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

   

   Text in Illustration

   *1

   Adhesive

   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 oil pressure switch.

   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. Install the sensor with the bolt so that the sensor is angled as shown in the illustration.

   

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   Text in Illustration

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

   Note

   The acceptable installation angle of the 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 sensor connector.

INSTALL INTAKE MANIFOLD

1. Install the wire harness clamp bracket with the bolt.

   

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

2. Connect the 2 vacuum hoses and check that the No. 1 check valve is installed as shown in the illustration.

   

   Text in Illustration

   *a

   Black

3. Check the tumble control valves.

   Note

   The tumble control valves may be damaged if they are not closed before installing the intake manifold.

   Tech Tips

   Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.

4. Install a new intake manifold gasket to the intake manifold.

5. Install the intake manifold by tightening the 6 bolts in the sequence shown in the illustration.

   

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

6. Connect the intake air control actuator connector and 2 wire harness clamps.

   

7. Install the wire harness clamp with the bolt.

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

8. Install the wire harness clamp bracket with the bolt.

   

   Torque:

   8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

9. Connect the 3 wire harness clamps and connector.

10. Connect the fuel vapor feed hose.

11. Install the 2 wire harness clamp brackets with the 2 bolts.

    

    Torque:

    8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

1. Install 4 new injector vibration insulators to the cylinder head.

   

   Text in Illustration

   *1	Fuel Delivery Spacer
   *a	Fuel Delivery Pipe Side
   *b	Cylinder Head Side

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 sub-assembly 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 injectors when installing the fuel delivery pipe sub-assembly.

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

INSTALL UNION TO CONNECTOR TUBE HOSE

1. Connect the union to connector tube hose to the intake manifold.

CONNECT NO. 2 VENTILATION HOSE

1. Connect the No. 2 ventilation hose to the intake manifold.

INSTALL VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

1. Install the vacuum switching valve assembly with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

2. Connect the 2 vacuum hoses and connector.

3. Connect the union to connector tube hose and wire harness clamp.

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  { 132 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 clamp.

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

7. Connect the water by-pass hose to the throttle with motor body assembly.

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

1. Install a new exhaust manifold to head gasket onto the cylinder head.

2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

3. Tighten the 5 nuts in the sequence shown in the illustration (except PZEV).

   

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

4. Tighten the 5 nuts in the sequence shown in the illustration (for PZEV).

   

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

INSTALL EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)

1. Install the EGR inlet exhaust manifold plate with the bolt.

   Torque:

   14 N*m  { 138 kgf*cm, 10 ft.*lbf }

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)

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 }