Part 1

Part 1 of 2

2GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket to the sensor.

(b) Using a 19 mm deep socket wrench, install the temperature sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft-lbf)
2. INSTALL OIL PRESSURE SWITCH ASSEMBLY

(a) 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: 15 Nm (153 kgf-cm, 11 ft-lbf)
NOTICE:
Do not start the engine within 1 hour after the installation.

3. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

4. INSTALL ENGINE OIL LEVEL SENSOR

(a) Install the engine oil level sensor and a new gasket with the 4 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
5. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL V-BANK COVER BRACKET

(a) Install the bracket with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)

7. INSTALL RADIO SETTING CONDENSER
(a) Install the 2 condensers with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL KNOCK SENSOR Installation

9. INSTALL FUEL INJECTOR SEAL (for Direct Injection) Installation

10. INSTALL FUEL INJECTOR ASSEMBLY
(a) for Port:
Install the injector assembly Installation.
(b) for Direct:
Install the injector assembly Installation.
11. INSTALL NO. 1 FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

12. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY Installation

13. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY Installation

14. INSTALL HIGH PRESSURE SIDE FUEL PUMP Installation

15. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY Installation

16. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY Installation

17. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY Installation

18. INSTALL FUEL TUBE SUB-ASSEMBLY
(a) Install the tube with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
19. INSTALL INTAKE MANIFOLD Installation

20. INSTALL WATER HOSE JOINT
(a) Connect the 2 hoses.
(b) Install the pipe with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
21. INSTALL NO. 2 SURGE TANK STAY
NOTICE:
Make sure there is no oil on the bolts. If there is oil on the bolts, clean them before installing them.

(a) Install the stay with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
22. INSTALL INTAKE AIR SURGE TANK SUB-ASSEMBLY Installation

23. INSTALL WATER PUMP PULLEY Installation

24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)

(a) Temporarily install the V-ribbed belt tensioner with the 5 bolts.
Each bolt length is as follows:

(b) Install the V-ribbed belt tensioner by tightening the bolt 1 and 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)
25. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)

(a) Temporarily install the V-ribbed belt tensioner with the 4 bolts.
Each bolt length is as follows:

(a) Install the pulley and idler pulley cover plate with the bolt.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)

27. INSTALL INJECTOR DRIVER
(a) Install the injector driver with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
28. CONNECT ENGINE WIRE AND CONNECTOR
(a) Install the engine wire and connector to the engine.
29. INSTALL ENGINE MOUNTING BRACKET (for 2WD)
(a) Install the 2 brackets with the 8 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Connect the 2 clamps to the LH side.

30. INSTALL ENGINE MOUNTING BRACKET (for 4WD)
(a) Install the 2 brackets with the 8 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Connect the 2 clamps to the LH side.

31. INSTALL NO. 1 ENGINE COVER
(a) Install the cover with the 3 clamps.

32. INSTALL NO. 2 ENGINE COVER
(a) Install the cover with the 3 clips.
(b) Connect the clamp.

33. INSTALL NO. 1 ENGINE HANGER
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Part No.:

Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
34. REMOVE ENGINE STAND
(a) Attach an engine sling device and hang the engine with a chain block.
(b) Lift the engine, and remove it from the engine stand.

35. INSTALL ENGINE TO FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
(a) Install the engine to the front suspension crossmember with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
36. INSTALL ENGINE TO FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 4WD)

(a) Install the engine to the front suspension crossmember with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
37. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

(a) Using SST, hold the crankshaft.
SST: 09213-70011
09213-70020
SST: 09330-00021
(b) Apply adhesive to 2 or 3 threads and under the heads of new bolts.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(c) Temporarily install the front spacer, drive plate and rear spacer with the 8 bolts.

(d) Tighten the 8 bolts uniformly in several steps in the order shown in the illustration.
Torque: 83 Nm (850 kgf-cm, 61 ft-lbf)
NOTICE:
Do not start the engine for at least 1 hour after installing.

38. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD) Installation

39. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD) Installation

40. TIGHTEN DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT Installation

41. INSTALL FLYWHEEL HOUSING SIDE COVER Installation

42. CONNECT HARNESS AND CONNECTOR TO AUTOMATIC TRANSMISSION (for 2WD) Installation

43. CONNECT HARNESS AND CONNECTOR TO AUTOMATIC TRANSMISSION (for 4WD) Installation

44. CONNECT WATER BY-PASS HOSE

(a) Connect the 2 hoses.

(b) Install the clamp with the bolt.
Torque: 20 Nm (204 kgf-cm, 5 ft-lbf)
45. INSTALL STARTER ASSEMBLY Installation

46. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

(b) Install the exhaust manifold to the cylinder head with the 6 nuts in the order shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Do not damage the stud bolt when installing the exhaust manifold.

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

(a) Install a new O-ring to the guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the No. 1 guide end into the guide hole.
(d) Install the No. 1 guide with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) Connect the harness clamp.

(f) Install a new O-ring to the guide.
(g) Apply a light coat of engine oil to the O-ring.
(h) Push in the No. 2 guide end into the No. 1 guide hole.
(i) Install the No. 2 guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(j) Install the dipstick.
49. INSTALL OIL DIPSTICK GUIDE (for 4WD)

(f) Install a new O-ring to the guide.
(g) Install the No. 2 guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(h) Install the dipstick.
50. REMOVE NO. 1 ENGINE HANGER
(a) Using the sling device and chain block to lift the engine, set the engine on an engine lifter.

(b) Remove the 4 bolts and 2 engine hangers.
51. INSTALL ENGINE AND TRANSMISSION (for 2WD)
(a) Operate the engine lifter, then install the engine to the vehicle.

(b) Install the engine and transmission with crossmember with the 10 bolts and 2 nuts.
Torque: 167 Nm (1703 kgf-cm, 123 ft-lbf)
Torque: 204 Nm (2080 kgf-cm, 150 ft-lbf)
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

(c) Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
52. INSTALL ENGINE AND TRANSMISSION (for 4WD)
(a) Operate the engine lifter, then install the engine to the vehicle.

(b) Install the engine and transmission with crossmember with the 6 bolts and 2 nuts.
Torque: 167 Nm (1703 kgf-cm, 123 ft-lbf)
Torque: 165 Nm (1683 kgf-cm, 122 ft-lbf)
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)

(c) Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)

Continued in Part 2 Part 2