07539688622008031900000) )
INSTALL GENERATOR ASSEMBLY (See «INSTALLATION»(ref-263636-S21179071572007091100000) )
INSTALL VANE PUMP ASSEMBLY (See «INSTALLATION»(ref-263620-S01802223722007091100000) )
INSTALL FAN PULLEY
INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission) REFERENCE TABLE TO INSTALLING CLUTCH DISC ASSEMBLY (FOR MANUAL TRANSMISSION) Transmission Reference RA60 «INSTALLATION»(ref-263646-S27879359882007091100000) RA60F «INSTALLATION»(ref-263646-S14840440092007091100000)
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission) REFERENCE TABLE TO INSTALLING CLUTCH COVER ASSEMBLY (FOR MANUAL TRANSMISSION) Transmission Reference RA60 «INSTALLATION»(ref-263646-S27879359882007091100000) RA60F «INSTALLATION»(ref-263646-S14840440092007091100000)
INSTALL TRANSMISSION ASSEMBLY HINT: Refer to «REFERENCE TABLE TO INSTALLING TRANSMISSION ASSEMBLY»(ref-263620-S24940122062007091100000) when installing transmission. REFERENCE TABLE TO INSTALLING TRANSMISSION ASSEMBLY Transmission Drive Type Reference Manual Transmission 2WD «INSTALLATION»(ref-263644-S01398578982007091100000) Manual Transmission 4WD «INSTALLATION»(ref-263645-S15021966692007091100000) Automatic Transmission 2WD «INSTALLATION»(ref-281737-S15141080542008031900000) Automatic Transmission 4WD «INSTALLATION»(ref-281740-S09675877532008031900000)
INSTALL RADIATOR ASSEMBLY (See «INSTALLATION»(ref-263626-S14308694572007091100000) )
INSTALL FAN SHROUD (See «INSTALLATION»(ref-263626-S14308694572007091100000) )
INSTALL RADIATOR SUPPORT TO FRAME SEAL LH
INSTALL HOOD SUB-ASSEMBLY (See «REASSEMBLY»(ref-263647-S29070790782007091100000) )
INSTALL BATTERY
ADD ENGINE COOLANT (See «COOLANT»(ref-263626-S39394347042007091100000) )
ADD ENGINE OIL (See «INSTALLATION»(ref-263624-S07410963482007091100000) )
PERFORM INITIALIZATION
CHECK FOR ENGINE COOLANT LEAKAGE (See «COOLANT»(ref-263626-S39394347042007091100000) )
CHECK FOR ENGINE OIL LEAKAGE
CHECK FOR FUEL LEAKAGE
CHECK FOR EXHAUST GAS LEAKAGE
INSTALL V-BANK COVER (See «INSTALLATION»(ref-281736-S15610641232008031900000) )
INSPECT IGNITION TIMING (See «ENGINE»(ref-263620-S37039823592007091100000) )
INSPECT ENGINE IDLING SPEED (See «ENGINE»(ref-263620-S37039823592007091100000) )
INSPECT CO/HC (See «ENGINE»(ref-263620-S37039823592007091100000) )