BRAKE BOOSTER (for RHD) INSTALLATION

CONNECT BRAKE MASTER CYLINDER PUSH ROD CLEVIS

1. 

   Apply lithium soap base glycol grease to the push rod pin.

2. Connect the brake master cylinder push rod clevis to the brake pedal with the push rod pin, and install a new clip as shown in the illustration.

INSTALL BRAKE PEDAL RETURN SPRING

1. 

   Install the brake pedal return spring between the instrument panel reinforcement and push rod pin.

INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY

1. Engage each clamp.

2. Connect each connector.

3. 

   Engage the claw and 2 guides.

4. Install the No. 1 instrument panel under cover sub- assembly with the 2 screws <D>.

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

1. 

   Apply seal packing as shown in the illustration.

   Table 2. Text in Illustration

   Seal Packing

   Seal Packing
   Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

   Note:
   

   • Remove any oil from the contact surface.

   • Install the cylinder head cover sub-assembly within 3 minutes of applying seal packing.

   • Do not start the engine for at least 2 hours after installation.

2. 

   Install 3 new gaskets shown in the illustration.

3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.

4. 

   Install the cylinder head cover sub-assembly with the 12 bolts and a new seal washer.

   Table 3. Text in Illustration

   *1	Seal Washer

   Bolt A
   21 N*m	214 kgf*cm	15 ft.*lbf
   Except bolt A
   10 N*m	102 kgf*cm	7 ft.*lbf

   Tip:

   After tightening all bolts, check the tightening torque of 1 and 11. Retighten the bolt if necessary.

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 RH.

2. 

   Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install the oil pipe (on the cylinder head cover sub-assembly side) with the oil pipe union.

   Table 4. Text in Illustration

   *1	Oil Pipe Union
   *2	Bolt

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

4. Install the bolt to the cylinder head sub-assembly.

   10 N*m

   102 kgf*cm

   7 ft.*lbf

5. Tighten the oil pipe union (on the cylinder head cover sub-assembly side).

   65 N*m

   663 kgf*cm

   48 ft.*lbf

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

   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)

1. 

   Install the No. 2 timing gear cover with the 2 bolts.

   6.0 N*m

   61 kgf*cm

   53 in.*lbf

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

1. 

   Install the No. 1 surge tank stay with the bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

INSTALL THROTTLE BODY BRACKET (for 2GR-FE)

1. 

   Install the throttle body bracket with the bolt.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

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

1. Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

2. 

   Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

   Bolt
   18 N*m	184 kgf*cm	13 ft.*lbf
   Nut
   16 N*m	163 kgf*cm	12 ft.*lbf

3. 

   Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

   21 N*m

   214 kgf*cm

   15 ft.*lbf

4. 

   Connect the connector to the intake air control valve assembly.

5. 

   Connect the ventilation hose and vacuum hose.

6. 

   Connect the 2 water by-pass hoses to the throttle body assembly.

7. 

   Connect the vacuum hose clamp and fuel vapor feed hose.

8. 

   Connect the throttle body assembly connector and wire harness clamp to the throttle body assembly.

9. 

   Connect the union to check valve hose.

   Table 5. Text in Illustration

   *1	for RHD:
   *2	for LHD:

INSTALL AIR CLEANER ASSEMBLY (for 2GR-FE)

1. 

   Insert the tab of the air cleaner assembly to the hole of the vehicle body as shown in the illustration.

   Table 6. Text in Illustration

   *1	Tab
   *2	Hole

2. 

   Install the air cleaner assembly with the 2 bolts.

   5.5 N*m

   56 kgf*cm

   49 in.*lbf

3. 

   Connect the air cleaner hose to the throttle body with the hose clamp.

   Table 7. Text in Illustration

   *1	Ventilation Hose
   *2	Fuel Vapor Feed Hose

4. Connect the ventilation hose and the fuel vapor feed hose.

5. 

   Connect the 2 vacuum hoses.

6. 

   Connect the 2 wire harness clamps and vacuum switching valve connector.

7. 

   Connect the vacuum hose to the intake air surge tank assembly.

8. Install the hose to the hose clamp.

9. 

   Connect the mass air flow meter connector and wire harness clamp.

INSTALL BATTERY (for 2GR-FE)

1. Install the battery and battery tray.

2. 

   Install the battery clamp with the bolt and nut.

   5.4 N*m

   55 kgf*cm

   48 in.*lbf

3. Connect the positive (+) cable to the positive (+) battery terminal.

   6.4 N*m

   65 kgf*cm

   57 in.*lbf

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

1. 

   Install the No. 1 air cleaner inlet with the bolt.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

2. Connect the vacuum hose clamp to the No. 1 air cleaner inlet.

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

1. 

   Install the No. 2 air cleaner inlet with the 2 bolts.

   8.0 N*m

   82 kgf*cm

   71 in.*lbf

2. Connect the 2 vacuum hose clamps to the No. 2 air cleaner inlet.

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

1. 

   Fit the 4 retainers and install the V-bank cover sub-assembly.

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

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

   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)

1. 

   Fit the 3 retainers and install the No. 1 engine cover sub-assembly.

ADD ENGINE COOLANT (for 2GR-FE)

1. Tighten the radiator drain cock plug by hand.

2. Tighten the cylinder block drain cock plug. (for Bank 1)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

3. Tighten the cylinder block drain cock plug. (for Bank 2, w/ Cylinder Block Drain Cock Plug)

   13 N*m

   130 kgf*cm

   9 ft.*lbf

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

5. Add engine coolant to the radiator inlet opening until engine coolant overflows from the air drain cock hole. Then tighten the air drain cock plug to the water inlet housing.

   13 N*m

   130 kgf*cm

   9 ft.*lbf

6. Slowly fill the radiator assembly with engine coolant.

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

   Note:

   Do not substitute plain water for engine coolant.

   Tip:

   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).

7. Remove the reserve tank cap.

8. 

   Slowly pour engine coolant into the radiator reserve tank assembly until it reaches the full line.

   Table 8. Text in Illustration

   *a

   Full Line

9. Squeeze the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.

   If the engine coolant level is low, add engine coolant.

10. Install the radiator cap sub-assembly and reserve tank cap.

11. Bleed air from the cooling system.

    Note:
    

    • Before starting the engine, turn the A/C switch off.

    • Adjust the heater control to the maximum hot setting.

    • Adjust the blower speed to the low setting.

    
    

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

       Tip:

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

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

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

       CAUTION:

       When squeezing the No. 1 radiator hose and No. 2 radiator hose:

       
       

       • Wear protective gloves.

       • Be careful as the No. 1 radiator hose and No. 2 radiator hose are hot.

       • Keep your hands away from the fan and No. 2 fan.

       Note:
       

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

       • Make sure that the radiator reserve tank assembly still has some engine coolant in it.

       • If the radiator reserve tank assembly does not have enough engine coolant, the engine may overheat or be seriously damaged.

       • If the radiator reserve tank assembly does not have enough engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant until the radiator reserve tank assembly 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 reserve tank assembly.

CHARGE WITH REFRIGERANT

1. Perform vacuum purging using a vacuum pump.

2. 

   Charge with refrigerant HFC-134a (R134a).

   Standard (for Suction Pipe Separate Type)
   450 to 550 g (15.9 to 19.4 oz.)

   Standard (except Suction Pipe Separate Type)
   500 to 600 g (17.6 to 21.2 oz.)

   09985-20010

   09985-02010

   09985-02050

   09985-02060

   09985-02070

   09985-02080

   09985-02090

   09985-02110

   09985-02130

   09985-02140

   09985-02150

   Note:
   

   • Do not turn the A/C switch on before charging with refrigerant. Doing so will cause the compressor to work without refrigerant, resulting in overheating of the compressor.

   • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, not with the sight glass.

   Tip:

   Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100% of the refrigerant from an A/C system.

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)

1. Remove the radiator cap.

2. 

   Fill the radiator with coolant and attach a radiator cap tester.

3. Warm up the engine.

4. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 psi), and check that the pressure does not drop.

   If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

5. Remove the radiator cap tester.

6. Install the radiator cap.

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. 

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

   Table 9. Text in Illustration

   *1	Inspect for Leak
   *2	Halogen Leak Detector

4. 

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

   Table 10. Text in Illustration

   *1	Halogen Leak Detector
   *2	Drain Hose

   Tip:
   

   • 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.