Installation
2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION
HINT
Perform "Inspection After Repair" after replacing the engine assembly Programming and Relearning.
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 (204 kgf-cm, 15 ft-lbf)
2. INSTALL KNOCK SENSOR WIRE
(a) Connect the 2 clamps, 2 knock sensor connectors and knock sensor wire connector.
3. INSTALL KNOCK CONTROL SENSOR Installation
4. 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 assembly.
Text in Illustration
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a deep socket wrench, install the oil pressure switch.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE:
Do not start the engine within 1 hour after installation to prevent oil leaks.
5. INSTALL NO. 1 VACUUM SWITCHING VALVE
(a) Install the No. 1 vacuum switching valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL WATER PUMP PULLEY
(a) Temporarily install the water pump pulley with the 4 bolts.
(b) Using SST, hold the water pump pulley.
SST : 09960-10010
09962-01000
09963-00700
(c) Tighten the 4 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
Torque : 54 Nm (550 kgf-cm, 40 ft-lbf)
8. 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, 53 in-lbf)
9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner assembly 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 assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(c) Tighten the other bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket as shown in the illustration.
Text in Illustration
(b) Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
12. INSTALL NO. 2 MANIFOLD STAY Installation
13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Install a new O-ring to the No. 2 engine oil level dipstick guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.
(d) Install the No. 2 engine oil level dipstick guide with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(e) Install the engine oil level dipstick.
14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
Text in Illustration
(b) Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
15. 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, 15 ft-lbf)
16. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 engine mounting stay RH with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
17. INSTALL IGNITION COIL ASSEMBLY Installation
18. INSTALL NO. 1 SURGE TANK STAY
NOTICE:
Do not apply oil to the bolt as listed below:
(a) Install the No. 1 surge tank stay with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
19. INSTALL THROTTLE BODY BRACKET
NOTICE:
Do not apply oil to the bolt as listed below:
(a) Install the throttle body bracket with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation
21. INSTALL ENGINE HANGERS
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No.
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
(b) Attach an engine sling device and hang the engine with a chain block.