Installation
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)
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 FLEXIBLE HOSE BRACKET SUB-ASSEMBLY
(a) Install the flexible hose bracket sub-assembly 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 flexible hose bracket sub-assembly.
10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) Installation
11. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)
(a) Install the rear engine mounting insulator assembly with the 2 bolts.
Torque : 75 Nm (765 kgf-cm, 55 ft-lbf)
12. INSTALL ENGINE MOUNTING INSULATOR RH
(a) Install the engine mounting insulator RH with the nut.
Torque : 95 Nm (969 kgf-cm, 71 ft-lbf)
13. INSTALL ENGINE MOUNTING INSULATOR LH
(a) Install the engine mounting insulator LH with the nut.
Torque : 95 Nm (969 kgf-cm, 71 ft-lbf)
14. INSTALL FRONT ENGINE MOUNTING INSULATOR
(a) Install the front engine mounting insulator with the bolt.
Torque : 87 Nm (888 kgf-cm, 65 ft-lbf)
(b) Connect the connector
15. INSTALL STEERING GEAR ASSEMBLY (for AWD) Installation
16. INSTALL FRONT STABILIZER BAR (for AWD) Installation
17. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD) Installation
18. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD)
HINT
Perform the same procedure as for the LH side.
19. INSTALL ENGINE WIRE
(a) Install the engine wire to the engine with transaxle.
20. INSTALL STARTER ASSEMBLY Installation
21. INSTALL COOLER COMPRESSOR ASSEMBLY Installation
22. INSTALL GENERATOR ASSEMBLY Installation
23. INSTALL FAN AND GENERATOR V BELT Removal
24. 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.
Text in Illustration
(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 6 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 6 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)
25. 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.
26. 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)
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation
29. INSTALL FRONT LOWER SUSPENSION ARM LH Installation
30. INSTALL FRONT LOWER SUSPENSION ARM RH
HINT
Perform the same procedure as for the LH side.
31. CONNECT TIE ROD ASSEMBLY LH Installation
32. CONNECT TIE ROD ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
33. CONNECT FRONT SPEED SENSOR LH Installation
34. CONNECT FRONT SPEED SENSOR RH
HINT
Perform the same procedure as for the LH side.
35. CONNECT FRONT STABILIZER LINK ASSEMBLY LH Installation
36. CONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT
Perform the same procedure as for the LH side.
37. INSTALL FRONT AXLE SHAFT NUT LH Installation
38. INSTALL FRONT AXLE SHAFT NUT RH
HINT
Perform the same procedure as for the LH side.
39. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
40. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
41. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for AWD) Installation
42. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET Installation
43. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)
Installation
44. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation
45. CONNECT DISCHARGE HOSE SUB-ASSEMBLY Installation
46. 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.
47. INSTALL ENGINE MOVING CONTROL ROD BRACKET
(a) When replacing 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 replacing the engine moving control rod.
(1) Install the engine moving control rod bracket with the 3 bolts.
Torque : 38 Nm (387 kgf-cm, 28 ft-lbf)
48. 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)
(b) Install the No. 2 ground wire with the 2 bolts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
49. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose.
50. CONNECT NO. 1 INLET OIL COOLER HOSE
(a) Connect the No. 1 inlet oil cooler hose.
51. CONNECT NO. 1 OUTLET OIL COOLER HOSE
(a) Connect the No. 1 outlet oil cooler hose.
52. 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.
53. CONNECT OUTLET HEATER WATER HOSE
(a) Connect the outlet heater water hose.
54. CONNECT INLET HEATER WATER HOSE
(a) Connect the inlet heater water hose.
55. CONNECT NO. 1 RADIATOR HOSE
(a) Install the No. 1 radiator hose to the radiator pipe clamp.
(b) Connect the No. 1 radiator hose.
56. CONNECT NO. 2 RADIATOR HOSE
(a) Connect the No. 2 radiator hose.
57. CONNECT NO. 1 FUEL VAPOR FEED HOSE
(a) Connect the No. 1 fuel vapor feed hose.
58. 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.
59. CONNECT ENGINE WIRE
(a) Connect the connector to the ECM with the lock lever.
(b) Connect the engine wire to the engine room junction block.
(c) Install the engine wire with the nut and 3 connectors.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(d) Install the ground wire with the 2 bolts.
Torque : 8.4 Nm (86 kgf-cm, 74 in-lbf)
(e) Install the engine room relay block cover.
60. INSTALL AIR CLEANER AND HOSE Installation
61. INSTALL BATTERY
(a) Install the battery and battery tray.
(b) Install the battery clamp with the bolt and nut.
Torque : 5.5 Nm (56 kgf-cm, 49 in-lbf)
(c) Connect the positive (+) cable to the positive (+) battery terminal.
Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)
62. INSTALL AIR CLEANER INLET COVER ASSEMBLY SEAL
(a) Install the air cleaner inlet cover assembly seal with the 2 bolts.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Connect the 2 vacuum hose clamps to the air cleaner inlet cover assembly seal.
63. INSPECT VACUUM HOSES
(a) Inspect the vacuum hoses.
64. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY Installation
65. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY Installation
66. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY Installation
67. INSTALL FRONT FENDER TO COWL SIDE SEAL LH Installation
68. INSTALL FRONT FENDER TO COWL SIDE SEAL RH Installation
69. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH Installation
70. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH Installation
71. INSTALL FRONT WIPER ARM HEAD CAP Installation
72. 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.
73. INSTALL FRONT WHEEL
Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)
74. ADD ENGINE OIL Replacement
75. ADD ENGINE COOLANT Service and Repair
76. ADD TRANSFER OIL (for AWD) Service and Repair
77. INSPECT TRANSFER OIL (for AWD) Testing and Inspection
78. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD)
79. ADD AUTOMATIC TRANSAXLE FLUID (for AWD)
Procedures
80. WARM UP ENGINE
81. INSPECT ENGINE OIL LEVEL Testing and Inspection
82. INSPECT ENGINE COOLANT LEVEL Testing and Inspection
83. CHARGE WITH REFRIGERANT Service and Repair
84. INSPECT FOR FUEL LEAK Fuel System
85. INSPECT FOR COOLANT LEAK Testing and Inspection
86. INSPECT FOR OIL LEAK
87. INSPECT FOR EXHAUST GAS LEAK
88. INSPECT IGNITION TIMING Engine
89. INSPECT ENGINE IDLE SPEED Engine
90. INSPECT CO/HC Engine
91. CHECK FOR SPEED SENSOR SIGNAL
Test Mode Procedure
92. INSPECT SHIFT LEVER POSITION (for 2WD)
93. INSPECT SHIFT LEVER POSITION (for AWD)
94. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
Front Wheel Alignment
95. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Fit the 4 retainers and install the V-bank cover sub-assembly.
96. INSTALL FRONT FENDER APRON SEAL LH
(a) Install the front fender apron seal LH with the 2 bolts and clip.
97. INSTALL FRONT FENDER APRON SEAL RH
(a) Install the front fender apron seal RH with the 2 bolts and clip.
98. INSTALL NO. 2 ENGINE UNDER COVER (for AWD) Installation
99. INSTALL NO. 1 ENGINE UNDER COVER Installation
100. INSTALL INSTRUMENT PANEL FINISH PANEL END LH Installation