From 08/2009

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY Installation

2. INSTALL REAR ENGINE MOUNTING BRACKET (for 2WD)

(a) Install the rear engine mounting bracket with the 3 bolts.

Torque : 64 Nm (649 kgf-cm, 47 ft-lbf)

3. INSTALL REAR ENGINE MOUNTING BRACKET (for AWD)

(a) Install the rear engine mounting bracket with the 3 bolts.

Torque : 64 Nm (649 kgf-cm, 47 ft-lbf)

4. 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)

5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD) Installation

6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) Installation

7. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)

(a) Install the transfer stiffener plate RH with the 4 bolts.

Bolt A - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

Bolt B - Torque : 78 Nm (796 kgf-cm, 58 ft-lbf)

8. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.

Bolt - Torque : 34 Nm (347 kgf-cm, 25 ft-lbf)

Nut - Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)

9. INSTALL RADIATOR PIPE CLAMP

(a) Install the radiator pipe clamp with the bolt.

Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)

(b) Install the sensor wire and the breather plug hose to the radiator pipe clamp.

10. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque : 52 Nm (531 kgf-cm, 39 ft-lbf)

HINT
Perform this procedure only when replacement of the rear engine mounting insulator assembly is necessary.

(b) Install the 2 hole plugs.

11. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 3 bolts.

Torque : 87 Nm (888 kgf-cm, 65 ft-lbf)

HINT
Perform this procedure only when replacement of the engine mounting insulator RH is necessary.

(b) Install the 2 hole plugs.

12. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 3 bolts.

Torque : 87 Nm (888 kgf-cm, 65 ft-lbf)

HINT
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

(b) Install the 2 hole plugs.

13. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator with the 3 bolts.

Torque : 52 Nm (531 kgf-cm, 39 ft-lbf)

HINT
Perform this procedure only when replacement of the front engine mounting insulator is necessary.

(b) Install the 2 hole plugs.

14. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine with transaxle.

15. INSTALL STARTER ASSEMBLY Installation

16. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Installation

17. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation

18. INSTALL GENERATOR ASSEMBLY Installation

19. INSTALL V-RIBBED BELT Installation

20. INSTALL NO. 2 EARTH WIRE

(a) Install the No. 2 earth wire with the bolt.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

21. INSTALL FRONT FRAME ASSEMBLY

(a) Install the engine mounting insulator RH with the nut.

Torque : 95 Nm (969 kgf-cm, 71 ft-lbf)

(b) Install the engine mounting insulator LH with the nut.

Torque : 95 Nm (969 kgf-cm, 71 ft-lbf)

(c) Install the front engine mounting insulator with the bolt.

Torque : 87 Nm (888 kgf-cm, 65 ft-lbf)

(d) Connect the wire clamp and connector.

(e) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque : 78 Nm (795 kgf-cm, 57 ft-lbf)

22. INSTALL STEERING LINK ASSEMBLY (for AWD) Installation

23. INSTALL FRONT STABILIZER BAR (for AWD)

24. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD) Installation

25. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD)

HINT
Perform the same procedure as for the LH side.

26. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

NOTICE:
* Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
* Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
HINT
Place the engine on wooden blocks or equivalents so that the engine is level.

(b) Remove the 4 bolts and 2 engine hangers.

(c) Install the engine assembly with transaxle to the vehicle.

NOTICE:
Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

HINT
* 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.
(d) Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

Text in Illustration

Nut - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt A - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt B - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

(e) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

Text in Illustration

Nut - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt C - Torque : 32 Nm (327 kgf-cm, 24 ft-lbf)

Bolt D - Torque : 85 Nm (867 kgf-cm, 63 ft-lbf)

27. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST : 09213-70011

09213-70020

SST : 09330-00021

(b) Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolt tips.

Text in Illustration

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

(c) Tighten the 6 drive plate and torque converter clutch setting bolts.

Torque : 41 Nm (418 kgf-cm, 30 ft-lbf)

NOTICE:
Install the black colored bolt first, and then the silver colored 5 bolts.

28. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)

29. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING Reassembly

30. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

31. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

32. INSTALL FRONT LOWER SUSPENSION ARM LH Installation

33. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT
Perform the same procedure as for the LH side.

34. CONNECT TIE ROD ASSEMBLY LH Installation

35. CONNECT TIE ROD ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

36. CONNECT FRONT SPEED SENSOR LH Installation

37. CONNECT FRONT SPEED SENSOR RH

HINT
Perform the same procedure as for the LH side.

38. CONNECT FRONT STABILIZER LINK ASSEMBLY LH Installation

39. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure as for the LH side.

40. INSTALL FRONT AXLE SHAFT NUT LH Installation

41. INSTALL FRONT AXLE SHAFT NUT RH

HINT
Perform the same procedure as for the LH side.

42. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY (w/ Air Suspension)

(a) Install the height control sensor link sub-assembly with the nut.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

43. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

44. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Installation

45. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Installation

46. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with the 2 nuts.

Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)

47. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

48. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation

49. CONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the hose.

(b) Apply sufficient compressor oil to a new O-ring.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring onto the suction hose sub-assembly.

(d) Connect the suction hose sub-assembly with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Be sure to hold the suction hose while tightening the nut so that the suction hose is not deformed.

50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

(a) Remove the attached vinyl tape from the hose.

(b) Apply sufficient compressor oil to a new O-ring.

Compressor oil:

ND-OIL 8 or equivalent

(c) Install the O-ring onto the discharge hose sub-assembly.

(d) Connect the discharge hose sub-assembly with the nut.

Torque : 9.8 Nm (100 kgf-cm, 87 in-lbf)

NOTICE:
Be sure to hold the discharge hose while tightening the nut so that the discharge hose is not deformed.

51. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.

HINT
Perform this procedure only when replacement of the engine moving control rod is necessary.

52. INSTALL ENGINE MOVING CONTROL ROD BRACKET

(a) When replaced the engine moving control rod.

(1) Temporarily install the engine moving control rod and engine moving control rod bracket with the 4 bolts.

(2) Install the engine moving control rod bracket with the bolts except A.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

(3) Tighten the bolt A.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

(b) When not replaced the engine moving control rod.

(1) Install the engine moving control rod bracket with the 4 bolts.

Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

53. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

Bolt - Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)

Nut - Torque : 23 Nm (234 kgf-cm, 17 ft-lbf)

54. CONNECT NO. 2 EARTH WIRE

(a) Install the No. 2 earth wire with the 2 bolts and connect the 2 wire clamps.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

55. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose.

56. CONNECT NO. 1 OUTLET OIL COOLER HOSE

(a) Connect the No. 1 outlet oil cooler hose.

57. CONNECT NO. 1 INLET OIL COOLER HOSE

(a) Connect the No. 1 inlet oil cooler hose.

58. CONNECT FUEL MAIN TUBE

(a) Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

NOTICE:
* Check that there is no damage or foreign objects on the fuel tube connector.
* After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.
(b) Install the No. 1 EFI fuel pipe clamp.

HINT
The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.

59. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

60. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

61. CONNECT NO. 1 RADIATOR HOSE

(a) Install the No. 1 radiator hose to the radiator pipe clamp.

(b) Connect the No. 1 radiator hose.

62. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.

63. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose.

64. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip to the control cable bracket.

(b) Install the control cable to the control cable bracket.

Text in Illustration

NOTICE:
* Make sure that the claws (A) on the clip are securely fit into the bracket holes.
* Make sure that the cable is securely installed inside of the claws (B) of the clip.
(c) Connect the transmission control cable to the control shaft lever with the nut.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

NOTICE:
Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.

65. CONNECT ENGINE WIRE

(a) Connect the 2 wire clamps.

(b) Connect the connector to the ECU with the lock lever.

(d) Install the engine wire with the nut and 3 connectors.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

(e) Connect the 2 wire clamps.

(f) Install the earth wire with the 2 bolts.

Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)

66. INSTALL NO. 1 RELAY BLOCK COVER

(a) Install the No. 1 relay block cover.

67. INSTALL RESERVOIR BRACKET

(a) Install the reservoir bracket with the 2 bolts.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

68. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY

(a) Install the brake master cylinder reservoir sub-assembly with the bolt.

Torque : 9.0 Nm (92 kgf-cm, 80 in-lbf)

(b) Connect the connector to the brake master cylinder reservoir sub-assembly.

69. INSTALL AIR CLEANER BRACKET

(a) Install the air cleaner bracket with the 2 bolts.

Torque : 13 Nm (132 kgf-cm, 10 ft-lbf)

(b) Connect the engine wire clamp.

70. INSTALL AIR CLEANER ASSEMBLY Installation

71. INSTALL BATTERY

(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

(c) Connect the positive (+) cable to the positive (+) battery terminal.

Torque : 6.4 Nm (65 kgf-cm, 57 in-lbf)

72. INSTALL NO. 1 AIR CLEANER INLET

(a) Install the No. 1 air cleaner inlet with the bolt.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Connect the vacuum hose clamp to the No. 1 air cleaner inlet.

73. INSTALL NO. 2 AIR CLEANER INLET

(a) Install the No. 2 air cleaner inlet with the 2 bolts.

Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

(b) Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.

74. INSPECT VACUUM HOSES

(a) Inspect the vacuum hoses.

75. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation

76. INSTALL FRONT SHOCK ABSORBER CAP (w/ Air Suspension) Installation

77. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation

78. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation

79. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation

80. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation

81. INSTALL FRONT WIPER ARM HEAD CAP Installation

82. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation

83. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation

84. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY LH Installation

85. INSTALL FRONT FENDER TOP REINFORCEMENT SUB-ASSEMBLY RH Installation

86. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Repair Instruction - Initialization.

87. INSTALL FRONT WHEEL

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

88. ADD ENGINE OIL Replacement

89. ADD ENGINE COOLANT Service and Repair

90. ADD TRANSFER OIL (for AWD)

91. INSPECT TRANSFER OIL (for AWD) Testing and Inspection

92. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD)

HINT
U660E Automatic Transaxle.)

93. ADD AUTOMATIC TRANSAXLE FLUID (for AWD)

HINT
U660F Automatic Transaxle.)

94. WARM UP ENGINE

95. INSPECT ENGINE OIL LEVEL Testing and Inspection

96. INSPECT FOR ENGINE COOLANT LEVEL Testing and Inspection

97. CHARGE WITH REFRIGERANT Service and Repair

98. INSPECT FOR FUEL LEAK Installation

99. INSPECT FOR COOLANT LEAK Testing and Inspection

100. INSPECT FOR OIL LEAK

101. INSPECT FOR EXHAUST GAS LEAK

102. INSPECT IGNITION TIMING Engine

103. INSPECT ENGINE IDLE SPEED Engine

104. INSPECT CO/HC Engine

105. CHECK FOR SPEED SENSOR SIGNAL

HINT
Test Mode Procedure.)

106. INSPECT SHIFT LEVER POSITION (for 2WD) U660E Automatic Transaxle

107. INSPECT SHIFT LEVER POSITION (for AWD) U660F Automatic Transaxle

108. CHECK VEHICLE HEIGHT (w/ Air Suspension)

NOTICE:
If the height control sensor link is removed, check the vehicle height.

(a) Change the height control switch from the "NORM" position to the "HIGH" position and back to the "NORM" position.

(b) Measure the vehicle height ( Front Wheel Alignment).

109. ADJUST VEHICLE HEIGHT (w/ Air Suspension)

NOTICE:
If the height control sensor has been replaced, be sure to adjust the vehicle height.

(a) Adjust the vehicle height ( Suspension Control System).

110. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT
Front Wheel Alignment.)

111. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for 2WD)

NOTICE:
If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary ( U660E Automatic Transaxle System).

112. INSPECT AUTOMATIC TRANSAXLE SYSTEM (for AWD)

NOTICE:
If automatic transmission parts have been replaced, refer to the Parts Replacement Compensation Table to determine if any additional operations are necessary ( U660F Automatic Transaxle System).

113. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 4 retainers and install the V-bank cover sub-assembly.

114. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the 2 bolts and clip.

115. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.

116. INSTALL FRONT FENDER LINER LH

117. INSTALL FRONT FENDER LINER RH

118. INSTALL NO. 2 ENGINE UNDER COVER

119. INSTALL NO. 1 ENGINE UNDER COVER

120. INSTALL FRONT FLOOR COVER LH Installation

121. PERFORM INITIALIZATION

(a) Perform initialization ( Repair Instruction - Initialization).

NOTICE:
Some systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

122. ADJUST HEADLIGHT ASSEMBLY (w/ Air Suspension)

(a) Adjust the headlight ( Adjustments).

123. INSTALL COOL AIR INTAKE DUCT SEAL Installation

124. INSTALL ENGINE ROOM SIDE COVER Installation

125. INSTALL ENGINE ROOM SIDE COVER LH Installation