Installation

2GR-FE ENGINE MECHANICAL: ENGINE UNIT: 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 (200 kgf-cm, 14 ft-lbf)
2. INSTALL KNOCK CONTROL SENSOR Installation
3. INSTALL KNOCK CONTROL SENSOR WIRE





(a) Connect the 2 knock control sensor connectors and 3 clamps.
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.
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 to prevent oil leaks.

5. INSTALL NO. 1 VACUUM SWITCHING VALVE





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





(a) Install the 2 bolts and 2 radio setting condensers.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
7. INSTALL WATER PUMP PULLEY Installation
8. 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)
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 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)
11. INSTALL GENERATOR ASSEMBLY Installation
12. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (for 4WD)





(a) Install the transverse engine mounting bracket with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
13. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (for 2WD)





(a) Install the transverse engine mounting bracket with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft-lbf)
14. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET





(a) Install the transverse engine mounting bracket with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft-lbf)
15. 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)
16. 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)
17. 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, 25 ft-lbf)
18. 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-rings.
(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.
19. 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)
20. INSTALL INTAKE MANIFOLD
NOTE: 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)
21. INSTALL NO. 2 ENGINE MOUNTING STAY RH





(a) Install the No. 2 mounting stay RH with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft-lbf)
22. INSTALL IGNITION COIL ASSEMBLY Installation
23. INSTALL ENGINE HANGERS
(a) Install the 2 engine hangers with the 4 bolts as shown in the 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.
24. REMOVE ENGINE STAND