2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION; 2016 MY Sienna [12/2015 - 08/2016]

Last Modified: 04-05-2023	6.11:8.1.0	Doc ID: RM100000000VIDJ
Model Year Start: 2016	Model: Sienna	Prod Date Range: [12/2015 - 08/2016]
Title: 2GR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION; 2016 MY Sienna [12/2015 - 08/2016]

INSTALLATION

PROCEDURE

1. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

2. INSTALL REAR ENGINE MOUNTING BRACKET (for 2WD)

(a) Install the rear engine mounting bracket with the 3 bolts.

Torque:

64 N·m {653 kgf·cm, 47 ft·lbf}

3. INSTALL REAR ENGINE MOUNTING BRACKET (for AWD)

(a) Install the rear engine mounting bracket with the 3 bolts.

Torque:

64 N·m {653 kgf·cm, 47 ft·lbf}

4. INSTALL ENGINE MOUNTING BRACKET RH

(a) 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 (for 2WD)

6. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)

7. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)

(a) Install the transfer stiffener plate RH with the 4 bolts.

Torque:

Bolt A :

34 N·m {347 kgf·cm, 25 ft·lbf}

Bolt B :

78 N·m {796 kgf·cm, 58 ft·lbf}

8. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the bolt and nut.

Torque:

Bolt :

34 N·m {347 kgf·cm, 25 ft·lbf}

Nut :

35 N·m {357 kgf·cm, 26 ft·lbf}

9. INSTALL FLEXIBLE HOSE BRACKET SUB-ASSEMBLY

(a) Install the flexible hose bracket sub-assembly with the bolt.

Torque:

5.5 N·m {56 kgf·cm, 49 in·lbf}

(b) Install the sensor wire and the breather plug hose to the flexible hose bracket sub-assembly.

10. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for AWD)

11. INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY (for AWD)

(a) Install the rear engine mounting insulator assembly with the 2 bolts.

Torque:

75 N·m {765 kgf·cm, 55 ft·lbf}

12. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the nut.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

13. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Install the engine mounting insulator LH with the nut.

Torque:

95 N·m {969 kgf·cm, 70 ft·lbf}

14. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator with the bolt.

Torque:

87 N·m {887 kgf·cm, 64 ft·lbf}

(b) Connect the connector

15. INSTALL STEERING GEAR ASSEMBLY (for AWD)

16. INSTALL FRONT STABILIZER BAR (for AWD)

17. INSTALL NO. 1 FRONT STABILIZER BRACKET LH (for AWD)

18. INSTALL NO. 1 FRONT STABILIZER BRACKET RH (for AWD)

HINT:

Perform the same procedure as for the LH side.

19. INSTALL ENGINE WIRE

(a) Install the engine wire to the engine with transaxle.

20. INSTALL STARTER ASSEMBLY

21. INSTALL COOLER COMPRESSOR ASSEMBLY

22. INSTALL GENERATOR ASSEMBLY

23. INSTALL FAN AND GENERATOR V BELT

24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle on the engine lifter.

NOTICE:

Install a height adjustment attachment and plate lift attachment onto the engine assembly with transaxle.
Do not position a height adjustment attachment or plate lift attachment onto the front frame assembly.

HINT:

Place the engine on wooden blocks or equivalents so that the engine is level.

(b) Remove the 4 bolts and 2 engine hangers.

(c) Install the engine assembly with transaxle to the vehicle.

NOTICE:

Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

HINT:

Make sure that the engine is clear of all wiring and hoses.
While raising the engine into the vehicle, do not allow it to contact the vehicle.

(d) Install the frame side rail plates RH and LH with the 6 bolts and 2 nuts.

Text in Illustration

*1

Nut

Torque:

Nut :

32 N·m {327 kgf·cm, 24 ft·lbf}

Bolt A :

32 N·m {327 kgf·cm, 24 ft·lbf}

Bolt B :

85 N·m {867 kgf·cm, 63 ft·lbf}

(e) Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.

Torque:

Nut :

32 N·m {327 kgf·cm, 24 ft·lbf}

Bolt A :

32 N·m {327 kgf·cm, 24 ft·lbf}

Bolt B :

85 N·m {867 kgf·cm, 63 ft·lbf}

25. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

(a) Using SST, hold the crankshaft pulley.

SST: 09213-70011

09213-70020

SST: 09330-00021

(b) Apply a few drops of adhesive to 2 or 3 threads of the 6 drive plate and torque converter clutch setting bolt tips.

Text in Illustration

*a	Adhesive 1324

Adhesive:

Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent.

(c) Tighten the 6 drive plate and torque converter clutch setting bolts.

Torque:

41 N·m {418 kgf·cm, 30 ft·lbf}

NOTICE:

Install the black colored bolt first, and then the silver colored 5 bolts.

26. INSTALL FLYWHEEL HOUSING UNDER COVER

(a) Install the flywheel housing under cover with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)

29. INSTALL FRONT LOWER SUSPENSION ARM LH

30. INSTALL FRONT LOWER SUSPENSION ARM RH

HINT:

Perform the same procedure as for the LH side.

31. CONNECT TIE ROD ASSEMBLY LH

32. CONNECT TIE ROD ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

33. CONNECT FRONT SPEED SENSOR LH

34. CONNECT FRONT SPEED SENSOR RH

HINT:

Perform the same procedure as for the LH side.

35. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

36. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

HINT:

Perform the same procedure as for the LH side.

37. INSTALL FRONT AXLE SHAFT NUT LH

38. INSTALL FRONT AXLE SHAFT NUT RH

HINT:

Perform the same procedure as for the LH side.

39. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

40. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

(a) Install the No. 1 exhaust pipe support bracket to the oil pan sub-assembly with 2 new nuts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

41. INSTALL FRONT EXHAUST PIPE ASSEMBLY

42. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for AWD)

43. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

(See page )

44. CONNECT SUCTION HOSE SUB-ASSEMBLY

45. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

46. INSTALL ENGINE MOVING CONTROL ROD

HINT:

Perform this procedure only when replacement of the engine moving control rod is necessary.

(a) Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.

47. INSTALL ENGINE MOVING CONTROL ROD BRACKET

(a) When replacing the engine moving control rod:

HINT:

Perform this procedure only when replacement of the engine moving control rod is necessary.

(1) Temporarily install the engine mounting control rod bracket together engine control rod to the front No. 1 engine mounting bracket LH and vehicle with the 3 bolts.

(2) Tighten the bolts except A.

Torque:

38 N·m {387 kgf·cm, 28 ft·lbf}

(3) Tighten the bolt A.

Torque:

52 N·m {530 kgf·cm, 38 ft·lbf}

(b) When not replacing the engine moving control rod:

(1) Install the engine mounting control rod bracket together engine control rod to the front No. 1 engine mounting bracket LH and vehicle with the 3 bolts.

Torque:

38 N·m {387 kgf·cm, 28 ft·lbf}

48. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH to the front No. 1 engine mounting bracket LH with the bolt and 2 nuts.

Torque:

Bolt :

38 N·m {387 kgf·cm, 28 ft·lbf}

Nut :

23 N·m {235 kgf·cm, 17 ft·lbf}

(b) Install the No. 2 ground wire to the cylinder head cover sub-assembly with the 2 bolts.

Torque:

8.4 N·m {86 kgf·cm, 74 in·lbf}

49. CONNECT UNION TO CHECK VALVE HOSE

(a) Connect the union to check valve hose.

50. CONNECT NO. 1 INLET OIL COOLER HOSE

(a) Connect the No. 1 inlet oil cooler hose.

51. CONNECT NO. 1 OUTLET OIL COOLER HOSE

(a) Connect the No. 1 outlet oil cooler hose.

52. CONNECT FUEL MAIN TUBE

(a) Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

NOTICE:

Check that there is no damage or foreign objects on the fuel tube connector.
After connecting, check that the fuel tube connector and the pipe are securely connected by pulling on them.

(b) Install the No. 1 EFI fuel pipe clamp.

HINT:

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

53. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose.

54. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose.

55. CONNECT NO. 1 RADIATOR HOSE

(a) Install the No. 1 radiator hose to the radiator pipe clamp.

(b) Connect the No. 1 radiator hose.

56. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose.

57. CONNECT NO. 1 FUEL VAPOR FEED HOSE

(a) Connect the No. 1 fuel vapor feed hose.

58. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

(a) Install a new clip to the control cable bracket.

(b) Install the control cable to the control cable bracket.

Text in Illustration

*a	Claw (A)
*b	Claw (B)
*c	Control Cable

NOTICE:

Make sure that the claws (A) on the clip are securely fit into the bracket holes.
Make sure that the cable is securely installed inside of the claws (B) of the clip.

(c) Connect the transmission control cable to the control shaft lever with the nut.

Torque:

13 N·m {130 kgf·cm, 9 ft·lbf}

NOTICE:

Before connecting the transmission control cable assembly, check that the park/neutral position switch and the shift lever are in N.

59. CONNECT ENGINE WIRE

(a) Connect the connector to the ECM with the lock lever.

(b) Connect the engine wire to the engine room junction block.

(c) Install the engine wire with the nut and 3 connectors.

Torque:

8.4 N·m {86 kgf·cm, 74 in·lbf}

(d) Install the ground wire with the 2 bolts.

Torque:

8.4 N·m {86 kgf·cm, 74 in·lbf}

(e) Install the engine room relay block cover.

60. INSTALL AIR CLEANER AND HOSE

61. INSTALL BATTERY

(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.

Torque:

5.5 N·m {56 kgf·cm, 49 in·lbf}

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

Torque:

5.4 N·m {55 kgf·cm, 48 in·lbf}

62. INSTALL AIR CLEANER INLET COVER ASSEMBLY SEAL

(a) Install the air cleaner inlet cover assembly seal with the 2 bolts.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

(b) Connect the 2 vacuum hose clamps to the air cleaner inlet cover assembly seal.

63. INSPECT VACUUM HOSES

(a) Check that the vacuum hoses are properly connected.

64. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

65. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

66. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

67. INSTALL FRONT FENDER TO COWL SIDE SEAL LH

68. INSTALL FRONT FENDER TO COWL SIDE SEAL RH

69. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH

70. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH

71. INSTALL FRONT WIPER ARM HEAD CAP

72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

NOTICE:

When disconnecting the cable, some systems need to be initialized after the cable is reconnected (See page ).

73. INSTALL FRONT WHEEL

Torque:

103 N·m {1050 kgf·cm, 76 ft·lbf}

74. ADD ENGINE OIL

75. ADD ENGINE COOLANT

76. ADD TRANSFER OIL (for AWD)

77. INSPECT TRANSFER OIL (for AWD)

78. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD)

(See page )

79. ADD AUTOMATIC TRANSAXLE FLUID (for AWD)

(See page )

80. WARM UP ENGINE

81. INSPECT ENGINE OIL LEVEL

82. INSPECT ENGINE COOLANT LEVEL

83. CHARGE WITH REFRIGERANT

84. INSPECT FOR FUEL LEAK

85. INSPECT FOR COOLANT LEAK

86. INSPECT FOR OIL LEAK

87. INSPECT FOR EXHAUST GAS LEAK

88. INSPECT IGNITION TIMING

89. INSPECT ENGINE IDLE SPEED

90. INSPECT CO/HC

91. CHECK FOR SPEED SENSOR SIGNAL

(See page )

92. INSPECT SHIFT LEVER POSITION (for 2WD)

93. INSPECT SHIFT LEVER POSITION (for AWD)

94. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

(See page )

95. INSTALL V-BANK COVER SUB-ASSEMBLY

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

96. INSTALL FRONT FENDER APRON SEAL LH

(a) Install the front fender apron seal LH with the bolt and 2 clips.

97. INSTALL FRONT FENDER APRON SEAL RH

(a) Install the front fender apron seal RH with the 2 bolts and clip.

98. INSTALL NO. 2 ENGINE UNDER COVER (for AWD)

99. INSTALL NO. 1 ENGINE UNDER COVER

100. INSTALL INSTRUMENT PANEL FINISH PANEL END LH