Installation (to 12/2010)
2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION
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 (200 kgf-cm, 14 ft-lbf)
2. INSTALL KNOCK CONTROL SENSOR Installation (to 12/2010)
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 VACUUM SWITCHING VALVE ASSEMBLY
(a) Install the No. 1 vacuum switching valve with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL RADIO SETTING CONDENSER
(a) Install the 2 radio setting condensers with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
6. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install the front No. 1 engine mounting bracket LH with the 6 bolts.
Torque : 54 Nm (551 kgf-cm, 40 ft-lbf)
7. INSTALL WATER PUMP PULLEY Installation
8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the No. 2 idler pulley sub-assembly and 2 plates with the bolt.
Torque : 54 Nm (550 kgf-cm, 40 ft-lbf)
HINT
Plate diameter:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
9. 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)
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner 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 by tightening 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)
11. 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)
12. 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)
13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Install a new gasket as shown in the illustration.
(b) Install the exhaust manifold sub-assembly LH with the 6 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
14. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the No. 2 exhaust manifold heat insulator with the 3 bolts.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
15. 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)
16. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY
(a) Install 2 new O-rings to the oil level dipstick guides.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the oil level dipstick guide end into the guide hole.
(d) Install the No. 1 oil level dipstick guide with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(e) Install the No. 2 oil level dipstick guide with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(f) Install the oil level dipstick.
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Install a new gasket as shown in the illustration.
(b) Install the exhaust manifold sub-assembly RH with the 6 nuts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
18. INSTALL INTAKE MANIFOLD
NOTICE:
DO NOT apply oil to the bolts listed below:
(a) Set a new gasket on each cylinder head.
NOTICE:
* Align the port holes of the gaskets and cylinder heads.
* Make sure that the gaskets are 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)
19. 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)
20. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
21. REMOVE ENGINE STAND
22. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation (to 12/2010)
23. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY Installation (to 12/2010)
24. CONNECT CONNECTOR Installation (to 12/2010)
25. INSTALL WIRE HARNESS Installation (to 12/2010)
26. INSTALL ENGINE WIRE
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation (to 12/2010)
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation (to 12/2010)
29. INSTALL FRONT FRAME ASSEMBLY
(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)
(b) Install the front engine mounting insulator with the bolt.
Torque : 87 Nm (887 kgf-cm, 64 ft-lbf)
(c) Connect the 2 clamps.
(d) Connect the connector and clamp.
30. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump with the 2 bolts.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Install the pressure feed tube clamp bolt.
Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)
31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly to the vehicle.
(c) Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
A - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
B - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)
(d) Install the front suspension member brace rears RH and LH with the 4 bolts and 2 nuts.
C - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)
D - Torque : 32 Nm (329 kgf-cm, 24 ft-lbf)
32. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Temporarily install the cooler compressor with the 4 bolts.
(b) Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
Torque : 25 Nm (250 kgf-cm, 18 ft-lbf)
(c) Install the 2 connector clamps.
33. INSTALL GENERATOR ASSEMBLY Installation (to 12/2010)
34. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY Installation (to 12/2010)
35. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT Installation (to 12/2010)
36. INSTALL FLYWHEEL HOUSING UNDER COVER Installation (to 12/2010)
37. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the No. 1 exhaust pipe support bracket with the nut.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
38. INSTALL FRONT AXLE ASSEMBLY LH Installation (to 12/2010)
39. INSTALL FRONT AXLE ASSEMBLY RH
HINT
Use the same procedure described for the LH side.
40. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation (to 12/2010)
41. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT
Use the same procedure described for the LH side.
42. INSTALL TIE ROD ASSEMBLY LH Installation (to 12/2010)
43. INSTALL TIE ROD ASSEMBLY RH
HINT
Use the same procedure described for the LH side.
44. INSTALL FRONT SPEED SENSOR LH Installation (to 12/2010)
45. INSTALL FRONT SPEED SENSOR RH
HINT
Use the same procedure described for the LH side.
46. INSTALL FRONT AXLE SHAFT LH NUT Installation (to 12/2010)
47. INSTALL FRONT AXLE SHAFT RH NUT
HINT
Use the same procedure described for the LH side.
48. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation (to 12/2010)
49. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT
Use the same procedure described for the LH side.
50. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
51. INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
52. CONNECT STEERING GEAR OUTLET RETURN TUBE
(a) Connect the steering gear outlet return tube.
53. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a) Connect the No. 1 oil reservoir to pump hose.
54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY Installation (to 12/2010)
55. CONNECT ENGINE WIRE
(a) Install the ground cable to the cylinder head with the 2 bolts.
Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)
(b) Connect the engine wire clamp.
(c) Install the ground cable with the bolt to the wire bracket.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(d) Install the 2 ground cables with the 2 bolts.
Bolt A - Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
Bolt B - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Connect the engine wire connector and 3 clamps.
(f) Connect the wire to the engine room junction block. Then, install it with the nut and 2 connectors.
Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)
56. INSTALL UPPER RELAY BLOCK COVER
57. INSTALL STARTER ASSEMBLY Installation (to 12/2010)
58. INSTALL ECM Installation (to 12/2010)
59. CONNECT HEATER WATER OUTLET HOSE A
(a) Connect the heater water outlet hose.
60. CONNECT HEATER WATER HOSE INLET A
(a) Connect the heater water hose inlet.
61. CONNECT NO. 1 OIL COOLER OUTLET HOSE Installation
62. CONNECT NO. 1 OIL COOLER INLET HOSE Installation
63. INSTALL RADIATOR HOSE OUTLET
(a) Install the clamp and connect the radiator hose outlet.
64. INSTALL RADIATOR HOSE INLET
(a) Install the clamp and connect the radiator hose inlet.
65. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
NOTICE:
* Check for damage or contamination on the connected part of the pipe.
* Check if the pipe and the connector are securely connected by trying to pull them apart.
(b) Engage the claw and install the No. 1 fuel pipe clamp.
66. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation (to 12/2010)
67. INSTALL NO. 1 FUEL VAPOR FEED HOSE
(a) Install the clamp and connect the No. 1 fuel vapor feed hose.
68. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
(a) Install the intake air resonator with the bolt and clip.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Connect the wire harness clamp.
69. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the No. 1 air cleaner inlet with the bolt.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
70. 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 connector, vacuum hose, and hose clamp.
(c) Install the air cleaner filter element to the air cleaner case.
71. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation (to 12/2010)
72. INSTALL NO. 2 AIR CLEANER INLET
(a) Install the No. 2 air cleaner inlet with the 2 bolts.
Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)
(b) Connect the clamp and 2 vacuum hoses.
73. CONNECT VACUUM HOSES
74. INSTALL ENGINE MOVING CONTROL ROD
(a) Temporarily install the engine moving control rod with the 4 bolts.
(b) First install the bolts A, and then the remaining bolt B.
Torque : 38 Nm (388 kgf-cm, 28 ft-lbf)
75. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Temporarily install the No. 2 engine mounting stay RH with the bolt.
Torque : 38 Nm (388 kgf-cm, 28 ft-lbf)
(b) Tighten the 2 nuts.
Torque : 23 Nm (235 kgf-cm, 17 ft-lbf)
76. INSTALL RADIATOR RESERVE TANK ASSEMBLY
77. INSTALL V-RIBBED BELT Installation (to 12/2010)
78. INSTALL BATTERY
NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.
79. INSTALL COWL TOP PANEL OUTER Installation (to 12/2010)
80. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
81. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
82. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH Installation
83. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH Installation
84. INSTALL FRONT WHEELS
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
85. ADD ENGINE OIL Replacement
86. ADD ENGINE COOLANT Service and Repair
87. ADD AUTOMATIC TRANSAXLE FLUID Installation (to 12/2010)
88. ADD POWER STEERING FLUID
89. BLEED POWER STEERING SYSTEM On-Vehicle Inspection (to 12/2010)
90. INSPECT FOR FUEL LEAK On-Vehicle Inspection (to 12/2010)
91. INSPECT FOR OIL LEAK
92. INSPECT FOR ENGINE COOLANT LEAK Service and Repair
93. INSPECT FOR EXHAUST GAS LEAK
94. INSPECT SHIFT LEVER POSITION Adjustment (to 12/2010)
95. ADJUST SHIFT LEVER POSITION Adjustment (to 12/2010)
96. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT
Adjust the front wheel alignment Adjustment (to 12/2010).
97. INSPECT IGNITION TIMING On-Vehicle Inspection (to 12/2010)
98. INSPECT ENGINE IDLE SPEED On-Vehicle Inspection (to 12/2010)
99. INSPECT CO/HC On-Vehicle Inspection (to 12/2010)
100. INSTALL V-BANK COVER SUB-ASSEMBLY Installation (to 12/2010)
101. INSTALL COOL AIR INTAKE DUCT SEAL
(a) Install the intake duct seal with the 6 clips.
102. CHECK SPEED SENSOR SIGNAL
(a) Check the speed sensor signal Test Mode Procedure (to 12/2010).