Engine unit 1GR-FE Installation

1. INSTALL FLYWHEEL RING GEAR (for Manual Transmission)

 

1. Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

   NOTICE:

   Be careful not to overheat the ring gear.

2. Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.

   NOTICE:

   After installing, allow the ring gear to cool before handling.

2. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

 

1. Install the No. 1 idler pulley with the bolt.

   Torque:

   54 N*m{ 551 kgf*cm , 40 ft.*lbf }

   HINT:

   "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

3. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

 

1. w/ Pulley Cover Plate:

   

   1. Install the idler pulley cover plate, idler pulley and No. 2 idler pulley cover plate with the bolt.

      Torque:

      54 N*m{ 551 kgf*cm , 40 ft.*lbf }

      NOTICE:

      If it is necessary to replace the pulley or either plate, replace the No. 2 idler pulley cover plate, No. 2 idler pulley and idler pulley cover plate as a set with new parts.

2. w/o Pulley Cover Plate: Install the 2 No. 2 idler pulleys with the 2 bolts.

   Torque:

   54 N*m{ 551 kgf*cm , 40 ft.*lbf }

4. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

1. Install the engine mounting bracket with the 3 bolts.

   Torque:

   43 N*m{ 438 kgf*cm , 32 ft.*lbf }

5. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

1. Install the engine mounting RH with the 4 bolts.

   Torque:

   43 N*m{ 438 kgf*cm , 32 ft.*lbf }

6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

 

1. Install a new O-ring to the dipstick guide.

2. Apply a light coat of engine oil to the O-ring.

3. Push the dipstick guide end into the guide hole.

4. Install the dipstick guide with the bolt.

   Torque:

   9.0 N*m{ 92 kgf*cm , 80 in.*lbf }

7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

 

1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

2. Tighten bolt 1 and 2 in numerical order.

   Torque:

   36 N*m{ 367 kgf*cm , 27 ft.*lbf }

3. Tighten the other bolts.

   Torque:

   36 N*m{ 367 kgf*cm , 27 ft.*lbf }

   Standard Bolt:

   Item	Length
   A	70 mm (2.76 in.)
   B	33 mm (1.30 in.)

8. INSTALL IGNITION COIL ASSEMBLY

1. Install the 6 ignition coils with the 6 bolts.

   Torque:

   10 N*m{ 102 kgf*cm , 7 ft.*lbf }

9. INSTALL ENGINE WIRE

10. INSTALL INTAKE MANIFOLD

 

1. Set a new gasket on each cylinder head.

   NOTICE:

   1. Align the port holes of the gasket and cylinder head.
   1. Be careful of the installation direction.

2. Set the intake manifold on the cylinder heads.

 

3. Install and uniformly tighten the 10 bolts in several passes.

   Torque:

   26 N*m{ 265 kgf*cm , 19 ft.*lbf }

   HINT:

   Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

11. INSTALL FUEL INJECTOR

 

1. Install a new insulator onto each fuel injector.

2. Apply a light coat of spindle oil or gasoline to each new O-ring and install one onto each fuel injector.

 

3. Install the 6 injectors.

   1. While turning each fuel injector left and right, install it onto the fuel delivery pipe.

   2. Position the fuel injector connectors facing outward.

12. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

 

1. Place the fuel delivery pipe together with the 6 fuel injectors on the intake manifold.

2. Temporarily install the 6 bolts, which are used to hold the fuel delivery pipe, to the intake manifold.

3. Check that the fuel injectors rotate smoothly.

   HINT:

   If the fuel injectors do not rotate smoothly, replace the O-ring of any injector that does not rotate smoothly.

4. Position the fuel injector connectors facing outward.

5. Tighten the 6 bolts, which are used to hold the fuel delivery pipe, to the intake manifold.

   Torque:

   15 N*m{ 153 kgf*cm , 11 ft.*lbf }

6. Connect the 6 fuel injector connectors.

13. CONNECT WATER HOSE SUB-ASSEMBLY (for Automatic Transmission)

1. Connect the heater water by-pass pipe hose to the rear water by-pass joint.

 

2. Temporarily install the heater water pipe, and then tighten the 2 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

   for bolt B:

   13 N*m{ 138 kgf*cm , 10 ft.*lbf }

14. CONNECT WATER HOSE SUB-ASSEMBLY (for Manual Transmission)

1. Connect the heater water by-pass pipe hose to the rear water by-pass joint.

 

2. Temporarily install the heater water pipe, and then tighten the 2 bolts in the order shown in the illustration.

   Torque:

   for bolt A:

   9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

   for bolt B:

   13 N*m{ 138 kgf*cm , 10 ft.*lbf }

15. CONNECT NO. 1 WATER BY-PASS PIPE (for Automatic Transmission)

1. Connect the water by-pass pipe hoses to the water by-pass pipe and No. 1 water outlet pipe.

16. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

1. Install a new gasket and the engine coolant temperature sensor.

   Torque:

   20 N*m{ 204 kgf*cm , 15 ft.*lbf }

17. INSTALL OIL PRESSURE SENSOR

1. Apply adhesive to 2 or 3 threads of the oil pressure sensor.

   Adhesive:

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

2. Using a 24 mm deep socket wrench, install the oil pressure sensor.

   Torque:

   15 N*m{ 150 kgf*cm , 11 ft.*lbf }

   NOTICE:

   Do not start the engine within 1 hour of installation.