BRAKE BOOSTER (for RHD) INSTALLATION

CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS

INSTALL BRAKE PEDAL RETURN SPRING

INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for 2GR-FE)

INSTALL OIL PIPE (for 2GR-FE)

1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

   Note

   Do not touch the mesh when installing the oil control valve filter.

2. 

   Text in Illustration

   *1	Oil Pipe Union

   Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side) with the union.

3. Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the union.

4. Install the bolt (A) to the cylinder head.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

5. Tighten the oil pipe union (on the head cover side).

   Torque:

   65 N*m  { 663 kgf*cm, 48 ft.*lbf }

6. Tighten the oil pipe union (on the cylinder head side).

   Torque:

   65 N*m  { 663 kgf*cm, 48 ft.*lbf }

   Note

   If the link that connects the gaskets is broken, remove the connecting link by using side cutters or a similar tool.

INSTALL NO. 2 TIMING GEAR COVER (for 2GR-FE)

INSTALL NO. 1 SURGE TANK STAY (for 2GR-FE)

INSTALL THROTTLE BODY BRACKET (for 2GR-FE)

INSTALL INTAKE AIR SURGE TANK ASSEMBLY (for 2GR-FE)

INSTALL AIR CLEANER ASSEMBLY (for 2GR-FE)

INSTALL BATTERY (for 2GR-FE)

INSTALL NO. 1 AIR CLEANER INLET (for 2GR-FE)

INSTALL NO. 2 AIR CLEANER INLET (for 2GR-FE)

INSTALL V-BANK COVER SUB-ASSEMBLY (for 2GR-FE)

INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for 1AR-FE)

1. Install the vacuum switching valve assembly with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

2. Connect the 2 vacuum hoses and connector.

3. Connect the union to connector tube hose and wire harness clamp.

INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (for 1AR-FE)

ADD ENGINE COOLANT (for 2GR-FE)

1. Tighten the radiator drain cock plug by hand.

2. Tighten the 2 cylinder block drain cock plugs.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

3. Remove the radiator cap.

4. Loosen the air drain cock plug on the water inlet housing.

5. Add TOYOTA Super Long Life Coolant (SLLC) to the radiator inlet opening until coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

   Torque:

   13 N*m  { 130 kgf*cm, 9 ft.*lbf }

6. Slowly fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

   Standard capacity
   9.5 liters (10.0 US qts, 8.3 lmp. qts)

   Tech Tips

   
   

   • TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology is a combination of low phosphates and organic acids).

   • Contact your TOYOTA dealer for further details.

   Note

   Never use water as a substitute for engine coolant.

7. Tighten the air drain plug.

8. 

   Text in Illustration

   *1

   FULL Line

   Slowly pour coolant into the radiator reservoir tank until it reaches the FULL line.

9. Install the radiator cap.

10. Squeeze the No. 1 and No. 2 radiator hoses several times by hand, and then check the level of the coolant.

    If the coolant level is low, add coolant.

11. Bleed air from the cooling system.

    
    

    1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.

       Tech Tips

       The thermostat open timing can be confirmed by squeezing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    2. Maintain the engine speed at 2500 to 3000 rpm.

    3. Squeeze the inlet and No. 1 and No. 2 radiator hoses several times by hand to bleed air.

       CAUTION:

       When squeezing the radiator hoses:

       
       

       • Wear protective gloves.

       • Be careful as the radiator hoses are hot.

       • Keep your hands away from the cooling fans.

       Note

       
       

       • Make sure that the radiator reservoir still has some coolant in it.

       • If the coolant temperature gauge indicates an excessive temperature, turn off the engine and let it cool.

       • If there is not enough coolant, the engine may overheat or be seriously damaged.

       • If the radiator reservoir does not have enough coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the reservoir is filled to the FULL line.

12. Stop the engine and wait until the engine coolant cools down.

13. Add engine coolant to the FULL line on the radiator reservoir.

CHARGE WITH REFRIGERANT

WARM UP ENGINE

1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

   Note

   Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

INSPECT ENGINE OIL LEVEL (for 2GR-FE)

1. Warm up and stop the engine, then wait for 5 minutes. The oil level should be between the low level and full level marks on the engine oil level dipstick.

   If the engine oil level is low, check for leakage and add oil up to the full level mark.

   Note

   Do not add engine oil to above the full level mark.

INSPECT FOR COOLANT LEAK (for 2GR-FE)

INSPECT FOR REFRIGERANT LEAK

1. After recharging with refrigerant, inspect for refrigerant leaks using a halogen leak detector.

2. Carry out the test under the following conditions:

   
   

   • Turn the engine switch off.

   • Secure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

   • Repeat the test 2 or 3 times.

   • Make sure that there is some refrigerant remaining in the refrigeration system.

     When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)

3. 

   Text in Illustration

   *1	Inspect for Leak
   *2	Halogen Leak Detector

   Using a halogen leak detector, inspect for refrigerant leaks from the refrigerant lines.

4. 

   Text in Illustration

   *1	Halogen Leak Detector
   *2	Drain Hose

   Bring the halogen leak detector close to the drain hose with the detector's power off, and then turn the detector on.

   Tech Tips

   
   

   • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

   • Bring the halogen leak detector sensor under the drain hose.

   • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to volatile gases. If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

5. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.