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Table of Contents
Intelligent Tester
CAN VIM
DLC3
2GR-FE ENGINE MECHANICAL – ENGINE
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
• If any dirt or a blockage remains even after
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
C110200E02
filter element, clean it with compressed air.
cleaning the air cleaner filter element with
compressed air, replace it.
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.
EM–1
EM

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Table of Contents

   Summary of Contents for Toyota 2GR-FE

  • Page 1 EM–1 2GR-FE ENGINE MECHANICAL – ENGINE ENGINE ON-VEHICLE INSPECTION INSPECT ENGINE COOLANT (a) Inspect the engine coolant (See page CO-1). INSPECT ENGINE OIL (a) Inspect the engine oil (See page LU-1). INSPECT BATTERY (a) Inspect the battery (See page CH-4).
  • Page 2 EM–2 2GR-FE ENGINE MECHANICAL – ENGINE (c) When not using the intelligent tester: Check the ignition timing. DLC3 (1) Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3. 09843-18040 NOTICE: 2 3 4 5 6 7 8 •...
  • Page 3 EM–3 2GR-FE ENGINE MECHANICAL – ENGINE • 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.
  • Page 4 EM–4 2GR-FE ENGINE MECHANICAL – ENGINE (h) Install the 6 ignition coils. Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 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.
  • Page 5: Drive Belt

    EM–5 2GR-FE ENGINE MECHANICAL – DRIVE BELT DRIVE BELT ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS V-BANK COVER SUB-ASSEMBLY FRONT FENDER APRON SEAL RH V-RIBBED BELT A134931E01...
  • Page 6 EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT REMOVAL REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) 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.
  • Page 7 EM–7 2GR-FE ENGINE MECHANICAL – DRIVE BELT INSPECTION REPLACE 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.
  • Page 8 EM–8 2GR-FE ENGINE MECHANICAL – DRIVE BELT INSTALL V-BANK COVER SUB-ASSEMBLY (See page EM-52) INSTALL FRONT FENDER APRON SEAL RH INSTALL FRONT WHEEL RH Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf)
  • Page 9 EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL ENGINE FRONT OIL SEAL ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS TIMING CHAIN CASE OIL SEAL 250 (2,550, 184) V-BANK COVER SUB-ASSEMBLY CRANKSHAFT PULLEY V-RIBBED BELT FRONT FENDER APRON SEAL RH N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 10 EM–9 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL REMOVAL REMOVE FRONT WHEEL RH REMOVE FRONT FENDER APRON SEAL RH REMOVE V-BANK COVER SUB-ASSEMBLY (See page EM-23) REMOVE V-RIBBED BELT (See page EM-6) REMOVE CRANKSHAFT PULLEY (a) Using SST, loosen the crankshaft pulley bolt.
  • Page 11 EM–10 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL INSTALLATION Chain Cover 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.
  • Page 12 EM–11 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL ENGINE REAR OIL SEAL ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS ENGINE REAR OIL SEAL FRONT SPACER 83 (850, 61) REAR SPACER DRIVE PLATE AND RING GEAR SUB-ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque...
  • Page 13 EM–12 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL REMOVAL REMOVE AUTOMATIC TRANSAXLE ASSEMBLY HINT: See page AX-207. REMOVE DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (a) Using SST, hold the crankshaft. 09213-70011 (09213-70020), 09330-00021 A129631E01 (b) Remove the 8 bolts, front spacer, drive plate and rear spacer.
  • Page 14 EM–13 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL INSTALL DRIVE PLATE AND RING GEAR SUB- ASSEMBLY (a) Using SST, hold the crankshaft. 09213-70011 (09213-70020), 09330-00021 A129631E01 (b) Apply adhesive to 2 or 3 threads of the mounting bolt end.
  • Page 15: Engine Assembly

    EM–14 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY ENGINE ASSEMBLY ENGINE 2GR-FE ENGINE MECHANICAL COMPONENTS FRONT WIPER ARM AND 20 (204, 15) BLADE ASSEMBLY RH FRONT FENDER TO COWL SIDE SEAL RH FRONT WIPER ARM AND COWL TOP VENTILATOR BLADE ASSEMBLY LH...
  • Page 16 EM–15 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY AIR CLEANER CAP SUB-ASSEMBLY V-BANK COVER SUB-ASSEMBLY AIR CLEANER FILTER ELEMENT COOL AIR INTAKE DUCT SEAL 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) AIR CLEANER INLET ASSEMBLY AIR CLEANER CASE RELAY BLOCK...
  • Page 17 EM–16 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 38 (388, 28) FRONT FENDER APRON SEAL RH V-RIBBED BELT 23 (235, 17) ENGINE MOVING CONTROL ROD SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) NO. 2 ENGINE MOUNTING STAY RH 43 (438, 32) NO. 1 FUEL VAPOR FEED HOSE...
  • Page 18 EM–17 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY STEERING SLIDING YOKE FRONT STABILIZER LINK ASSEMBLY LH 35 (360, 26) TIE ROD ASSEMBLY LH 74 (755, 55) 49 (500, 36) COTTER PIN FRONT SPEED SENSOR LH 8.0 (85, 71 in.*lbf) 294 (3,000, 217)
  • Page 19 EM–18 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 87 (887, 64) ENGINE ASSEMBLY ENGINE WIRE WITH TRANSAXLE 95 (969, 70) 95 (969, 70) VANE PUMP ASSEMBLY NO. 2 FUEL PIPE CLAMP FUEL TUBE SUB-ASSEMBLY STARTER ASSEMBLY 43 (439, 32) 37 (380, 26)
  • Page 20 EM–19 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 54 (551, 40) ENGINE MOUNTING BRACKET RH DRIVE SHAFT BEARING BRACKET HOLE SNAP RING FRONT DRIVE SHAFT DRIVE SHAFT BEARING BRACKET ASSEMBLY RH 64 (650, 47) 32 (334, 30) FRONT DRIVE SHAFT INNER NO.
  • Page 21 EM–20 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY UNION TO CHECK VALVE HOSE 21 (214, 15) 5.4 (55, 48 in.*lbf) VACUUM HOSE CLAMP 21 (214, 15) THROTTLE BODY BRACKET VENTILATION HOSE 21 (214, 15) NO. 1 SURGE TANK STAY 16 (163, 12) NO.
  • Page 22 EM–21 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 8.5 (87, 75 in.*lbf) EXHAUST MANIFOLD TO HEAD GASKET NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 21 (214, 15) EXHAUST MANIFOLD TO 8.5 (87, 75 in.*lbf) HEAD LH GASKET IGNITION COIL ASSEMBLY 10 (102, 7)
  • Page 23 EM–22 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY 21 (214, 15) INTAKE MANIFOLD NO. 2 ENGINE MOUNTING NO. 2 INTAKE MANIFOLD STAY RH TO HEAD GASKET 20 (200, 14) ENGINE COOLANT NO. 1 INTAKE MANIFOLD TEMPERATURE TO HEAD GASKET SENSOR RADIO SETTING...
  • Page 24 EM–23 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY REMOVAL DISCHARGE FUEL SYST