Installation

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, 14ft-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, 15ft-lbf)
NOTICE: 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, 7ft-lbf)
5. INSTALL RADIO SETTING CONDENSER

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

(a) Install the No. 1 engine mounting bracket front LH with the 6 bolts.
Torque: 54 Nm (551 kgf-cm, 40ft-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 2 plates with the bolt.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)
HINT: Plate diameter:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)

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, 53in-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, 32ft-lbf)
(c) Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32ft-lbf)
11. INSTALL DRIVE SHAFT BEARING BRACKET

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

(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40ft-lbf)
13. 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.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
14. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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

(a) Install the No. 2 manifold stay with the bolt and nut.
Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
16. 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 oil level gauge guide No. 1 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(e) Install the oil level gauge guide No. 2 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(f) Install the oil level gauge.
17. 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.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
18. INSTALL INTAKE MANIFOLD
(a) Set a new gasket on each cylinder head.
NOTICE:
- 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, 15ft-lbf)
19. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 mounting stay RH with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
20. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
NOTICE:
DO NOT apply oil to the bolts as 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, 13ft-lbf)
Nut - Torque: 16 Nm (163 kgf-cm, 12ft-lbf)
(c) Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)

(d) Connect the connector.

(e) Install the vacuum hose clamp with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
(f) Connect the No. 1 ventilation hose.

(g) Install the clamp and connect the throttle with motor body assembly connector.
(h) Connect the vapor feed hose.
(i) Connect the 2 water by-pass hoses to the throttle with motor body assembly.
22. REMOVE ENGINE STAND
23. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation
24. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
HINT: Installation.

25. INSTALL STARTER ASSEMBLY Installation
26. INSTALL ENGINE WIRE
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
29. INSTALL FRONT FRAME ASSEMBLY

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

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

(d) Connect the 2 clamps.
30. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32ft-lbf)
(b) Install the pressure feed tube clamp bolt.
Torque: 9.8 Nm (100 kgf-cm, 87in-lbf)
(c) Connect the power steering oil pressure switch connector.
31. 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 4 bolts and 2 nuts.
A - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
B - Torque: 32 Nm (329 kgf-cm, 24ft-lbf)
(d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
C - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
D - Torque: 32 Nm (329 kgf-cm, 24ft-lbf)
32. INSTALL COOLER COMPRESSOR ASSEMBLY

(a) Temporarily install the cooler compressor with the 4 bolts.
(b) Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
Torque: 25 Nm (250 kgf-cm, 18ft-lbf)
(c) Install the 2 connector clamps.
33. INSTALL GENERATOR ASSEMBLY Installation
34. INSTALL STEERING SLIDING YOKE Installation
35. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Installation
36. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the No. 1 exhaust pipe support bracket with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
37. INSTALL FRONT AXLE ASSEMBLY LH Installation
38. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

39. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation
40. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedure described for the LH side.

41. INSTALL TIE ROD ASSEMBLY LH Installation
42. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

43. INSTALL FRONT SPEED SENSOR LH Installation
44. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedure described for the LH side.

45. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
46. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

47. INSTALL FRONT AXLE HUB NUT LH Installation
48. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedure described for the LH side.

49. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
50. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET Installation
51. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Connect the No. 1 oil reservoir to pump hose.
52. CONNECT RETURN TUBE SUB-ASSEMBLY

(a) Connect the return tube sub-assembly.
53. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
NOTICE:
- Check for damage or contamination on the connected part of the pipe.
- Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.
54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip and the nut, and connect the cable to the transaxle.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
55. CONNECT ENGINE WIRE

(a) Install the bolt and clamp to the bracket.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)

(b) Install the 2 bolts and 2 clamps to the body.
Bolt A - Torque: 12 Nm (123 kgf-cm, 9ft-lbf)
Bolt B - Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)

(c) Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
56. INSTALL RELAY BLOCK COVER UPPER
57. INSTALL ECM Installation
58. CONNECT HEATER WATER HOSE INLET

(a) Connect the heater inlet water hose.
59. CONNECT HEATER WATER HOSE OUTLET
(a) Connect the heater outlet water hose.
60. CONNECT NO. 1 OIL COOLER INLET HOSE

(a) Install the clamp and connect the oil cooler inlet hose.
61. CONNECT NO. 1 OIL COOLER OUTLET HOSE
(a) Install the clamp and connect the oil cooler outlet hose.
62. INSTALL RADIATOR HOSE INLET

(a) Install the clamp and connect the radiator hose inlet.
63. INSTALL RADIATOR HOSE OUTLET

(a) Install the clamp and connect the radiator hose outlet.
64. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE

(a) Install the clamp and connect the check valve to brake booster hose.
65. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 1 fuel vapor feed hose.
66. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Temporarily install the engine moving control rod with the 4 bolts.
(b) First install bolts A, and then remaining bolt B.
Torque: 38 Nm (388 kgf-cm, 28ft-lbf)
67. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Temporarily install the No. 2 engine mounting stay RH with the bolt.
Torque: 38 Nm (388 kgf-cm, 28ft-lbf)
(b) Tighten the 2 nuts.
Torque: 23 Nm (235 kgf-cm, 17ft-lbf)
68. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Install the intake air resonator with the bolt and clip.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
69. INSTALL BATTERY

(a) Install the battery and battery tray.
(b) Install the battery clamp with the bolt and nut.
Bolt - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31in-lbf)
70. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No. 1 air cleaner inlet with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
71. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the vacuum hose and hose clamp.
72. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
73. INSTALL AIR CLEANER INLET ASSEMBLY

(a) Install the air cleaner inlet with the clamp and 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
74. CONNECT VACUUM HOSES

75. INSTALL V-RIBBED BELT Installation
76. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
77. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT: Installation.

78. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76ft-lbf)
79. ADD ENGINE OIL
80. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.9 Nm (70 kgf-cm, 61in-lbf)
81. ADD ENGINE COOLANT Testing and Inspection
82. ADD AUTOMATIC TRANSAXLE FLUID Installation
83. ADD POWER STEERING FLUID
84. BLEED POWER STEERING FLUID Service and Repair
85. INSPECT FOR FUEL LEAK Testing and Inspection
86. INSPECT FOR ENGINE OIL LEAK
87. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
88. INSPECT FOR EXHAUST GAS LEAK
89. CHECK SHIFT LEVER POSITION Adjustments
90. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
HINT: Service and Repair.

91. CHECK IGNITION TIMING Engine
92. CHECK ENGINE IDLE SPEED Engine
93. CHECK CO/HC Engine
94. CHECK FUNCTION OF THROTTLE BODY On-Vehicle Inspection
95. INSTALL FRONT FENDER APRON SEAL RH
96. INSTALL ENGINE UNDER COVER LH
97. INSTALL ENGINE UNDER COVER RH
98. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the V-bank cover.
99. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 7 clips.
100. CHECK ABS SPEED SENSOR SIGNAL
(a) ABS: Test Mode Procedure.
(b) VSC (for BOSCH): Test Mode Procedure.
(c) VSC (for ADVICS): Test Mode Procedure.