Installation
2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.
1. REMOVE ENGINE STAND
2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation
3. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque : 64 Nm (650 kgf-cm, 47 ft-lbf)
4. INSTALL ENGINE MOUNTING BRACKET RH
(a) Install the engine mounting bracket RH with the 3 bolts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation
6. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine with transaxle.
7. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY
(a) Temporarily install the front engine mounting insulator assembly with the 3 nuts.
HINT
Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.
8. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Temporarily install the engine mounting insulator LH with the 3 nuts.
HINT
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
9. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Temporarily install the engine mounting insulator RH with the 3 nuts.
HINT
Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
10. INSTALL FRONT FRAME ASSEMBLY
(a) Install the engine mounting insulator RH with the nut.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(b) Install the engine mounting insulator LH with the nut.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(c) Install the front engine mounting insulator assembly with the bolt.
Torque : 87 Nm (888 kgf-cm, 65 ft-lbf)
(d) Connect the 2 wire clamps and vacuum switching valve connector.
(e) Connect the 2 wire clamps and oil pressure switch connector.
(f) Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Text in Illustration
A - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
B - Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)
(g) Install the 4 hole plugs.
HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Text in Illustration
11. INSTALL TRANSMISSION OIL COOLER Installation
12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation
13. INSTALL GENERATOR ASSEMBLY Installation
14. INSTALL V-RIBBED BELT Installation
15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on an engine lifter.
NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
* Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
* To prevent the oil pan from deforming, do not place any attachments onto the oil pan of the engine assembly with transaxle.
* Make sure to support the engine assembly with transaxle securely to prevent it from falling.
(b) Remove the engine hangers Removal.
(c) Install the engine assembly with transaxle to the vehicle.
NOTICE:
* Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
* Make sure that the engine is clear of all wiring and hoses.
* While raising the engine into the vehicle, do not allow it to contact the vehicle.
(d) Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
A - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)
B - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)
(e) Install the front suspension member rear braces RH and LH with the 4 bolts and 2 nuts.
C - Torque : 85 Nm (867 kgf-cm, 62 ft-lbf)
D - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)
HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.
16. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT
(a) Apply a few drops of adhesive to 2 or 3 threads at the tip of each of the 6 torque converter setting bolts.
Text in Illustration
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.
(b) Turn the crankshaft to gain access to the installation locations of the 6 torque converter setting bolts and install each bolt while holding the crankshaft pulley bolt with a wrench.
Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)
NOTICE:
First install the black colored bolt, and then the remaining 5 silver colored bolts.
17. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
(a) Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.
Torque : 7.8 Nm (80 kgf-cm, 69 in-lbf)
18. 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, 15 ft-lbf)
19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Reassembly
20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation
22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation
23. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
24. CONNECT TIE ROD ASSEMBLY LH Installation
25. CONNECT TIE ROD ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
26. INSTALL FRONT SPEED SENSOR LH Installation
27. INSTALL FRONT SPEED SENSOR RH
HINT
Perform the same procedure as for the LH side.
28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
30. INSTALL FRONT AXLE SHAFT NUT LH Installation
31. INSTALL FRONT AXLE SHAFT NUT RH
HINT
Perform the same procedure as for the LH side.
32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
33. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
34. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
35. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation
36. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Installation
37. CONNECT FUEL MAIN TUBE
(a) Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.
NOTICE:
* Check that there is no damage or foreign objects on the fuel tube connector.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Install the No. 1 fuel pipe clamp.
HINT
The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.
38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation
39. INSTALL AIR CLEANER BRACKET
(a) Install the air cleaner bracket to the battery carrier with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 wire clamps.
40. CONNECT ENGINE WIRE
(a) Connect the 2 wire clamps.
(b) Connect the connector to the ECM with the lock lever.
(c) Connect the engine wire to the engine room relay block.
(d) Connect the 4 connectors.
(e) Connect the engine wire to the engine room relay block.
(f) Connect the wire clamp and install the 2 nuts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(g) Install the No. 1 relay block cover.
41. INSTALL STARTER ASSEMBLY Installation
42. CONNECT WATER HOSE SUB-ASSEMBLY
(a) Connect the water hose sub-assembly with the hose clip.
43. CONNECT INLET HEATER WATER HOSE
(a) Connect the inlet heater water hose with the hose clip.
44. CONNECT NO. 3 WATER BY-PASS HOSE
(a) Connect the No. 3 water by-pass hose to the transmission oil cooler with the hose clip.
45. CONNECT OUTLET RADIATOR HOSE
(a) Connect the outlet radiator hose with the hose clip.
46. CONNECT INLET RADIATOR HOSE
(a) Connect the inlet radiator hose with the hose clip.
(b) Install the No. 3 water by-pass hose to the inlet radiator hose with the hose clamp.
(c) Install the air fuel ratio sensor wire to the inlet radiator hose with the hose clamp.
47. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose to the brake booster with the hose clip.
48. CONNECT NO. 1 FUEL VAPOR FEED HOSE
(a) Connect the No. 1 fuel vapor feed hose with the hose clip.
49. CONNECT EARTH WIRE
(a) Install the earth wire with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
50. INSTALL ENGINE MOVING CONTROL ROD
(a) Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.
HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.
51. INSTALL ENGINE MOVING CONTROL ROD BRACKET
(a) When replacing the engine moving control rod.
(1) Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.
Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)
NOTICE:
Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B.
(2) Tighten the bolt E.
Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)
(b) When not replacing the engine moving control rod.
(1) Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.
Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)
NOTICE:
Temporarily tighten bolt A and B, and then fully tighten the 4 bolts in the order of C, D, A and B.
52. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 engine mounting stay RH with the bolt.
Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)
(b) Tighten the 2 nuts.
Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)
53. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
(a) Install the intake air resonator sub-assembly with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 vacuum hoses and engage the claw.
54. INSTALL INLET NO. 1 AIR CLEANER
(a) Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.
(b) Engage the pin to the radiator support.
55. 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, 80 in-lbf)
Nut - Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)
(c) Connect the positive (+) cable to the positive (+) battery terminal.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.
(b) Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.
Text in Illustration
(c) Tighten the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(d) Connect the wire harness clamp, connector, vacuum hose and No. 1 fuel vapor feed hose.
57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
58. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
59. INSTALL INLET NO. 2 AIR CLEANER
(a) Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 wire harness clamps and vacuum hose clamp.
60. INSPECT VACUUM HOSES
(a) Inspect the vacuum hoses.
61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
(a) Connect the negative (-) cable to the negative (-) battery terminal.
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
Torque : 6.9 Nm (70 kgf-cm, 61 in-lbf)
62. INSTALL FRONT WHEEL
Torque : 103 Nm (1049 kgf-cm, 76 ft-lbf)
63. ADD ENGINE OIL Replacement
64. ADD ENGINE COOLANT
Service and Repair
65. ADD AUTOMATIC TRANSAXLE FLUID
Procedures
66. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT Service and Repair
67. WARM UP ENGINE Service and Repair
68. INSPECT FOR REFRIGERANT LEAK Service and Repair
69. INSPECT ENGINE OIL LEVEL Testing and Inspection
70. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR Testing and Inspection
71. INSPECT FOR FUEL LEAK Fuel System
72. INSPECT FOR COOLANT LEAK Testing and Inspection
73. INSPECT FOR OIL LEAK
74. INSPECT FOR EXHAUST GAS LEAK
75. INSPECT IGNITION TIMING Engine
76. INSPECT ENGINE IDLE SPEED Engine
77. INSPECT CO/HC Engine
78. CHECK FOR SPEED SENSOR SIGNAL
Test Mode Procedure
79. INSPECT SHIFT LEVER POSITION Adjustments
80. ADJUST SHIFT LEVER POSITION Adjustments
81. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Front Wheel Alignment
82. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Fit the 3 retainers and install the V-bank cover sub-assembly.
83. INSTALL COOL AIR INTAKE DUCT SEAL Installation
84. INSTALL FRONT FENDER APRON SEAL LH
85. INSTALL ENGINE UNDER COVER LH
86. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
87. INSTALL FRONT FENDER APRON SEAL RH
88. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
89. INSTALL ENGINE UNDER COVER RH