ENGINE UNIT INSTALLATION

Tech Tips

Check whether the engine is TMC made or not by referring to the following illustration.

A01CE8JE01
Text in Illustration
*A for TMC Made Engine *B except TMC Made Engine
*1 Engine Oil Level Dipstick Guide *2 Water Inlet Housing
*3 Water Inlet Housing Drain Cock Assembly - -

  1. INSTALL STUD BOLT


    1. Using a socket wrench (8 mm), install the stud bolt to the engine mounting bracket RH.

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

  2. INSTALL RADIO SETTING CONDENSER


    1. Install the radio setting condenser with the bolt.

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

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


    1. A01CCZRE01
      Text in Illustration
      *1 New Gasket

      Install the engine coolant temperature sensor through a new gasket.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. A01CFQU

      Connect the engine coolant temperature sensor connector.

  4. INSTALL OIL PRESSURE SWITCH


    1. A01CDPIE08
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01CESY

      Using a 24 mm deep socket wrench, install the 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 oil pressure switch connector.

  5. INSTALL KNOCK SENSOR


    1. A01CG7HE05

      Install the knock control sensor with the nut.

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

    2. Connect the sensor connector.

  6. INSTALL IGNITION COIL ASSEMBLY


    1. A01CC5A

      Install the 4 ignition coils with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 4 ignition coil connectors.

  7. INSTALL UNION BOLT (for TMC Made Engine with Engine Oil Cooler)


    1. Apply adhesive to the threads of the union bolt.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    2. Install the union bolt.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  8. INSTALL OIL COOLER PIPE (for TMC Made Engine with Engine Oil Cooler)


    1. for Automatic Transaxle:


      1. Install a new gasket and the oil cooler pipe with the bolt and 2 nuts.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  9. INSTALL NO. 3 WATER BY-PASS HOSE (for TMC Made Engine with Engine Oil Cooler)


    1. A01CEETE05
      Text in Illustration
      *1 No. 3 Water By-pass Hose
      *2 No. 4 Water By-pass Hose
      *3 Yellow Paint Mark
      *4 White Paint Mark
      *a Top
      *b LH Side

      Connect the No. 3 water by-pass hose.

  10. INSTALL NO. 4 WATER BY-PASS HOSE (for TMC Made Engine with Engine Oil Cooler)


    1. Connect the No. 4 water by-pass hose.

  11. INSTALL NO. 3 WATER BY-PASS PIPE (for CVT)


    1. Install a new gasket and the No. 3 water by-pass pipe with the bolt and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  12. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 1 water by-pass pipe with the bolt and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  13. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring and the engine oil level dipstick guide with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  14. INSTALL ENGINE OIL LEVEL DIPSTICK


    1. Install the engine oil level dipstick.

  15. INSTALL NO. 4 WATER BY-PASS PIPE (for TMC Made Engine with Engine Oil Cooler)


    1. for CVT:


      1. Install the No. 4 water by-pass pipe with the bolt and nut.

        Torque:
        9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  16. INSTALL THERMOSTAT


    1. Position a new gasket onto the thermostat.

    2. A01CAU1E04
      Text in Illustration
      *1 Upward
      *2 Jiggle Valve

      Install the thermostat with the jiggle valve upward.

      Tech Tips

      The jiggle valve may be set to within 10° on either side of the indicated position.

  17. INSTALL WATER INLET


    1. A01CB3FE01
      Text in Illustration
      *1 Mark

      Install the water inlet with the mark upward.

    2. Install the water inlet with the 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  18. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install a new exhaust manifold to head gasket.

    2. A01CDXGE02

      Using a 12 mm deep socket wrench, install the exhaust manifold converter sub-assembly and 5 nuts in the order shown in the illustration.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  19. INSTALL NO. 2 MANIFOLD STAY


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

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  20. INSTALL MANIFOLD STAY


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

      Torque:
      44 N*m  { 449 kgf*cm, 33 ft.*lbf }

  21. 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 }

  22. INSTALL INTAKE MANIFOLD


    1. Install the vacuum hose clamp with the bolt.

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

    2. Install the union to check valve hose, No. 2 ventilation hose and No. 1 throttle body hose.

    3. Install the No. 1 intake manifold insulator.

    4. Install a new No. 1 intake manifold to head gasket.

    5. Set the intake manifold.

    6. Connect the engine wire.


      1. A01CF25

        Connect the engine wire harness with the 2 bolts.

      2. A01CATI

        Connect the connector and wire harness clamp.

      3. A01CBF3

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      4. Connect the 4 connectors.

      5. A01CD02

        Connect the 4 connectors.

      6. A01CD1G

        Install the earth bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      7. Connect the connector and 3 wire harness clamps.

      8. A01CAQ1

        Connect the earth connector and wire harness clamp.

      9. A01CGIS

        Connect the terminal B with the nut and install the terminal cap.

        Torque:
        9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

      10. Connect the 2 connectors and 2 wire harness clamps.

      11. A01CBKV

        Connect the compressor connector and clamp.

    7. Using an E7 "TORX" wrench, install the 2 stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    8. Install the intake manifold with the 5 bolts and 2 nuts.

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

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

    10. Connect the oxygen sensor connector and clamp.

  23. CONNECT NO. 2 VENTILATION HOSE


    1. A01CF7HE03

      Connect the ventilation hose to the ventilation valve.

      Note

      Make sure that the paint mark and hose clamp are positioned as shown in the illustration after connecting the hose.

  24. INSTALL FUEL INJECTOR ASSEMBLY


    1. A01CEFRE06
      Text in Illustration
      *1 O-ring

      Apply a light coat of gasoline or spindle oil to new O-rings, then install them to each fuel injector.

    2. A01CFXY

      Apply a light coat of gasoline or spindle oil to the part of the fuel delivery pipe which comes into contact with the O-ring of the fuel injector.

    3. Push and twist each fuel injector to install them into the fuel delivery pipe.

      Note

      Make sure that the O-ring is not cracked or jammed before installing the injector.

    4. Check that the fuel injector rotates smoothly. If the fuel injector does not rotate, replace the O-ring.

  25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01CE68

      Install 4 new insulators into the cylinder head.

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

    3. A01CCM5E08
      Text in Illustration
      *1 O-ring
      *2 Fuel Injector
      *3 Insulator
      *4 Fuel Delivery Pipe

      Install the fuel delivery pipe together with the 4 fuel injectors, then temporarily tighten the 2 bolts.

      Note

      Be careful not to drop the fuel injectors when installing the fuel delivery pipe.

    4. Check that the fuel injector rotates smoothly.

      If the fuel injector does not rotate smoothly, replace the O-ring.

    5. A01CDXZ

      Tighten the 2 bolts to the specified torque.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    6. A01CGBI

      Connect the 4 fuel injector connectors.

    7. Connect the oil control valve connector.

    8. Install the 2 wire harness clamps.

  26. INSTALL THROTTLE BODY ASSEMBLY


    1. A01CD9V

      Install a new gasket onto the intake manifold.

    2. A01CAZR

      Temporarily install the throttle body assembly and fuel pipe support bracket with the 3 bolts.

    3. A01CEV1E01

      Connect the 2 water by-pass hoses. (*1).

    4. Connect the purge line hose. (*2)

    5. Connect the No. 1 throttle body hose. (*3)

    6. A01CCON

      Install the fuel pipe support bracket and throttle body assembly with the 4 bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    7. A01CB1V

      Connect the throttle body connector to the throttle body assembly.

    8. Connect the wire harness clamp to the fuel pipe support bracket.

    9. Install the hose to the fuel pipe support bracket.

  27. INSTALL ENGINE WIRE


    1. Install the engine wire.

  28. INSTALL IDLER PULLEY BRACKET


    1. Install the idler pulley bracket with the 2 bolts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  29. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 652 kgf*cm, 47 ft.*lbf }

  30. INSTALL ENGINE HANGERS


    1. A01CG33E08
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger

      12281-28010 or

      12281-0H010
      No. 2 engine hanger

      12282-28010 or

      12282-0H010
      Bolt

      91552-B1020 or

      90105-C0076