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Home >> Toyota Truck >> 2008 >> RAV4 2WD V6-3.5L (2GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine Assembly >> Installation

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 sensor and a new gasket.
Torque: 20 Nm (204 kgf-cm, 14 ft-lbf)
2. INSTALL KNOCK 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:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)






4. INSTALL NO. 1 FRONT ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 6 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
5. INSTALL WATER PUMP PULLEY Installation







6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley and cover plate with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
7. INSTALL NO. 2 TIMING GEAR COVER
(a) Install the gear cover with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)






8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
(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, 32 ft-lbf)
(c) Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

Each bolt length is as follows:









9. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the drive shaft bearing bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft-lbf)
10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH





(a) Install a new gasket as shown in the illustration.






(b) Install the manifold with the 6 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the No. 2 heat insulator with the 3 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)






12. INSTALL NO. 2 MANIFOLD STAY
(a) Install the No. 2 manifold stay with the bolt and nut.
Torque: 34 Nm (347 kgf-cm, 25 ft-lbf)






13. INSTALL OIL DIPSTICK GUIDE
(a) Install 2 new O-rings to the guide.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the guide end into the guide hole.
(d) Install the No. 1 guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(e) Install the No. 2 guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(f) Install the dipstick.
14. INSTALL GENERATOR ASSEMBLY

15. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY

16. INSTALL FAN AND GENERATOR V BELT Installation

17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH





(a) Install a new gasket as shown in the illustration.






(b) Install the manifold with the 6 nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-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.
- Be careful of the installation direction.

(b) Set the intake manifold on the cylinder heads.






(c) Install and uniformly tighten the 6 bolts and 4 nuts in several passes.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Connect the 6 fuel injector connectors.
19. INSTALL FUEL INJECTOR ASSEMBLY Installation

20. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the mounting stay with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
21. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts to the cylinder head.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY





NOTICE:
DO NOT apply oil to the bolts listed below:






(a) Install a new gasket to the surge tank.
(b) Using a 5 mm hexagon socket wrench, install the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
(c) Install the surge tank with the 2 nuts and 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf) for bolt
Torque: 16 Nm (163 kgf-cm, 12 ft-lbf) for nut






(d) Connect the connector.






(e) Install the vacuum hose clamp with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)






(f) Connect the union to check valve hose.
(g) Connect the No. 2 ventilation hose.






(h) Install the clamp and connect the throttle body connector.
(i) Connect the vapor feed hose.
(j) Connect the 2 water by-pass hoses to the throttle body.
23. REMOVE ENGINE FROM ENGINE STAND
(a) Install a sling device and chain block to the engine.
(b) Remove the engine from the engine stand.
24. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY





(a) Clean the bolt and its hole.
(b) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or Equivalent






(c) Using SST, hold the crankshaft.
SST: 09213-70011
SST: 09330-00021
(d) Install the flywheel, drive plate and drive plate spacer on the crankshaft.






(e) Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.
Torque: 178 Nm (1,815 kgf-cm, 132 ft-lbf)
NOTE: Do not start the engine for at least 1 hour after the installation.

25. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) 2WD:
Install the automatic transaxle Service and Repair.
(b) 4WD:
Install the automatic transaxle Service and Repair.
26. INSTALL TRANSFER ASSEMBLY (for 4WD)

27. INSTALL STARTER ASSEMBLY

28. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine.
29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Attach the engine together with the transaxle to the suspension crossmember and mounting.






(b) Install the bolt which secures the engine mounting bracket to the mounting insulator.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
30. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY






(a) Install the bolt and nut which secures the engine mounting bracket to the mounting insulator.
Torque: 145 Nm (1,479 kgf-cm, 107 ft-lbf)
31. INSTALL ENGINE WITH TRANSAXLE
(a) Place the engine on an engine lifter.
HINT: Place the engine on wooden blocks or an equivalent so that the engine is level.

(b) Using the chain block, slowly install the engine to the vehicle and the intermediate shaft to the pinion.
CAUTION: Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
NOTICE:
- 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.
- Align the matchmarks on the intermediate shaft and pinion.





(c) Temporarily install the suspension member and crossmember with the 10 bolts.
(d) Temporarily install the member brace rear RH and LH with the 6 bolts.






(e) Install the engine mounting insulator LH with the bolt and nut.
Torque: 56 Nm (571 kgf-cm, 41 ft-lbf)
NOTE: While holding the bolt in place, tighten the nut.





(f) Install the engine mounting insulator RH with the 2 bolts and 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)






(g) Tighten the suspension member and crossmember's bolts.
Torque: 96 Nm (979 kgf-cm, 71 ft-lbf)
Torque: 145 Nm (1,478 kgf-cm, 107 ft-lbf)
(h) Tighten the member brace rear's bolts.
Torque: 145 Nm (1,478 kgf-cm, 107 ft-lbf) for bolt C
Torque: 93 Nm (948 kgf-cm, 69 ft-lbf) for bolt D
(i) Remove the sling device and chain block.
(j) Remove the 2 bolts and No. 1 and No. 2 engine hangers.
32. INSTALL FRONT DRIVE SHAFT LH
(a) 2WD:
Install the drive shaft Service and Repair.
(b) 4WD:
Install the drive shaft Service and Repair.
33. INSTALL FRONT DRIVE SHAFT RH
(a) 2WD:
Install the drive shaft Service and Repair.
(b) 4WD:
Install the drive shaft Service and Repair.
34. CONNECT TIE ROD END SUB-ASSEMBLY LH

35. CONNECT TIE ROD END SUB-ASSEMBLY RH

36. CONNECT STEERING INTERMEDIATE SHAFT

37. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

38. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

39. INSTALL FRONT AXLE HUB NUT LH
(a) Install the hub nut .
40. INSTALL FRONT AXLE HUB NUT RH
(a) Install the hub nut .
41. INSTALL FRONT WHEELS
42. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY.

43. INSTALL CENTER EXHAUST PIPE ASSEMBLY Installation

44. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) 2WD:
Connect the control cable Service and Repair.
(b) 4WD:
Connect the control cable Service and Repair.
46. CONNECT RADIATOR HOSE INLET
47. CONNECT RADIATOR HOSE OUTLET
48. CONNECT OIL COOLER HOSE
49. CONNECT SUCTION HOSE SUB-ASSEMBLY

50. INSTALL DISCHARGE HOSE SUB-ASSEMBLY







51. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY
(a) Install the reservoir tank with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Connect the 2 hoses
52. INSTALL ECM Installation

53. CONNECT HOSES AND CONNECTORS
(a) Connect the 2 ECM connectors.
(b) Connect the 2 heater hoses.
(c) Connect the fuel hoses.
(d) Connect the starter wire with the nut.
Torque: 9.8 Nm (100 kgf-cm, 7 ft-lbf)
(e) Connect the 3 connectors and wire with the nut.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)
(f) Install the engine room junction block cover (upper).






54. INSTALL AIR CLEANER CASE
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Connect the harness clamp.
55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner filter element onto the air cleaner case.






(b) Insert the hinge part of the air cleaner cap into the air cleaner case, then hang the 2 hook clamps.






(c) Tighten the No. 1 air cleaner hose clamp.
(d) Connect the No. 2 ventilation hose to the air cleaner hose.
(e) Connect the wire harness clamp and 3 vacuum hoses.
(f) Connect the VSV (intake air control) connector.
(g) Connect the mass air flow meter connector.






56. INSTALL BATTERY BRACKET REINFORCEMENT
(a) Install the bracket reinforcement with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)






57. INSTALL FRONT BATTERY BRACKET
(a) Install the bracket front with the 4 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Attach the 2 wire harness clamps.
58. INSTALL BATTERY
59. REMOVE BATTERY CLAMP SUB-ASSEMBLY
(a) Attach the hook of the battery clamp to the battery bracket front.
(b) Temporarily tighten the nut and install the bolt.
(c) Adjust the battery clamp's position.
(d) Fully tighten the nut and bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
(e) Attach the 2 wire harness clamps.
60. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
61. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood .
(b) Adjust the hood .
62. ADD AUTOMATIC TRANSAXLE FLUID
(a) 2WD:
Add automatic transmission fluid Service and Repair.
(b) 4WD:
Add automatic transmission fluid Service and Repair.
63. ADD TRANSFER OIL (for 4WD).

64. ADD ENGINE OIL Replacement

65. ADD ENGINE COOLANT Service and Repair

66. CHARGE REFRIGERANT

67. INSPECT FOR REFRIGERANT LEAK

68. INSPECT FOR ENGINE OIL LEAK Replacement

69. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

70. INSPECT FOR FUEL LEAK
71. INSPECT FOR EXHAUST GAS LEAK
72. INSPECT SHIFT LEVER POSITION
(a) 2WD:
Inspect the shift lever position Adjustments.
(b) 4WD:
Inspect the shift lever position Adjustments.
73. ADJUST TRANSMISSION CONTROL CABLE
(a) 2WD:
Adjust the shift lever position Adjustments.
(b) 4WD:
Adjust the shift lever position Adjustments.
74. INSTALL FRONT FLOOR COVER Adjustments

75. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 2 clips.
76. INSTALL REAR ENGINE UNDER COVER LH
(a) Install the under cover with the 2 clips.
77. INSTALL REAR ENGINE UNDER COVER RH
(a) Install the under cover with the 2 clips.
78. INSTALL NO. 1 ENGINE UNDER COVER
(a) Install the under cover with the 4 bolts and 12 clips.






79. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 3 clips to install the engine cover.






80. INSTALL RADIATOR SUPPORT OPENING COVER
(a) Install the cover with the 9 clips.
81. ADJUST FRONT WHEEL ALIGNMENT
(a) Adjust the front wheel alignment .
82. INSPECT IDLE SPEED Engine
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