ENGINE UNIT INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly Click here.

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    1. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.

      A011SR1
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  2. INSTALL KNOCK SENSOR WIRE

    1. Connect the 2 clamps, 2 knock sensor connectors and knock sensor wire connector.

  3. INSTALL KNOCK CONTROL SENSOR

    1. Install the 2 knock control sensors with the 2 bolts as shown in the illustration.

      A011SHGE04
      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      Text in Illustration
      *a for Bank 1
      *b for Bank 2
      *c Front of Vehicle

      Note

      Make sure that each knock control sensor is in the correct position.

    2. Connect the 2 knock control sensor connectors.

  4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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

      A011TQSE08
      Text in Illustration
      *1 Adhesive
      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 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 after installation to prevent oil leaks.

  5. INSTALL NO. 1 VACUUM SWITCHING VALVE

    1. Install the No. 1 vacuum switching valve with the bolt.

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

  6. INSTALL WATER PUMP PULLEY

    1. Temporarily install the water pump pulley with the 4 bolts.

    2. Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    3. Tighten the 4 bolts.

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

  7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

    1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 550 kgf*cm, 40 ft.*lbf }

  8. INSTALL NO. 2 TIMING GEAR COVER

    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      A011SX7E01

      Tech Tips

      Each bolt length is as follows:

      A: 70 mm (2.76 in.)

      B: 33 mm (1.30 in.)

    2. Install the V-ribbed belt tensioner assembly by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    1. Install a new gasket as shown in the illustration.

      A011TVA
      Text in Illustration
      A011V7Q Engine Front

    2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.

      A011SO6E01
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

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

  12. INSTALL NO. 2 MANIFOLD STAY

    1. Tighten the bolt and nut in the order shown in the illustration.

      A011V3QE03
      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

  13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    1. Install a new gasket as shown in the illustration.

      A011T78
      Text in Illustration
      A011V7Q Engine Front

    2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.

      A011T6YE01
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  15. INSTALL INTAKE MANIFOLD

    1. Set a new gasket on each cylinder head.

      Note

      • Align the port holes of the gasket and cylinder head.

      • Make sure that the gasket is installed in the correct direction.

    2. Set the intake manifold on the cylinder heads.

    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  16. INSTALL NO. 2 ENGINE MOUNTING STAY RH

    1. Install the No. 2 engine mounting stay RH with the bolt.

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

  17. INSTALL IGNITION COIL ASSEMBLY

    1. Install the 6 ignition coils with the 6 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 6 ignition coil connectors.

    3. Connect the 2 wire harness clamps.

    4. Install the nut.

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

  18. INSTALL NO. 1 SURGE TANK STAY

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for No. 1 surge tank stay and cylinder head cover

    1. Install the No. 1 surge tank stay with the bolt.

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

  19. INSTALL THROTTLE BODY BRACKET

    Note

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for throttle body bracket and cylinder head cover

    1. Install the throttle body bracket with the bolt.

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

  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Note

    DO NOT apply oil to the bolts as listed below

    Oil Application Prohibited Bolt
    Intake Air Surge Tank Assembly and Intake Manifold
    No. 1 Surge Tank Stay and Intake Air Surge Tank Assembly
    Throttle Body Bracket and Intake Air Surge Tank Assembly

    1. Install 3 new gaskets to the intake air surge tank assembly.

    2. Temporarily install the intake air surge tank assembly with the 4 bolts and 2 nuts.

    3. Using a 5 mm hexagon socket wrench, in several steps, uniformly tighten the 4 bolts and 2 nuts in the order shown in the illustration.

      A011RQ5E01
      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    4. Install the throttle body bracket and No. 1 surge tank stay with the 2 bolts.

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

    5. Install the vacuum hose clamp with the bolt.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    6. Connect the connector to the intake air control valve assembly.

    7. Connect the 2 water by-pass hoses and fuel vapor feed hose.

    8. Connect the connector and wire harness clamp to the throttle body assembly.

    9. Connect the hose clamp and union to check valve hose.

    10. Connect the ventilation hose.

  21. INSTALL ENGINE HANGERS

    1. Install the 2 engine hangers with the 4 bolts.

      Part No.
      Item Part No.
      No. 1 engine hanger 12281-31120
      No. 2 engine hanger 12282-31100
      Bolt 90119-A0117
      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    2. Attach an engine sling device and hang the engine with a chain block.