Up to 08/2009
2GR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR Installation
2. INSTALL KNOCK CONTROL SENSOR Installation
3. INSTALL KNOCK CONTROL SENSOR WIRE
(a) Connect the 2 clamps, 2 knock control sensor connectors and knock control sensor wire connector.
4. 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 assembly.
Text in Illustration
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 installation to prevent oil leaks.
5. 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)
6. INSTALL WATER PUMP PULLEY Installation
7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.
Torque : 54 Nm (550 kgf-cm, 40 ft-lbf)
8. 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)
9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Temporarily install the V-ribbed belt tensioner assembly 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 assembly 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)
10. 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, 15 ft-lbf)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR Installation
12. INSTALL NO. 2 MANIFOLD STAY Installation
13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
(a) Install a new O-ring to the No. 2 engine oil level dipstick guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.
(d) Install the No. 2 engine oil level dipstick guide with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(e) Install the engine oil level dipstick.
14. 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, 15 ft-lbf)
15. 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 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, 15 ft-lbf)
16. 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)
17. INSTALL IGNITION COIL ASSEMBLY Installation
18. INSTALL NO. 1 SURGE TANK STAY
(a) Install the No. 1 surge tank stay with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
19. INSTALL THROTTLE BODY BRACKET
(a) Install the throttle body bracket with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY Installation
21. INSTALL ENGINE HANGERS
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Text in Illustration
Part No.:
No. 1 engine hanger 12281-31120
No. 2 engine hanger 12282-31100
Bolts 91671-10825
Torque : 33 Nm (337 kgf-cm, 24 ft-lbf)
(b) Attach the engine sling device and hang the engine with the chain block.
22. REMOVE ENGINE STAND