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Home >> Toyota >> 2017 >> Avalon XLE Plus >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2GR-FE) (Service Information) (Except Hybrid) >> Engine Assembly & Engine Under Cover >> Installation [10/2014 - ] >> Procedure

Installation [10/2014 - ]: Procedure

  1. REMOVE ENGINE FROM ENGINE STAND 
  2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY 

    See step  2

  3. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

  4. INSTALL ENGINE MOUNTING BRACKET RH 
    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY 

    Refer to PROCEDURE - Step 6

  6. INSTALL ENGINE WIRE 
    1. Install the engine wire to the engine assembly with transaxle.
  7. INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY 
    1. Temporarily install the front engine mounting insulator assembly with the 3 nuts.

      HINT: 

      Perform this procedure only when replacement of the front engine mounting insulator assembly is necessary.

  8. INSTALL ENGINE MOUNTING INSULATOR LH 
    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

  9. INSTALL ENGINE MOUNTING INSULATOR RH 
    1. Temporarily install the engine mounting insulator RH with the 3 nuts.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulator RH is necessary.

  10. INSTALL FRONT FRAME ASSEMBLY 
    1. Install the engine mounting insulator RH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

    2. Install the engine mounting insulator LH with the nut.

      Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

    3. Install the front engine mounting insulator assembly with the bolt.

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

    4. Connect the 2 wire clamps and vacuum switching valve connector.
    5. Connect the 2 wire clamps.
    6. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators to the specified torque.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulators is necessary.

      GTY580904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Front Engine Mounting Insulator Assembly *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -

      A 

      Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

      B 

      Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

    7. Install the 4 hole plugs to the front frame assembly.

      HINT: 

      Perform this procedure only when replacement of the engine mounting insulators is necessary.

      GTY370206Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Mounting Insulator RH *2 Engine Mounting Insulator LH
  11. INSTALL TRANSMISSION OIL COOLER 

    Refer to PROCEDURE - Step 1

  12. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 

    Refer to PROCEDURE - Step 2

  13. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  14. INSTALL V-RIBBED BELT 

    See step  1

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE 
    1. Set the engine assembly with transaxle on the engine lifter.
      NOTE:
      • Place the height adjustment and plate lift attachments under the engine assembly with transaxle.
      • Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.
      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
      • To prevent the oil pan from deforming, do not place any attachments under the oil pan of the engine assembly with transaxle.
      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.
    2. Remove the engine hangers See step  1.
    3. Install the engine assembly with transaxle to the vehicle.
      NOTE:
      • Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.
      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.
    4. Install the frame side rail plate RH and frame side rail plate LH with the 4 bolts and 2 nuts.
      GTY548842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      A 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      B 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

    5. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 4 bolts and 2 nuts.

      C 

      Torque: 85 N*m (867 kgf*cm, 63 ft.*lbf) 

      D 

      Torque: 32 N*m (329 kgf*cm, 24 ft.*lbf) 

      HINT: 

      Perform "Inspection After Repair" after replacing the engine assembly (Refer to INITIALIZATION [10/2014 - ] .

  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT 

    Refer to PROCEDURE - Step 12

  17. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY 
    1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

      Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

  18. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) 
    1. Install the No. 1 exhaust pipe support bracket (for Front Side) with the bolt.

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH 

    Refer to PROCEDURE - Step 12

  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH 

    Refer to PROCEDURE - Step 1

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH 

    Refer to PROCEDURE - Step 2

  22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 8

  23. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  24. CONNECT TIE ROD ASSEMBLY LH 

    Refer to PROCEDURE - Step 9

  25. CONNECT TIE ROD ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  26. INSTALL FRONT SPEED SENSOR LH 

    Refer to PROCEDURE - Step 19

  27. INSTALL FRONT SPEED SENSOR RH 

    HINT: 

    Perform the same procedure as for the LH side.

  28. INSTALL FRONT STABILIZER LINK ASSEMBLY LH 

    Refer to PROCEDURE - Step 9 or PROCEDURE - Step 13

  29. INSTALL FRONT STABILIZER LINK ASSEMBLY RH 

    HINT: 

    Perform the same procedure as for the LH side.

  30. INSTALL FRONT AXLE SHAFT NUT LH 

    Refer to PROCEDURE - Step 7

  31. INSTALL FRONT AXLE SHAFT NUT RH 

    HINT: 

    Perform the same procedure as for the LH side.

  32. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY 

    Refer to PROCEDURE - Step 11

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) 

    Refer to PROCEDURE - Step 8

  34. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Front Side) 

    Refer to PROCEDURE - Step 4

  35. CONNECT SUCTION HOSE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  36. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE 

    Refer to PROCEDURE - Step 4

  37. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Push the fuel tube connector onto the fuel main tube until the fuel tube connector makes a "click" sound.
      GTY295311Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Check that there is no damage or foreign matter on the fuel tube connector.
      • After connecting, check that the fuel tube connector and the fuel main tube are securely connected by pulling on them.
    2. Install the fuel pipe clamp.
      GTY318519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel main tube is not securely connected.

  38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  39. INSTALL AIR CLEANER BRACKET 
    1. Install the air cleaner bracket to the battery carrier with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the 2 wire clamps.
  40. CONNECT ENGINE WIRE 
    1. Connect the 2 wire clamps.
      GTY382797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the connector to the ECM with the lock lever.
    3. Connect the engine wire to the engine room relay block.
    4. Connect the 4 connectors.
    5. Connect the engine wire to the engine room relay block.
      GTY371123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Connect the 2 wire clamps and install the 2 nuts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    7. Install the No. 1 relay block cover.
  41. INSTALL STARTER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  42. CONNECT WATER HOSE SUB-ASSEMBLY 
    1. Connect the water hose sub-assembly to the engine assembly and slide the clip to secure it.
  43. CONNECT INLET HEATER WATER HOSE 
    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.
  44. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. Connect the No. 3 water by-pass hose to the transmission oil cooler and slide the clip to secure it.
  45. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
  46. CONNECT NO. 1 RADIATOR HOSE 
    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.
    2. Install the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.
  47. CONNECT UNION TO CHECK VALVE HOSE 
    1. Connect the union to check valve hose to the brake booster and slide the clip to secure it.
  48. CONNECT NO. 1 FUEL VAPOR FEED HOSE 
    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve and slide the clip to secure it.
  49. CONNECT EARTH WIRE 
    1. Install the earth wire to the engine assembly with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

  50. INSTALL NO. 3 ENGINE MOUNTING STAY RH 

    HINT: 

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.

    1. Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.
      GTY364042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket
    2. Tighten the bolt (A).

      Torque: 78 N*m (795 kgf*cm, 58 ft.*lbf) 

  51. INSTALL ENGINE MOVING CONTROL ROD 
    1. When replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY592531Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

      2. Tighten the bolt (E).

        Torque: 52 N*m (530 kgf*cm, 38 ft.*lbf) 

    2. When not replacing the engine moving control rod or No. 3 engine mounting stay RH.
      GTY571535Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

        NOTE:

        Temporarily tighten the bolt (A) and (B), and then fully tighten the 4 bolts in the order of (C), (D), (A) and (B).

  52. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH with the bolt.

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

    2. Tighten the 2 nuts.

      Torque: 23 N*m (235 kgf*cm, 17 ft.*lbf) 

  53. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY 
    1. Install the intake air resonator sub-assembly to the battery carrier with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the 2 vacuum hoses and engage the claw to the intake air resonator sub-assembly.
  54. INSTALL INLET NO. 1 AIR CLEANER 
    1. Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.
      GTY362896Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Engage the pin to the radiator support.
  55. INSTALL BATTERY 
    1. Install the battery and battery tray.
    2. Install the battery clamp with the bolt and nut.

      Bolt 

      Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf) 

      Nut 

      Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf) 

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

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

  56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY 
    1. Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.
      GTY546066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.
      TEXT IN ILLUSTRATION

      *1 Air Cleaner Case Sub-assembly
      *2 Inlet No. 1 Air Cleaner
      *a Projection
      *b Hole of No. 2 Air Cleaner Bracket
    3. Tighten the 2 bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

    4. Connect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose to the air cleaner case sub-assembly.
  57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY 
    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
      NOTE:

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  58. INSTALL AIR CLEANER CAP SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 3

  59. INSTALL INLET NO. 2 AIR CLEANER 
    1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    2. Connect the 2 wire harness clamps and vacuum hose clamp to the No. 2 air cleaner.
  60. INSPECT VACUUM HOSES 
    1. Inspect the vacuum hoses.
      GTY377256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
    1. Connect the negative (-) cable to the negative (-) battery terminal.

      Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

  62. INSTALL FRONT WHEELS 

    Torque: 103 N*m (1049 kgf*cm, 76 ft.*lbf) 

  63. ADD ENGINE OIL 

    Refer to PROCEDURE - Step 4

  64. ADD ENGINE COOLANT 

    Refer to PROCEDURE - Step 2

  65. ADD AUTOMATIC TRANSAXLE FLUID 

    (Refer to ADJUSTMENT [10/2014 - ] )

  66. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT 

    Refer to PROCEDURE - Step 2

  67. WARM UP ENGINE 

    Refer to PROCEDURE - Step 3

  68. INSPECT FOR REFRIGERANT LEAK 

    Refer to PROCEDURE - Step 4

  69. INSPECT ENGINE OIL LEVEL 

    Refer to PROCEDURE - Step 1

  70. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR 

    Refer to PROCEDURE - Step 2

  71. INSPECT FOR FUEL LEAK 

    Refer to PROCEDURE - Step 1

  72. INSPECT FOR COOLANT LEAK 

    Refer to PROCEDURE - Step 1

  73. INSPECT FOR OIL LEAK 
  74. INSPECT FOR EXHAUST GAS LEAK 
  75. INSPECT IGNITION TIMING 

    See step  9

  76. INSPECT ENGINE IDLE SPEED 

    See step  10

  77. INSPECT CO/HC 

    See step  12

  78. CHECK FOR SPEED SENSOR SIGNAL 

    (Refer to TEST MODE PROCEDURE [10/2014 - 10/2015] or TEST MODE PROCEDURE [10/2015 - ] )

  79. INSPECT SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 1

  80. ADJUST SHIFT LEVER POSITION 

    Refer to PROCEDURE - Step 2

  81. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT 

    (Refer to ADJUSTMENT [10/2014 - 10/2015] or ADJUSTMENT [10/2015 - ] )

  82. INSTALL V-BANK COVER SUB-ASSEMBLY 
    1. Fit the 3 retainers and install the V-bank cover sub-assembly.
  83. INSTALL COOL AIR INTAKE DUCT SEAL 

    Refer to PROCEDURE - Step 3 or PROCEDURE - Step 3

  84. INSTALL FRONT FENDER APRON SEAL LH 
    1. Install the front fender apron seal LH with the 2 screws and clip.
  85. INSTALL ENGINE UNDER COVER LH 
    1. Install the engine under cover LH with the 2 screws and 2 clips.
  86. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH 
    1. Install the front wheel opening extension pad LH with the 3 screws and clip.
  87. INSTALL FRONT FENDER APRON SEAL RH 
    1. Install the front fender apron seal RH with the 2 screws and clip.
  88. INSTALL ENGINE UNDER COVER RH 
    1. Install the engine under cover RH with the 2 screws and 3 clips.
  89. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH 
    1. Install the front wheel opening extension pad RH with the 3 screws and clip.
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