ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL NOISE FILTER


    1. RH:

      Install the noise filter to the cylinder head cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. LH:

      Install the noise filter to the cylinder head cover with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  2. INSTALL IGNITION COIL ASSEMBLY


    1. A01WVPE

      Install the 8 ignition coils with the 8 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

    A01WU2H

    1. Install the mounting bracket with the 4 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  4. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

    A01WQ7O

    1. Install the mounting bracket with the 4 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  5. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

    A01WRTNE28
    *1 Adhesive

    1. Apply adhesive to 2 or 3 threads of the drain cocks.

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01WUB4E01
      *1 Front

      Install the water drain cocks as shown in the illustration.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note


      • Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.

      • Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.

    3. Install the water drain cock plugs to the water drain cocks.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

  6. INSTALL KNOCK SENSOR


    1. A01WPR9E17

      Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      Note

      The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position.

  7. INSTALL SEPARATOR CASE


    1. A01WSN3E05

      After inserting the pipe on the rear of the separator case into the oil return pipe and the pipe on the front into the ventilation pipe, temporarily install bolt A.

    2. Temporarily install bolt B and tighten bolt A.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Install the bolts labeled C.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Tighten bolt B.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Standard Bolt
      Item Length Thread Diameter
      Bolt A 25 mm (0.984 in.) 6 mm (0.236 in.)
      Bolt B and C 16 mm (0.630 in.) 6 mm (0.236 in.)

  8. INSTALL SENSOR WIRE

    A01WUPX

    1. Connect the 3 clamps and 4 knock sensor connectors.

  9. INSTALL NO. 3 AIR TUBE (w/ Secondary Air Injection System)

    Click here

  10. INSTALL NO. 2 AIR TUBE (w/ Secondary Air Injection System)

    Click here

  11. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)

    Click here

  12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01WQNH

      Install the water by-pass pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  13. INSTALL WATER INLET HOUSING

    Click here

  14. INSTALL AIR PIPE SUB-ASSEMBLY (w/ Secondary Air Injection System)


    1. A01WUPS

      Install the 2 No. 1 air hoses and air pipe with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL FRONT WATER BY-PASS JOINT

    Click here

  16. INSTALL NO. 1 WATER BY-PASS HOSE

    Click here

  17. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)

    Click here

  18. INSTALL NO. 1 ENGINE COVER

    Click here

  19. INSTALL NO. 2 ENGINE COVER

    Click here

  20. INSTALL NO. 1 FUEL TUBE

    A01WU5Q

  21. INSTALL NO. 2 FUEL TUBE


    1. A01WTTG

      Install the No. 2 fuel tube with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  22. INSTALL INTAKE MANIFOLD


    1. B0018M2

      Place 2 new gaskets on the intake manifold.

    2. Place the intake manifold on the cylinder head.

    3. A01WWFM

      Install and uniformly tighten the 8 bolts and 2 nuts in several steps.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01WWYZ

      Install the wire bracket to the intake manifold with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B0019WM

      Connect the No. 1 ventilation hose.

    6. A01WSFJ

      Connect the 2 water by-pass hoses.

    7. A01WTCT

      Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.

  23. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH

    Click here

  25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH

    Click here

  26. CONNECT NO. 1 FUEL TUBE

    Click here

  27. CONNECT NO. 2 FUEL TUBE

    Click here

  28. INSTALL NO. 1 FUEL HOSE

    A01WV10

    1. Install the fuel hose Click here.

  29. INSTALL NO. 3 ENGINE COVER

    Click here

  30. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  31. INSTALL ENGINE WIRE

    A01WUO7E02
    *1 for LHD:
    *2 for RHD:

    1. Install the engine wire.

    2. Engine Rear Side:


      1. Install the 3 bolts as shown in the illustration.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. for RHD:

        Connect the 4 clamps.

      3. for LHD:

        Connect the 5 clamps.

      4. Connect the sensor wire connector.

      5. w/ Secondary Air Injection System:

        Connect the 2 air switching valve connectors.

    3. A01WT43

      Engine RH Side:


      1. Connect the 9 clamps.

      2. Connect the oil level sensor connector.

      3. Connect the oil pressure sender gauge connector.

      4. Connect the throttle sensor connector.

      5. Connect the noise filter connector.

      6. Connect the fuel injector connector.

      7. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      8. Connect the 4 ignition coil connectors.

      9. Connect the 2 camshaft timing control valve connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

    4. A01WSZX

      Engine LH Side:


      1. Connect the 7 clamps and install the engine wire with the bolt.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }

      2. Connect the noise filter connector.

      3. Connect the fuel injector connector.

      4. Connect the engine coolant temperature sensor connector.

      5. Connect the purge VSV connector.

      6. Connect the vacuum switching valve connector (for ACIS).

      7. Connect the camshaft position sensor connector.

      8. Connect the 2 VVT sensor connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.

      9. Connect the 4 ignition coil connectors.

      10. Connect the 2 camshaft timing control valve connectors.

        Tech Tips

        The wire harnesses on the exhaust side are wrapped with white tape.