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 engine coolant temperature sensor and a new gasket.
Torque: 20 Nm (204 kgf-cm, 15ft-lbf)
2. INSTALL KNOCK CONTROL 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, 15ft-lbf)
NOTICE:
Do not start the engine within 1 hour after installation to prevent oil leaks.

4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY (w/ Oil Cooler)

(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

(a) Install the bolt and No. 1 vacuum switching valve.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
6. INSTALL RADIO SETTING CONDENSER

(a) Install the 2 bolts and 2 radio setting condensers.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
7. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH

(a) Install the No. 1 engine mounting bracket front LH with the 6 bolts.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)
8. INSTALL WATER PUMP PULLEY Installation
9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the No. 2 idler pulley sub-assembly and 2 idler pulley cover plates with the bolt.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)

Plate diameter
HINT:
Idler pulley cover plate: 33.6 mm (1.32 in.)
No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
Use the same procedure for both sides.
10. 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, 53in-lbf)
11. 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 the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 Nm (438 kgf-cm, 32ft-lbf)
(c) Tighten the other bolts.
Torque: 43 Nm (438 kgf-cm, 32ft-lbf)
12. INSTALL ENGINE MOUNTING BRACKET RR

(a) Install the engine mounting bracket RR with the 3 bolts.
Torque: 64 Nm (652 kgf-cm, 47ft-lbf)
13. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)
14. 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 in the order shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
15. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 2 insulator with the 3 bolts.
Torque: 8.5 Nm (87 kgf-cm, 75in-lbf)
16. INSTALL NO. 2 MANIFOLD STAY

(a) Install the No. 2 manifold stay with the bolt and nut in the order shown in the illustration.
Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
17. INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY

(a) Install 2 new O-rings to the oil level gauge guide.
(b) Apply a light coat of engine oil to the O-rings.
(c) Push in the oil level gauge guide end into the guide hole.
(d) Install the oil level gauge guide No. 1 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(e) Install the oil level gauge guide No. 2 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
(f) Install the oil level gauge.
18. 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 in the order shown in the illustration.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
19. INSTALL INTAKE MANIFOLD
NOTICE:
Do not apply oil to the bolts as listed below:

(a) Set a new gasket on each cylinder head.
- 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, 15ft-lbf)
20. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 mounting stay RH with the bolt.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
21. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coil assemblies with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7ft-lbf)
22. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
NOTICE:
Do not apply oil to the bolts as listed below:

(a) Install a new gasket to the intake air surge tank.

(b) Using a 5 mm socket hexagon wrench, install the 4 bolts and 2 nuts.
Bolt - Torque: 18 Nm (184 kgf-cm, 13ft-lbf)
Nut - Torque: 16 Nm (163 kgf-cm, 12ft-lbf)
(c) Install the throttle body bracket and No. 1 surge tank stay with the 4 bolts.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)

(d) Connect the connector.
(e) Connect the No. 1 ventilation hose.

(f) Install the clamp and connect the throttle with motor body assembly connector.
(g) Connect the vapor feed hose.
(h) Connect the 2 water by-pass hoses to the throttle with motor body assembly.
23. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the 2 bolts and exhaust pipe support bracket.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
24. REMOVE ENGINE STAND
25. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation
26. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
HINT:
Installation.

27. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 4WD)
HINT:
Installation.

28. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD) Installation
29. INSTALL MANIFOLD STAY
(a) Install the bolt, nut, and manifold stay.
Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
30. INSTALL ENGINE MOUNTING BRACKET FRONT Installation
31. INSTALL STARTER ASSEMBLY Installation
32. INSTALL ENGINE WIRE
33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation
35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD) Installation
36. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70ft-lbf)

(b) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64ft-lbf)

(d) Connect the connector and clamp.

(e) Connect the 2 clamps.
37. INSTALL POWER STEERING LINK (for 4WD)
HINT:
Installation.

38. INSTALL FRONT STABILIZER BAR (for 4WD)
HINT:
Installation.

39. INSTALL VANE PUMP ASSEMBLY

(a) Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32ft-lbf)
(b) Install the 3 pressure feed tube clamp bolts.
Torque: 7.8 Nm (80 kgf-cm, 69in-lbf)
(c) Connect the power steering oil pressure switch connector.
40. 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 6 bolts and 2 nuts.
A - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
B - Torque: 32 Nm (329 kgf-cm, 24ft-lbf)

(d) Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
A - Torque: 85 Nm (867 kgf-cm, 63ft-lbf)
B - Torque: 32 Nm (329 kgf-cm, 24ft-lbf)
41. 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, 18ft-lbf)
(c) Install the 2 connector clamps.
42. INSTALL GENERATOR ASSEMBLY Installation
43. CONNECT HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT LH (w/ Air Suspension)

(a) Install the nut and connect the height control sensor.
Torque: 5.4 Nm (55 kgf-cm, 48in-lbf)
44. CONNECT HEIGHT CONTROL SENSOR SUB-ASSEMBLY FRONT RH (w/ Air Suspension)
HINT: Use the same procedure described for the LH side.

45. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY Installation
46. 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, 15ft-lbf)
47. INSTALL FRONT AXLE ASSEMBLY LH Installation
48. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

49. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH Installation
50. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH
HINT: Use the same procedure described for the LH side.

51. INSTALL TIE ROD ASSEMBLY LH Installation
52. INSTALL TIE ROD ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

53. INSTALL FRONT SPEED SENSOR LH Installation
54. INSTALL FRONT SPEED SENSOR RH
HINT: Use the same procedure described for the LH side.

55. INSTALL FRONT AXLE HUB NUT LH Installation
56. INSTALL FRONT AXLE HUB NUT RH
HINT: Use the same procedure described for the LH side.

57. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation
58. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Use the same procedure described for the LH side.

59. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation
60. INSTALL NO. 3 EXHAUST PIPE SUB-ASSEMBLY FRONT Installation
61. INSTALL OXYGEN SENSOR Installation
62. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
63. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
64. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

(a) Connect the No. 1 oil reservoir to pump hose.
65. CONNECT RETURN TUBE SUB-ASSEMBLY

(a) Connect the return tube sub-assembly.
NOTICE:
Take care not to damage the hose protector.

66. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
- Check for damage or contamination on the connected part of the pipe.
- Check if the pipe and connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.
67. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the control cable to the control cable clamp.

(b) Install the transmission control cable assembly to the control shaft lever with the nut.
Torque: 12 Nm (122 kgf-cm, 9ft-lbf)

(a) Install the bolt and ground cable.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)

(b) Install the bolt and 2 clamps to the body.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)

(c) Connect the wire to the engine room junction block. Then, install it with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
(d) Install the engine wire to the body with the 2 nuts.
Torque: 8.4 Nm (85 kgf-cm, 74in-lbf)
69. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY Installation
70. INSTALL JUNCTION BLOCK COVER
71. CONNECT HEATER WATER HOSE INLET

(a) Connect the heater inlet water hose.
72. CONNECT HEATER WATER HOSE OUTLET
(a) Connect the heater outlet water hose.
73. CONNECT OIL COOLER INLET HOSE

(a) Install the clamp and connect the oil cooler inlet hose.
74. CONNECT OIL COOLER OUTLET HOSE
(a) Install the clamp and connect the oil cooler outlet hose.
75. INSTALL RADIATOR HOSE INLET

(a) Install the clamp and connect the radiator hose inlet.
76. INSTALL RADIATOR HOSE OUTLET

(a) Install the clamp and connect the radiator hose outlet.
77. CONNECT UNION TO CHECK VALVE HOSE
(a) Install the clamp and connect the check valve hose.
78. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 1 fuel vapor feed hose.
79. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY

(a) Temporarily install the engine moving control rod with the 3 bolts.
(b) First install the bolts A, and then the remaining bolt B.
Torque: 38 Nm (388 kgf-cm, 28ft-lbf)
80. 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, 28ft-lbf)
(b) Tighten the 2 nuts.
Torque: 23 Nm (235 kgf-cm, 17ft-lbf)
81. INSTALL AIR CLEANER BRACKET

(a) Install the 2 bolts and air cleaner bracket.
Torque: 12 Nm (122 kgf-cm, 9ft-lbf)
82. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY

(a) Install the intake air resonator with the bolt and clip.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
83. 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, 80in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31in-lbf)
84. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No. 1 air cleaner inlet with the bolt.
Torque: 7.0 Nm (71 kgf-cm, 62in-lbf)
85. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the vacuum hose.
86. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation
87. INSTALL NO. 2 AIR CLEANER INLET

(a) Install the No. 2 air cleaner inlet with the 2 clamps and 2 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62in-lbf)
88. CONNECT VACUUM HOSES

89. INSTALL V-RIBBED BELT Installation
90. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY Installation
91. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
HINT:
Installation.

92. INSTALL FRONT WHEELS
Torque: 103 Nm (1050 kgf-cm, 76ft-lbf)
93. ADD ENGINE OIL
94. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.4 Nm (65 kgf-cm, 56in-lbf)
95. ADD ENGINE COOLANT Testing and Inspection
96. ADD AUTOMATIC TRANSAXLE FLUID
97. CHECK AUTOMATIC TRANSAXLE FLUID U151E Automatic Transaxle
98. ADD POWER STEERING FLUID
99. BLEED POWER STEERING FLUID Service and Repair
100. INSPECT FOR FUEL LEAK Testing and Inspection
101. INSPECT FOR OIL LEAK
102. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection
103. INSPECT FOR EXHAUST GAS LEAK
104. INSPECT SHIFT LEVER POSITION U151F Automatic Transaxle
105. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
Front Wheel Alignment.

106. INSPECT IGNITION TIMING Engine
107. INSPECT ENGINE IDLE SPEED Engine
108. INSPECT CO/HC Engine
109. INSPECT FUNCTION OF THROTTLE BODY On-Vehicle Inspection
110. INSTALL FRONT FENDER APRON SEAL RH
111. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
112. INSTALL NO. 2 ENGINE UNDER COVER (w/ No. 2 Engine Under Cover)
113. INSTALL NO. 1 ENGINE UNDER COVER
114. INSTALL ENGINE UNDER COVER ASSEMBLY (w/ Engine Under Cover Assembly)
115. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the V-bank cover.
116. INSTALL ENGINE ROOM COVER SIDE

(a) Install the engine room cover side with the 4 clips.
117. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 4 clips.
118. INSPECT ABS SPEED SENSOR SIGNAL
HINT:
Test Mode Procedure.

119. PERFORM INITIALIZATION
(a) Perform initialization procedure Repair Instruction - Initialization.
HINT: Some systems need initialization after reconnecting the cable to the negative battery terminal. Repair Instruction - Initialization