ENGINE UNIT INSTALLATION

INSTALL IGNITION COIL ASSEMBLY

1. Install the 4 ignition coil assemblies with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Tech Tips

   Perform "Inspection After Repair" after replacing an ignition coil assembly Click here.

2. Connect the 4 ignition coil assembly connectors.

INSTALL ENGINE COOLANT TEMPERATURE SENSOR

1. Install a new gasket to the engine coolant temperature sensor.

2. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Note

   Use the torque value compensation formula to calculate the torque value for use when a torque wrench is combined with a tool such as a ball joint lock nut wrench Click here.

   Tech Tips

   Perform "Inspection After Repair" after replacing the engine coolant temperature sensor Click here.

3. Connect the engine coolant temperature sensor connector.

4. Install the wire harness with the 2 bolts.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

1. 

   Text in Illustration

   *1

   Adhesive

   Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.

   Adhesive
   TOYOTA Genuine Adhesive 1344, Three Bond 1344 or equivalent.

   Note

   Do not let adhesive adhere to the oil hole.

2. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

   Torque:

   15 N*m  { 153 kgf*cm, 11 ft.*lbf }

   Note

   Do not start the engine within 1 hour of installation.

3. Connect the connector.

INSTALL KNOCK CONTROL SENSOR

1. 

   Text in Illustration

   *a	Front of Engine
   *b	Up
   *c	7°
   *d	10°

   Install the knock control sensor with the bolt so that the sensor is positioned as shown in the illustration.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Note

   The acceptable installation angle of the knock control sensor is between 7° upward and 10° downward from the horizontal position.

   Tech Tips

   Perform "Inspection After Repair" after replacing the knock control sensor Click here

2. Connect the knock control sensor sensor connector.

INSTALL INTAKE MANIFOLD

INSTALL FUEL DELIVERY PIPE

1. 

   Text in Illustration

   *1	Fuel Delivery Spacer
   *2	Injector Vibration Insulator
   *a	Fuel Delivery Pipe Side
   *b	Cylinder Head Side

   Install 4 new injector vibration insulators to the cylinder head.

2. Install the 2 fuel delivery spacers onto the cylinder head.

   Tech Tips

   Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

3. Install the fuel delivery pipe with the 4 fuel injector assemblies and install the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Note

   
   

   • Do not drop the fuel injector assemblies when installing the fuel delivery pipe.

   • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe.

CONNECT UNION TO VACUUM TUBE HOSE (for LHD)

1. Connect the union to vacuum tube hose to the intake manifold and slide the clip to secure it.

CONNECT UNION TO CHECK VALVE HOSE (for RHD)

1. Connect the union to check valve hose to the intake manifold and slide the clip to secure it.

CONNECT NO. 2 VENTILATION HOSE

1. Connect the No. 2 ventilation hose to the intake manifold and slide the clip to secure it.

INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

1. Install the vacuum switching valve assembly to the intake manifold with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

2. Connect the 2 vacuum hoses and vacuum switching valve assembly connector.

3. for LHD:

   
   

   1. Engage the wire harness clamp.

   2. Connect the union to vacuum tube hose.

4. for RHD:

   
   

   1. Engage the wire harness clamp.

   2. Connect the union to check valve hose.

INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

1. Install a new gasket to the intake manifold.

2. Install the fuel tube bracket with the bolt.

   Torque:

   13 N*m  { 133 kgf*cm, 10 ft.*lbf }

3. Install the throttle with motor body assembly with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

4. Connect the throttle body connector.

5. Connect the fuel tube to the fuel tube bracket.

6. Connect the No. 2 water by-pass hose to the throttle with motor body assembly.

7. Connect the No. 1 water by-pass hose to the throttle with motor body assembly.

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

INSTALL NO. 2 MANIFOLD STAY

1. Install the No. 2 manifold stay with the bolt and nut.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

INSTALL MANIFOLD STAY

1. Install the manifold stay with the bolt and nut.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }