Toyota Engine 2gr Fe Repair Manual

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2GR-FE ENGINE MECHANICAL – ENGINE EM–1

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: EM
• 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:
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
CAN VIM HINT:
DLC3 Refer to the intelligent tester operator's manual
C110200E02 for help when selecting the DATA LIST.

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 EM–2 2GR-FE ENGINE MECHANICAL – ENGINE

(c) When not using the intelligent tester:

DLC3 Check the ignition timing.
(1) Using SST, connect terminals 13 (TC) and 4
CG (CG) of the DLC3.
SST 09843-18040
1 2 3 4 5 6 7 8 NOTICE:
• Confirm the terminal numbers before
9 1011 1213 141516 connecting them. Connection with a
wrong terminal can damage the engine.
TC
A122830E14 • 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.
Red Lead
Wire
(4) Connect the tester terminal of the timing light to
the red lead wire as shown in the illustration.
NOTICE:
EM Use a timing light which can detect the first
signal.
Tester Terminal (5) Check the ignition timing at idle.
Ignition timing:
8 to 12° BTDC at idle
A129620E01 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:
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
CAN VIM NOTICE:
DLC3 • When checking the idle speed, the
C110200E02 transmission should be in neutral.
• Check the idle speed with the cooling fan
off.
 2GR-FE ENGINE MECHANICAL – ENGINE EM–3

• 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.
DLC3 (1) Using SST, connect the tachometer test probe
to terminal 9 (TAC) of the DLC3.
SST 09843-18030
1 2 3 4 5 6 7 8 (2) Check the idle speed.
Idle speed:
TAC 9 1011 1213 141516 600 to 700 rpm
9. INSPECT COMPRESSION
A122830E15
(a) Warm up and stop the engine.
(b) Disconnect the injector connectors.
(c) Remove the intake air surge tank (See page FU-
13).
EM
(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)
A129621
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)
 EM–4 2GR-FE ENGINE MECHANICAL – ENGINE

(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
EM 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
1. Faulty ignitions:
– Incorrect timing
– Fouled, shorted or improperly gapped plugs
Normal High Rough idle
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
1. Vacuum leaks:
– PCV hoses
Rough idle – Intake manifold
Low High
(fluctuating HC reading) – Throttle body
– Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
– Faulty fuel pressure regulator
Rough idle
High High – Defective ECT sensor
(black smoke from exhaust)
– Defective MAF meter
– Faulty ECM
– Faulty injectors
– Faulty throttle position sensor
 2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–5

DRIVE BELT
2GR-FE ENGINE MECHANICAL
ENGINE

COMPONENTS

V-BANK COVER SUB-ASSEMBLY

FRONT FENDER APRON SEAL RH EM

V-RIBBED BELT

A134931E01
 EM–6 2GR-FE ENGINE MECHANICAL – DRIVE BELT

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

SST

EM
A129622E01

(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.

A095070
 2GR-FE ENGINE MECHANICAL – DRIVE BELT EM–7

INSPECTION
REPLACE
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.
CORRECT INCORRECT
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
(a) Check that nothing gets caught in the tensioner by
turning it clockwise and counterclockwise.
EM
A131418E01 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

SST

A129622E01

(c) If it is difficult to install the V-ribbed belt, perform the

following procedure:
Generator (1) Put the V-ribbed belt on every pulley except the
Idler tensioner pulley as shown in the illustration.
Water Pump (2) While releasing the belt tension by turning the
belt tensioner counterclockwise, put the V-
Tensioner
ribbed belt on the tensioner pulley.
NOTICE:
• Put the backside of the V-ribbed belt on
Idler the tensioner pulley and idler pulley.
• Check that the V-ribbed belt is properly
A/C Compressor set to each pulley.
Vane Pump
(3) After installing the V-ribbed belt, check that it
Crankshaft
fits properly in the ribbed grooves. Confirm that
the belt has not slipped out of the grooves on
A129623E01
the bottom of the crank pulley by hand.
 EM–8 2GR-FE ENGINE MECHANICAL – DRIVE BELT

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
 EM–8 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL

ENGINE FRONT OIL SEAL

2GR-FE ENGINE MECHANICAL
ENGINE

COMPONENTS

250 (2,550, 184) TIMING CHAIN CASE OIL SEAL

EM V-BANK COVER SUB-ASSEMBLY

CRANKSHAFT PULLEY

V-RIBBED BELT

FRONT FENDER APRON

SEAL RH

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part
A134932E01
 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL EM–9

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 SST 09213-70011 (09213-70020), 09330-00021

SST
EM

A119083E01

(b) Using SST, remove the crankshaft pulley bolt and

crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010,
SST
09953-05020, 09954-05021)

SST

A119085E01

6. REMOVE TIMING CHAIN CASE OIL SEAL

(a) Using a screwdriver, pry out the oil seal.
Cut Position Protective Tape 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.

A132241E01
 EM–10 2GR-FE ENGINE MECHANICAL – ENGINE FRONT OIL SEAL

Chain Cover
INSTALLATION
1. INSTALL TIMING CHAIN CASE OIL SEAL
(a) Apply MP grease to a new oil seal lip.
SST (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.
A132242E01
• 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)
EM 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)

SST
A119084E01
 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–11

ENGINE REAR OIL SEAL

2GR-FE ENGINE MECHANICAL
ENGINE

COMPONENTS

EM
ENGINE REAR OIL SEAL

FRONT SPACER 83 (850, 61)

x8
REAR SPACER
DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

Non-reusable part

A134930E01
 EM–12 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL

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

SST

A129631E01

(b) Remove the 8 bolts, front spacer, drive plate and

rear spacer.
EM

A132243

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.
Cut Position
NOTICE:
Be careful not to damage the crankshaft. Tape
the screwdriver tip before use.

Protective Tape
A132244E01

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:
SST
-0.5 to 0.5 mm (-0.020 to 0.020 in.)

-0.5 to 0.5 mm
Retainer
SST

A132245E01
 2GR-FE ENGINE MECHANICAL – ENGINE REAR OIL SEAL EM–13

2. INSTALL DRIVE PLATE AND RING GEAR SUB-

ASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021

SST

A129631E01

(b) Apply adhesive to 2 or 3 threads of the mounting

bolt end.
Adhesive Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent

EM
P000601E04

(1) Install the front spacer, drive plate and rear

1
spacer on the crankshaft.
5 (2) Install and tighten the 8 mounting bolts
7 uniformly in several steps.
4 Torque: 83 N*m (850 kgf*cm, 61 ft.*lbf)
3
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
8 6 HINT:
2 See page AX-214.
A132243E01
 EM–14 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY

ENGINE ASSEMBLY
2GR-FE ENGINE MECHANICAL
ENGINE

COMPONENTS

FRONT WIPER ARM AND 20 (204, 15)

BLADE ASSEMBLY RH

FRONT FENDER TO COWL

SIDE SEAL RH

COWL TOP VENTILATOR FRONT WIPER ARM AND

LOUVER SUB-ASSEMBLY BLADE ASSEMBLY LH

EM 85 (867, 63)
7.5 (77, 66 in.*lbf)
5.0 (51, 44 in.*lbf)
FRONT FENDER TO COWL
SIDE SEAL LH

WINDSHIELD WIPER
LINK ASSEMBLY

COWL TOP PANEL OUTER SUB-ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque

A134938E01
 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–15

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
EM
RELAY BLOCK AIR CLEANER CASE
COVER UPPER SUB-ASSEMBLY

5.0 (51, 44 in.*lbf)

NO. 1 AIR CLEANER INLET

3.5 (36, 31 in.*lbf)

9.0 (92, 80 in.*lbf)

ENGINE UNDER COVER RH

5.0 (51, 44 in.*lbf)
BATTERY

BATTERY TRAY

INTAKE AIR RESONATOR

SUB-ASSEMBLY

ENGINE UNDER COVER LH

N*m (kgf*cm, ft.*lbf) : Specified torque
A132994E01
 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)

GENERATOR ASSEMBLY NO. 1 FUEL VAPOR FEED HOSE

10 (102, 7)

EM NO. 1 OIL RESERVOIR NO. 1 VACUUM SWITCHING

VALVE ASSEMBLY
TO PUMP HOSE

FUEL TUBE SUB-ASSEMBLY

43 (438, 32)
RADIATOR HOSE INLET HEATER INLET WATER HOSE

RADIATOR HOSE
OUTLET

RETURN TUBE
SUB-ASSEMBLY

NO. 1 OIL COOLER NO. 1 FUEL PIPE CLAMP

INLET HOSE

25 (250, 18)
HEATER OUTLET WATER HOSE
NO. 1 OIL COOLER
OUTLET HOSE
CLIP
13 (130, 9)

25 (250, 18)
TRANSMISSION CONTROL
COOLER COMPRESSOR ASSEMBLY CABLE ASSEMBLY

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

A132995E01
 2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–17

STEERING SLIDING YOKE

FRONT STABILIZER LINK ASSEMBLY LH

35 (360, 26)

TIE ROD ASSEMBLY LH

EM
74 (755, 55)

49 (500, 36)

COTTER PIN

FRONT SPEED
SENSOR LH

8.0 (85, 71 in.*lbf)

FRONT SUSPENSION 294 (3,000, 217)

LOWER NO. 1 ARM LH FRONT AXLE HUB NUT LH
GASKET

75 (765, 55) 62 (632, 46) GASKET

GASKET

56 (571, 41)

62 (632, 46)
EXHAUST PIPE ASSEMBLY FRONT
NO. 1 EXHAUST PIPE SUPPORT BRACKET

21 (214, 15)
33 (337, 24)

EXHAUST PIPE NO. 1

SUPPORT BRACKET

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

A132996E01
 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

EM NO. 2 FUEL PIPE CLAMP

FUEL TUBE SUB-ASSEMBLY

STARTER ASSEMBLY
43 (439, 32)
37 (380, 26)

FRONT FRAME 37 (380, 26)

ASSEMBLY 9.8 (100, 87 in.*lbf)

7.8 (80, 69 in.*lbf)

FRONT SUSPENSION
MEMBER BRACE
REAR RH
FRAME SIDE RAIL
32 (329, 24) PLATE RH

85 (867, 63)

32 (329, 24)
85 (867, 63)

FRAME SIDE RAIL PLATE LH 32 (329, 24)

85 (867, 63)
32 (329, 24)
32 (329, 24)
85 (867, 63) FRONT SUSPENSION
N*m (kgf*cm, ft.*lbf) : Specified torque MEMBER BRACE REAR LH
32 (329, 24)
A134929E01
Toyota Engine 2gr Fe Repair Manual
Full download: http://manualplace.com/download/toyota-engine-2gr-fe-repair-manual/
2GR-FE ENGINE MECHANICAL – ENGINE ASSEMBLY EM–19

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)

EM
32 (334, 30)
FRONT DRIVE SHAFT INNER
NO. 1 DRIVE SHAFT BEARING LH SHAFT SNAP RING
BRACKET SETTING BOLT

46 (469, 34)

FRONT DRIVE SHAFT ASSEMBLY LH

7.8 (80, 69 in.*lbf)

FLYWHEEL HOUSING
UNDER COVER

64 (653, 47)

43 (438, 32)

64 (653, 47)
EXHAUST PIPE
SUPPORT BRACKET

41 (413, 30)
AUTOMATIC TRANSAXLE
DRIVE PLATE AND TORQUE ASSEMBLY
CONVERTER CLUTCH
SETTING BOLT ENGINE MOUNTING BRACKET FR

N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part

A134940E01

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