Toyota 2GR-FE User manual

2GR-FE ENGINE MECHANICAL – ENGINE EM–1
EM
ENGINE
ON-VEHICLE INSPECTION
1. INSPECT ENGINE COOLANT
(a) Inspect the engine coolant (See page CO-1).
2. INSPECT ENGINE OIL
(a) Inspect the engine oil (See page LU-1).
3. INSPECT BATTERY
(a) Inspect the battery (See page CH-4).
4. INSPECT SPARK PLUGS
(a) Inspect the spark plugs (See page IG-5).
5. INSPECT AIR CLEANER FILTER ELEMENT SUB-
ASSEMBLY
(a) Remove the air cleaner filter element sub-assembly.
(b) Visually check that there is no dirt, blockage, and/or
damage to the air cleaner filter element.
HINT:
• If there is any dirt or a blockage in the air cleaner
filter element, clean it with compressed air.
• If any dirt or a blockage remains even after
cleaning the air cleaner filter element with
compressed air, replace it.
6. INSPECT VALVE LASH ADJUSTER NOISE
(a) Rev up the engine several times. Check that the
engine does not emit unusual noises.
If unusual noises occur, warm up the engine and
idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the
inspection above, perform lash adjuster inspection
(See page EM-87).
7. INSPECT IGNITION TIMING
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the ignition timing.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Ignition timing:
8 to 12°BTDC at idle
HINT:
Refer to the intelligent tester operator's manual
for help when selecting the DATA LIST.
Intelligent Tester
DLC3 CAN VIM
C110200E02

EM–2 2GR-FE ENGINE MECHANICAL – ENGINE
EM
(c) When not using the intelligent tester:
Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
(CG) of the DLC3.
SST 09843-18040
NOTICE:
• Confirm the terminal numbers before
connecting them. Connection with a
wrong terminal can damage the engine.
• Turn off all electrical systems before
connecting the terminals.
• Perform this inspection after the cooling
fan motor is turned off.
(2) Remove the V-bank cover.
(3) Pull out the red lead wire harness.
(4) Connect the tester terminal of the timing light to
the red lead wire as shown in the illustration.
NOTICE:
Use a timing light which can detect the first
signal.
(5) Check the ignition timing at idle.
Ignition timing:
8 to 12°BTDC at idle
NOTICE:
When checking the ignition timing, the
transmission should be in neutral.
HINT:
Run the engine at 1,000 to 1,300 rpm for 5
seconds, and then check that the engine rpm
returns to idle speed.
(6) Disconnect terminals 13 (TC) and 4 (CG) of the
DLC3.
(7) Check the ignition timing at idle.
Ignition timing:
12 to 22°BTDC at idle
(8) Confirm that the ignition timing moves to the
advanced angle side when the engine rpm is
increased.
(9) Remove the timing light.
8. INSPECT ENGINE IDLE SPEED
(a) Warm up the engine.
(b) When using the intelligent tester:
Check the idle speed.
(1) Connect the intelligent tester to the DLC3.
(2) Enter DATA LIST mode with the intelligent
tester.
Idle speed:
600 to 700 rpm
NOTICE:
• When checking the idle speed, the
transmission should be in neutral.
• Check the idle speed with the cooling fan
off.
1
910111213141516
2345678
CG
DLC3
TC A122830E14
Red Lead
Wire
Tester Terminal
A129620E01
Intelligent Tester
DLC3 CAN VIM
C110200E02

2GR-FE ENGINE MECHANICAL – ENGINE EM–3
EM
• Switch off all accessories and air
conditioning before connecting the
intelligent tester.
HINT:
Refer to the intelligent tester operator's manual
for further details.
(c) When not using the intelligent tester:
Check the idle speed.
(1) Using SST, connect the tachometer test probe
to terminal 9 (TAC) of the DLC3.
SST 09843-18030
(2) Check the idle speed.
Idle speed:
600 to 700 rpm
9. INSPECT COMPRESSION
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the intake air surge tank (See page FU-
13).
(d) Remove the 6 ignition coils.
(e) Remove the 6 spark plugs.
(f) Check the cylinder compression pressure.
(1) Insert a compression gauge into the spark plug
hole.
(2) While cranking the engine, measure the
compression pressure.
Compression pressure:
1.4 MPa (14 kgf/cm2, 199 psi)
Minimum pressure:
0.98 MPa (10 kgf/cm2, 142 psi)
Difference between each cylinder:
0.1 MPa (1.0 kgf/cm2, 15 psi)
NOTICE:
• Always use a fully charged battery to
obtain an engine speed of 250 rpm or
more.
• Check the other cylinders' compression
pressure in the same way.
• This measurement must be done as
quickly as possible.
(3) If the cylinder compression is low, pour a small
amount of engine oil into the cylinder through
the spark plug hole and inspect again.
HINT:
• If adding oil increases the compression, the
piston rings and/or cylinder bore may be
worn or damaged.
• If pressure stays low, a valve may be stuck
or seated improperly, or there may be
leakage in the gasket.
(g) Install the 6 spark plugs.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
1
910111213141516
2345678
DLC3
TAC
A122830E15
A129621

EM–4 2GR-FE ENGINE MECHANICAL – ENGINE
EM
(h) Install the 6 ignition coils.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(i) Install the intake air surge tank. (See page FU-17).
10. INSPECT CO/HC
(a) Start the engine.
(b) Run the engine at 2,500 rpm for approximately 180
seconds.
(c) Insert the CO/HC meter testing probe at least 40 cm
(1.3 ft) into the tailpipe during idling.
(d) Check CO/HC concentration at idle and/or 2,500
rpm.
HINT:
Check regulations and restrictions in your area
when performing 2 mode CO/HC concentration
testing (engine check at both idle speed and at
2,500 rpm).
If the CO/HC concentration does not comply with
regulations, perform troubleshooting in the order
given below.
(1) Check A/F sensor and heated oxygen sensor
operation.
(2) See the table below for possible causes, and
then inspect and repair.
CO HC Problems Causes
Normal High Rough idle
1. Faulty ignitions:
– Incorrect timing
– Fouled, shorted or improperly gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low High Rough idle
(fluctuating HC reading)
1. Vacuum leaks:
– PCV hoses
– Intake manifold
– Throttle body
– Brake booster line
2. Lean mixture causing misfire
High High Rough idle
(black smoke from exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty fuel pressure regulator
– Defective ECT sensor
– Defective MAF meter
–FaultyECM
– Faulty injectors
– Faulty throttle position sensor

2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–5
EM
ENGINE2GR-FE ENGINE MECHANICAL
DRIVE BELT
COMPONENTS
V-BANK COVER SUB-ASSEMBLY
V-RIBBED BELT
FRONT FENDER APRON SEAL RH
A134931E01

EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT
EM
REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-23)
4. REMOVE V-RIBBED BELT
(a) Using SST, release the belt tension by turning the
belt tensioner counterclockwise, and remove the V-
ribbed belt from the belt tensioner.
SST 09249-63010
(b) While turning the belt tensioner counterclockwise,
align with its holes, and then insert the 5 mm bi-
hexagon wrench into the holes to fix the V-ribbed
belt tensioner.
SST
A129622E01
A095070

2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–7
EM
INSPECTION
1. INSPECT V-RIBBED BELT
(a) Visually check the V-ribbed belt for excessive wear,
frayed cords, etc.
If any defect has been found, replace the V-ribbed
belt.
HINT:
Cracks on the rib side of a V-ribbed belt are
considered acceptable.
If the drive belt has chunks missing from its ribs, it
should be replaced.
HINT:
• A "new belt" is a belt which has been used for
less than 5 minutes with the engine running.
• A "used belt" is a belt which has been used for 5
minutes or more with the engine running.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
(a) Check that nothing gets caught in the tensioner by
turning it clockwise and counterclockwise.
If a malfunction exitsts, replace the tensioner.
INSTALLATION
1. INSTALL V-RIBBED BELT
(a) Install the V-ribbed belt.
(b) Using SST, turn the belt tensioner counterclockwise
and remove the bar.
SST 09249-63010
(c) If it is difficult to install the V-ribbed belt, perform the
following procedure:
(1) Put the V-ribbed belt on every pulley except the
tensioner pulley as shown in the illustration.
(2) While releasing the belt tension by turning the
belt tensioner counterclockwise, put the V-
ribbed belt on the tensioner pulley.
NOTICE:
• Put the backside of the V-ribbed belt on
the tensioner pulley and idler pulley.
• Check that the V-ribbed belt is properly
set to each pulley.
(3) After installing the V-ribbed belt, check that it
fits properly in the ribbed grooves. Confirm that
the belt has not slipped out of the grooves on
the bottom of the crank pulley by hand.
REPLACE
CORRECT INCORRECT
A131418E01
SST
A129622E01
Crankshaft
Vane Pump
Water Pump
Generator
Tensioner
Idler
Idler
A/C Compressor
A129623E01

EM–8 2GR-FE ENGINE MECHANICAL – DRIVE BELT
EM
2. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-52)
3. INSTALL FRONT FENDER APRON SEAL RH
4. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)

EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL
EM
ENGINE2GR-FE ENGINE MECHANICAL
ENGINE FRONT OIL SEAL
COMPONENTS
CRANKSHAFT PULLEY
TIMING CHAIN CASE OIL SEAL
V-BANK COVER SUB-ASSEMBLY
V-RIBBED BELT
FRONT FENDER APRON
SEAL RH
250 (2,550, 184)
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
A134932E01

2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–9
EM
REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V-BANK COVER SUB-ASSEMBLY (See
page EM-23)
4. REMOVE V-RIBBED BELT (See page EM-6)
5. REMOVE CRANKSHAFT PULLEY
(a) Using SST, loosen the crankshaft pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
(b) Using SST, remove the crankshaft pulley bolt and
crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
6. REMOVE TIMING CHAIN CASE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.
HINT:
Tape the screwdriver tip before use.
NOTICE:
After the removal, check the crankshaft for
damage. If it is damaged, smooth the surface
with 400-grit sandpaper.
SST
SST
A119083E01
SST
SST
A119085E01
Protective Tape
Cut Position
A132241E01

EM–10 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL
EM
INSTALLATION
1. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST and a hammer, tap in the oil seal until its
surface is flush with the timing chain cover edge.
SST 09316-60011 (09316-00011)
NOTICE:
• Keep the lip free of foreign matter.
• Do not tap the oil seal at an angle.
2. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the
pulley, and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 N*m (2,550 kgf*cm, 184 ft.*lbf)
3. INSTALL V-RIBBED BELT (See page EM-7)
4. INSTALL V-BANK COVER SUB-ASSEMBLY (See
page EM-52)
5. INSTALL FRONT FENDER APRON SEAL RH
6. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
Chain Cover
SST
A132242E01
SST
A119084E01

2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–11
EM
ENGINE2GR-FE ENGINE MECHANICAL
ENGINE REAR OIL SEAL
COMPONENTS
DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
ENGINE REAR OIL SEAL
FRONT SPACER
REAR SPACER
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
83 (850, 61)
x8
A134930E01

EM–12 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL
EM
REMOVAL
1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
HINT:
See page AX-207.
2. REMOVE DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
(b) Remove the 8 bolts, front spacer, drive plate and
rear spacer.
3. REMOVE ENGINE REAR OIL SEAL
(a) Using a knife, cut off the oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft. Tape
the screwdriver tip before use.
INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
(a) Apply MP grease to a new oil seal lip.
(b) Using SST and a hammer, tap in the oil seal.
SST 09223-15030, 09950-70010 (09951-07150)
Oil seal tap in depth:
-0.5 to 0.5 mm (-0.020 to 0.020 in.)
SST
A129631E01
A132243
Cut Position
Protective Tape
A132244E01
SST
SST
Retainer
-0.5 to 0.5 mm
A132245E01

2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–13
EM
2. INSTALL DRIVE PLATE AND RING GEAR SUB-
ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
(b) Apply adhesive to 2 or 3 threads of the mounting
bolt end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent
(1) Install the front spacer, drive plate and rear
spacer on the crankshaft.
(2) Install and tighten the 8 mounting bolts
uniformly in several steps.
Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf)
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
HINT:
See page AX-214.
SST
A129631E01
Adhesive
P000601E04
1
7
4
6
2
8
3
5
A132243E01

EM–14 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
ENGINE2GR-FE ENGINE MECHANICAL
ENGINE ASSEMBLY
COMPONENTS
FRONT WIPER ARM AND
BLADE ASSEMBLY RH
FRONT WIPER ARM AND
BLADE ASSEMBLY LH
COWL TOP VENTILATOR
LOUVER SUB-ASSEMBLY
COWL TOP PANEL OUTER SUB-ASSEMBLY
FRONT FENDER TO COWL
SIDE SEAL LH
FRONT FENDER TO COWL
SIDE SEAL RH
20 (204, 15)
7.5 (77, 66 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
5.0 (51, 44 in.*lbf)
85 (867, 63)
WINDSHIELD WIPER
LINK ASSEMBLY
A134938E01

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–15
EM
AIR CLEANER CAP SUB-ASSEMBLY
AIR CLEANER CASE
SUB-ASSEMBLY
AIR CLEANER INLET
ASSEMBLY
BATTERY
COOL AIR INTAKE DUCT SEAL
INTAKE AIR RESONATOR
SUB-ASSEMBLY
NO. 1 AIR CLEANER INLET
RELAY BLOCK
COVER UPPER
V-BANK COVER SUB-ASSEMBLY
5.0 (51, 44 in.*lbf)
5.0 (51, 44 in.*lbf)
5.0 (51, 44 in.*lbf)
5.0 (51, 44 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
3.5 (36, 31 in.*lbf)
9.0 (92, 80 in.*lbf)
AIR CLEANER
FILTER ELEMENT
ENGINE UNDER COVER RH
ENGINE UNDER COVER LH
BATTERY TRAY
A132994E01

EM–16 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
FRONT FENDER APRON SEAL RH
FUEL TUBE SUB-ASSEMBLY
RADIATOR HOSE INLET
RADIATOR HOSE
OUTLET
TRANSMISSION CONTROL
CABLE ASSEMBLY
COOLER COMPRESSOR ASSEMBLY
ENGINE MOVING CONTROL
ROD SUB-ASSEMBLY
NO. 2 ENGINE MOUNTING STAY RH
V-RIBBED BELT
HEATER INLET WATER HOSE
HEATER OUTLET WATER HOSE
NO. 1 OIL COOLER
INLET HOSE
NO. 1 OIL COOLER
OUTLET HOSE
CLIP
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
38 (388, 28)
23 (235, 17)
43 (438, 32)
43 (438, 32)
9.8 (100, 87 in.*lbf)
25 (250, 18)
25 (250, 18)
13 (130, 9)
NO. 1 OIL RESERVOIR
TO PUMP HOSE
NO. 1 FUEL PIPE CLAMP
NO. 1 FUEL VAPOR FEED HOSE
NO. 1 VACUUM SWITCHING
VALVE ASSEMBLY
10 (102, 7)
GENERATOR ASSEMBLY
RETURN TUBE
SUB-ASSEMBLY
A132995E01

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–17
EM
EXHAUST PIPE ASSEMBLY FRONT
FRONT STABILIZER LINK ASSEMBLY LH
TIE ROD ASSEMBLY LH
EXHAUST PIPE NO. 1
SUPPORT BRACKET
NO. 1 EXHAUST PIPE SUPPORT BRACKET
35 (360, 26)
74 (755, 55)
49 (500, 36)
COTTER PIN
8.0 (85, 71 in.*lbf)
75 (765, 55)
294 (3,000, 217)
GASKET
GASKET
GASKET
62 (632, 46)
62 (632, 46)
56 (571, 41)
33 (337, 24)
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
21 (214, 15)
FRONT AXLE HUB NUT LH
STEERING SLIDING YOKE
FRONT SUSPENSION
LOWER NO. 1 ARM LH
FRONT SPEED
SENSOR LH
A132996E01

EM–18 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY
EM
FRONT FRAME
ASSEMBLY
FUEL TUBE SUB-ASSEMBLY
STARTER ASSEMBLY
VANE PUMP ASSEMBLY
ENGINE WIRE
ENGINE ASSEMBLY
WITH TRANSAXLE
NO. 2 FUEL PIPE CLAMP
N*m (kgf*cm, ft.*lbf) : Specified torque
95 (969, 70)
95 (969, 70)
87 (887, 64)
37 (380, 26)
37 (380, 26)
32 (329, 24)
32 (329, 24)
32 (329, 24)
32 (329, 24)
32 (329, 24)
85 (867, 63)
85 (867, 63)
85 (867, 63)
85 (867, 63)
32 (329, 24)
FRAME SIDE RAIL PLATE LH
FRAME SIDE RAIL
PLATE RH
FRONT SUSPENSION
MEMBER BRACE
REAR RH
FRONT SUSPENSION
MEMBER BRACE REAR LH
9.8 (100, 87 in.*lbf)
7.8 (80, 69 in.*lbf)
43 (439, 32)
A134929E01

2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–19
EM
DRIVE PLATE AND TORQUE
CONVERTER CLUTCH
SETTING BOLT
DRIVE SHAFT BEARING BRACKET
ENGINE MOUNTING BRACKET RH
FRONT DRIVE SHAFT ASSEMBLY LH
FRONT DRIVE SHAFT
ASSEMBLY RH
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
7.8 (80, 69 in.*lbf)
64 (653, 47)
46 (469, 34)
43 (438, 32)
41 (413, 30)
64 (653, 47)
64 (650, 47)
54 (551, 40)
DRIVE SHAFT BEARING BRACKET HOLE SNAP RING
NO. 1 DRIVE SHAFT BEARING
BRACKET SETTING BOLT
FRONT DRIVE SHAFT INNER
LH SHAFT SNAP RING
AUTOMATIC TRANSAXLE
ASSEMBLY
ENGINE MOUNTING BRACKET FR
FLYWHEEL HOUSING
UNDER COVER
EXHAUST PIPE
SUPPORT BRACKET
32 (334, 30)
A134940E01