Installation

2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

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, 47ft-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, 47ft-lbf)
4. INSTALL ENGINE MOUNTING BRACKET RH

(a) Install the front engine mounting bracket with the 3 bolts.
Torque: 54 Nm (550 kgf-cm, 40ft-lbf)
5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD) Installation
7. INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY
8. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)
(a) Temporarily install the transfer stiffener plate RH.

(b) Tighten the transfer stiffener plate RH with the 4 bolts to the transfer and rear engine mounting bracket.
Bolt A - Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
Bolt B - Torque: 78 Nm (795 kgf-cm, 58ft-lbf)
9. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.
Torque: 34 Nm (347 kgf-cm, 25ft-lbf)
10. INSTALL ENGINE WIRE
11. INSTALL STARTER ASSEMBLY Installation
12. TEMPORARILY TIGHTEN COMPRESSOR AND MAGNETIC CLUTCH Installation
13. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Installation
14. INSTALL GENERATOR ASSEMBLY Installation
15. INSTALL V-RIBBED BELT Installation
16. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Temporarily install the front engine mounting insulator with the 3 nuts.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

17. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the 3 nuts.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

18. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Temporarily install the engine mounting insulator RH with the 3 nuts.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

19. INSTALL REAR ENGINE MOUNTING INSULATOR

(a) Temporarily install the rear engine mounting insulator with the 2 nuts.
20. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY

(a) Install the engine mounting insulators RH and LH with the 2 nuts.
Torque: 95 Nm (968 kgf-cm, 70ft-lbf)

(b) Install the front engine mounting insulator with the bolt.
Torque: 87 Nm (887 kgf-cm, 64ft-lbf)

(d) Install the rear engine mounting insulator with the 2 bolts.
Torque: 75 Nm (764 kgf-cm, 55ft-lbf)

(e) Connect the 2 clamps with the engine wire.
21. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

(a) Install the front engine mounting insulator with the 3 nuts.
Torque: 52 Nm (530 kgf-cm, 38ft-lbf)
(b) Install the 3 hole plugs.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

22. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the 3 nuts.
Torque: 87 Nm (887 kgf-cm, 64ft-lbf)
(b) Install the 3 hole plugs.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

23. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 3 nuts.
Torque: 87 Nm (887 kgf-cm, 64ft-lbf)
(b) Install the 3 hole plugs.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

24. INSTALL REAR ENGINE MOUNTING INSULATOR

(a) Install the rear engine mounting insulator with the 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38ft-lbf)
(b) Install the 2 hole plugs.
HINT: Perform this procedure only when replacement of the engine mounting insulator is necessary.

25. INSTALL STEERING LINK ASSEMBLY (for AWD) Installation
26. INSTALL FRONT STABILIZER BAR (for AWD)
27. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD) Installation
28. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD)
HINT: Perform the same procedure as for the LH side.

29. 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 crossmember sub-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 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.
A - Torque: 85 Nm (866 kgf-cm, 62ft-lbf)
B - Torque: 32 Nm (326 kgf-cm, 24ft-lbf)
(e) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
C - Torque: 85 Nm (866 kgf-cm, 62ft-lbf)
D - Torque: 32 Nm (326 kgf-cm, 24ft-lbf)
30. INSTALL FRONT FLOOR BRACE

(a) Install the front floor brace with the 4 nuts.
Torque: 11 Nm (112 kgf-cm, 8ft-lbf)
31. 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.
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, 30ft-lbf)
NOTICE: Install the black colored bolt first, and then the 5 silver colored bolts.

32. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (79 kgf-cm, 69in-lbf)
33. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket with the nut.
Torque: 21 Nm (214 kgf-cm, 15ft-lbf)
34. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Reassembly
35. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation
36. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD) Installation
37. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD) Installation
38. INSTALL FRONT AXLE ASSEMBLY LH Installation
39. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as for the LH side.

40. CONNECT FRONT LOWER SUSPENSION ARM LH Installation
41. CONNECT FRONT LOWER SUSPENSION ARM RH
HINT: Perform the same procedure as for the LH side.

42. CONNECT FRONT STABILIZER LINK ASSEMBLY LH Installation
43. CONNECT FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as for the LH side.

44. CONNECT TIE ROD ASSEMBLY LH Installation
45. CONNECT TIE ROD ASSEMBLY RH
HINT: Perform the same procedure as for the LH side.

46. CONNECT FRONT SPEED SENSOR LH Installation
47. CONNECT FRONT SPEED SENSOR RH
HINT: Perform the same procedure as for the LH side.

48. INSTALL FRONT AXLE SHAFT NUT LH Installation
49. INSTALL FRONT AXLE SHAFT NUT RH
HINT: Perform the same procedure as for the LH side.

50. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY Installation
51. TEMPORARILY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Installation
52. FULLY TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD) Installation
53. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation
54. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY Installation
55. 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 pipe connectors.
- After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

(b) Close the No. 1 EFI fuel pipe clamp cover.
HINT: The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube is not securely connected.

56. CONNECT SUCTION HOSE SUB-ASSEMBLY Installation
57. CONNECT COOLER REFRIGERANT DISCHARGE HOSE Installation
58. INSTALL ENGINE MOVING CONTROL ROD

(a) Temporarily install the bolt A.
(b) Install the engine moving control rod with the bolts except A.
Torque: 38 Nm (387 kgf-cm, 28ft-lbf)
(c) Tighten the bolt A.
Torque: 52 Nm (530 kgf-cm, 38ft-lbf)
59. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.
for Bolt - Torque: 38 Nm (387 kgf-cm, 28ft-lbf)
for Nut - Torque: 23 Nm (234 kgf-cm, 17ft-lbf)
60. CONNECT ENGINE WIRE

(a) Connect the connector to the ECM with the lock lever.

(b) Install the engine wire with the bolt and connect the clamp.
Torque: 8.3 Nm (85 kgf-cm, 73in-lbf)

(d) Connect the wire to the engine room junction block. Then, install it with the nut and 2 connectors.
Torque: 8.0 Nm (85 kgf-cm, 74in-lbf)
(e) Install the engine room relay block cover.
(f) Connect the engine wire to the positive (+) battery terminal assembly.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
61. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Connect the transmission control cable assembly to the transaxle with the new clip and nut.
Torque: 13 Nm (130 kgf-cm, 9ft-lbf)
62. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE

(a) Connect the union to connector tube hose.
63. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose.
64. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater hose.
65. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater hose.
66. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose.
(b) Connect the clamp.
67. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.
68. CONNECT OUTLET NO. 1 OIL COOLER HOSE

(a) Connect the outlet oil cooler hose.
69. CONNECT INLET NO. 1 OIL COOLER HOSE

(a) Connect the inlet oil cooler hose.
70. INSTALL INLET NO. 1 AIR CLEANER

(a) Install the inlet No. 1 air cleaner with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the hose clamp.
71. INSTALL BATTERY
(a) Install the battery, battery insulator and battery tray.

(b) Install the battery clamp with the bolt and nut.
for Bolt - Torque: 9.0 Nm (92 kgf-cm, 80in-lbf)
for Nut - Torque: 3.5 Nm (36 kgf-cm, 31in-lbf)
(c) Connect the positive (+) battery terminal, and tighten the nut.
Torque: 5.4 Nm (55 kgf-cm, 47in-lbf)
72. INSTALL AIR CLEANER CASE

(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the hose and hose clamp.
(c) Install the air cleaner filter element.
73. INSTALL AIR CLEANER CAP WITH HOSE Installation
74. INSTALL INLET NO. 2 AIR CLEANER

(a) Install the inlet No. 2 air cleaner with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44in-lbf)
(b) Connect the wire harness clamp and vacuum hose clamp.
75. INSPECT VACUUM HOSES
(a) Inspect vacuum hoses.

Text in Illustration

76. INSTALL OUTER COWL TOP PANEL
HINT: Installation.

77. ADD ENGINE OIL Replacement
78. ADD ENGINE COOLANT Service and Repair
79. ADD TRANSFER OIL (for AWD)
80. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD)
HINT: .

81. ADD AUTOMATIC TRANSAXLE FLUID (for AWD)
HINT: Procedures.

82. 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.

83. WARM UP ENGINE
84. INSPECT ENGINE OIL LEVEL Testing and Inspection
85. INSPECT FOR ENGINE COOLANT LEVEL Testing and Inspection
86. INSPECT TRANSFER OIL (for AWD) Testing and Inspection
87. CHARGE WITH REFRIGERANT Service and Repair
88. INSPECT FOR FUEL LEAK Testing and Inspection
89. INSPECT FOR COOLANT LEAK Testing and Inspection
90. INSPECT FOR OIL LEAK
91. INSPECT FOR EXHAUST GAS LEAK
92. INSTALL NO. 3 ENGINE UNDER COVER
93. INSTALL FRONT FENDER APRON RH
94. INSTALL FRONT FENDER APRON LH
95. INSTALL FRONT FENDER LINER RH
96. INSTALL NO. 2 ENGINE UNDER COVER
97. INSTALL NO. 1 ENGINE UNDER COVER
98. INSTALL FRONT WHEEL
Torque: 103 Nm (1050 kgf-cm, 76ft-lbf)
99. INSPECT SHIFT LEVER POSITION (for 2WD)
100. INSPECT SHIFT LEVER POSITION (for AWD) Adjustments
101. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Service and Repair
102. INSTALL V-BANK COVER SUB-ASSEMBLY

(a) Fit the 3 retainers and install the V-bank cover sub-assembly.
103. INSTALL COOL AIR INTAKE DUCT SEAL

(a) Install the intake duct seal with the 12 clips.
104. INSPECT IGNITION TIMING Engine
105. INSPECT ENGINE IDLE SPEED Engine
106. INSPECT COMPRESSION Engine
107. INSPECT SPEED SENSOR SIGNAL
HINT: Test Mode Procedure.

108. 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 .

109. 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 Service Precautions.