Installation

2GR-FSE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

(a) 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)
NOTE:
Do not start the engine within 1 hour after installation for prevent oil leaks.

3. 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)
4. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 6 ignition coils with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL V-BANK COVER BRACKET SUB-ASSEMBLY

(a) Install the V-bank cover bracket with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
6. REMOVE RADIO SETTING CONDENSER

(a) Install the 2 bolts and 2 radio setting condensers.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL KNOCK SENSOR Installation
8. INSTALL FUEL INJECTOR ASSEMBLY
HINT:
Installation.

9. INSTALL FUEL PUMP
HINT:
Installation.

10. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Install the 2 bolts and fuel tube sub-assembly.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
11. INSTALL INTAKE MANIFOLD Installation
12. INSTALL WATER HOSE JOINT

(a) Connect the 2 hoses, and install the bolt and water hose joint.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
13. INSTALL NO. 2 SURGE TANK STAY
(a) Install the bolt and No. 2 surge tank stay.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
14. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
HINT:
Installation

15. INSTALL INJECTOR DRIVER

(a) Install the injector driver with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
16. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine assembly.
17. INSTALL WATER PUMP PULLEY Installation
18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(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 bolt 2 in the order shown in the illustration.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
(c) Tighten the other bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
19. INSTALL ENGINE MOUNTING BRACKET LH

(a) Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
(b) Connect the 2 clamps.
20. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft-lbf)
21. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
22. INSTALL GENERATOR ASSEMBLY Installation
23. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) Install the plate and idler pulley with the bolt.
Torque: 54 Nm (550 kgf-cm, 40 ft-lbf)
24. INSTALL NO. 1 ENGINE COVER

(a) Install the No. 1 engine cover with the 3 clips.
25. INSTALL NO. 2 ENGINE COVER

(a) Install the No. 2 engine cover with the 3 clips.
(b) Connect the clamp.
26. INSTALL V-RIBBED BELT Installation
27. INSTALL ENGINE HANGERS
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
28. 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 of the mounting bolts ends.
Adhesive:
Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(c) Install the front spacer, drive plate and rear spacer on the crankshaft.

(d) Install and tighten the 8 mounting bolts uniformly in several steps.
Torque: 83 Nm (846 kgf-cm, 61 ft-lbf)
NOTE:
Do not start the engine for at least 1 hour after installing.

29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

(a) Install the front suspension crossmember sub-assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft-lbf)
30. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
HINT:
Installation.

31. INSTALL STARTER ASSEMBLY Installation
32. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

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

LH:

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

RH:

(b) Install the exhaust manifold with 6 new nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
- Do not damage the stud bolt when installing the exhaust manifold.
- Be sure to tighten either of nuts A first as shown in the illustration.

34. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY
(a) Install a new O-ring to the oil dipstick guide.
(b) Apply a light coat of engine oil to the O-ring.
(c) Push in the oil dipstick guide end into the guide hole.

(d) Install the No. 1 oil dipstick guide with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
(e) Connect the clamp.

(f) Install the No. 2 oil dipstick guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
(g) Install the oil dipstick.
35. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
(a) Set the engine lifter.
(b) Operate the engine lifter, then install the engine to the vehicle.

(c) Install the engine and transmission assembly with crossmember with the 12 bolts.
Torque: 167 Nm (1,700 kgf-cm, 123 ft-lbf)
Torque: 204 Nm (2,080 kgf-cm, 150 ft-lbf)
Torque: 50 Nm (510 kgf-cm, 37 ft-lbf)
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)

(d) Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
36. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY Installation
37. CONNECT POWER STEERING LINK WIRE HARNESS

(a) Install the power steering earth wire to the power steering link assembly with bolt (B).
Torque: 13 Nm (130 kgf-cm, 10 ft-lbf)
(b) Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.
(c) Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.
(d) Install the 2 wire harness clamps to the power steering link assembly.
(e) Connect the earth wire to the bracket with bolt (A).
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
38. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

(a) Install the front lower ball joint with the 2 bolts.
Torque: 120 Nm (1,224 kgf-cm, 89 ft-lbf)
39. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH
HINT:
Install the RH side following the same procedures as for the LH side.

40. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH

(a) Install the bolt on the lower side of the front shock absorber while holding the nut.
Torque: 157 Nm (1,600 kgf-cm, 116 ft-lbf)
41. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH
HINT:
Install the RH side following the same procedures as for the LH side.

42. CONNECT HEIGHT CONTROL SENSOR LINK

(a) Connect the height control sensor link and install it with the nut.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
43. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY Installation
44. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

(a) Install the protector with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
45. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the connector to the fuel main pipe. Push the two parts together firmly until a "click" sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.
- Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
- Check that the connector and fuel main pipe are securely connected by trying to pull them apart.

(b) Install the fuel pipe clamp.
46. CONNECT NO. 3 FUEL HOSE

(a) Connect the No. 3 fuel hose and clamp.
47. CONNECT FUEL MAIN TUBE
HINT:
Service Precautions.

48. CONNECT ENGINE WIRE

(a) Install the bolt, clamp and engine wire No. 3.
Torque: 8.5 Nm (87 kgf-cm, 75 in-lbf)
(b) Connect the ground cable and install it with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)

(c) Connect the connector and install the 4 clamps to the body.
(d) Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.
Torque: 12 Nm (124 kgf-cm, 9 ft-lbf)
(e) Install the engine room No. 1 relay block cover.
(f) Connect the battery positive (+) cable and install it with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(g) Connect the ECM connectors.

(h) Connect the connector holder.
49. INSTALL ECM COVER Installation
50. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation
51. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE Installation
52. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.
53. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.
54. CONNECT INLET RADIATOR HOSE

(a) Install the clamp and connect the inlet radiator hose.
55. CONNECT OUTLET RADIATOR HOSE
(a) Install the clamp and connect the outlet radiator hose.
56. CONNECT RADIATOR RESERVOIR TANK HOSE
(a) Install the clamp and connect the reservoir tank hose.
57. CONNECT NO. 2 FUEL VAPOR FEED HOSE

(a) Install the clamp and connect the No. 2 fuel vapor feed hose.
58. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the hose to the surge tank.
59. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Install the air cleaner case, clamp and 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
60. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE Installation
61. INSTALL NO. 1 INLET AIR CLEANER

(a) Install the inlet air cleaner with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
62. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING
HINT:
Installation.

63. INSTALL FRONT EXHAUST PIPE ASSEMBLY
HINT:
Installation.

64. ADD ENGINE OIL Replacement
65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
66. ADD ENGINE COOLANT Testing and Inspection
67. CHARGE REFRIGERANT Service and Repair
68. INSPECT FOR FUEL LEAK Testing and Inspection
69. INSPECT FOR COOLANT LEAK Testing and Inspection
70. INSPECT FOR OIL LEAK
71. INSPECT FOR EXHAUST GAS LEAK
72. CHECK FOR LEAKAGE OF REFRIGERANT Service and Repair
73. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
74. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
75. ADJUST SHIFT LEVER POSITION Adjustments
76. CHECK SHIFT LEVER POSITION Shift Lever Assembly
77. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
Front Wheel Alignment.

78. CHECK IGNITION TIMING On-Vehicle Inspection
79. CHECK ENGINE IDLE SPEED On-Vehicle Inspection
80. CHECK CO / HC On-Vehicle Inspection
81. CHECK ENGINE OIL LEVEL Testing and Inspection
82. INSTALL ENGINE UNDER COVER REAR LH

(a) Install the engine under cover rear LH with the bolt.
83. INSTALL ENGINE UNDER COVER REAR RH
HINT:
Install the RH side following the same procedures as for the LH side.

84. INSTALL NO. 2 ENGINE UNDER COVER
85. INSTALL ENGINE UNDER COVER
86. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Engage the 3 clips to install the V-bank cover.
- Be sure to engage the clips securely.
- Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.

87. INSTALL ENGINE ROOM SIDE COVER LH

(a) Install the side cover with the 5 clips.
88. INSTALL ENGINE ROOM SIDE COVER RH

(a) Install the side cover with the 2 clips.
89. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 11 clips.