ENGINE UNIT INSTALLATION


  1. INSTALL ENGINE OIL LEVEL SENSOR


    1. A01NFNY

      Install the engine oil level sensor with the 4 bolts.

      Torque:
      8.2 N*m  { 84 kgf*cm, 73 in.*lbf }

  2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR


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

    2. A01NGNAE01
      Text in Illustration
      *1 New Gasket

      Install the engine coolant temperature sensor and gasket.

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

    3. Connect the engine coolant temperature sensor connector.

  3. INSTALL KNOCK CONTROL SENSOR


    1. A01NE9IE03

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

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

      Note

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

    2. Connect the 2 knock control sensor connectors.

  4. INSTALL SENSOR WIRE


    1. A01NG9S

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

  5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01ND1ZE01
      Text in Illustration
      *1 Adhesive

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

      Adhesive
      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
    2. A01NHVV

      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 after installation to prevent oil leaks.

  6. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. A01NGI5

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

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

  7. INSTALL RADIO SETTING CONDENSER


    1. A01NG5Y

      Install the 2 radio setting condensers with the 2 bolts.

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

  8. INSTALL WATER PUMP PULLEY


    1. A01NHTCE01

      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 }

  9. INSTALL NO. 2 TIMING GEAR COVER


    1. A01NEQS

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

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

  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01ND6IE01

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

      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 }

  11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A01NFHPE04
      Text in Illustration
      *1 Front

      Install a new gasket as shown in the illustration.

    2. A01NGUOE01

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

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

  12. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01NDHM

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

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    2. A01NHIN

      Connect the sensor wire to the radiator pipe clamp.

    3. Connect the air fuel ratio sensor connector (for Bank 2 Sensor 1).

  13. INSTALL NO. 2 MANIFOLD STAY


    1. A01NERIE01

      Install the No. 2 manifold stay by tightening the bolt and nut in the order shown in the illustration.

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

  14. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01NEKR

      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 No. 1 engine oil level dipstick guide.

    4. A01NDZG

      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.

  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A01NEOCE03
      Text in Illustration
      *1 Front

      Install a new gasket as shown in the illustration.

    2. A01NFSEE01

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

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

  16. INSTALL INTAKE MANIFOLD

    Note

    DO NOT apply oil to the bolts listed below:

    Tightening Part
    Intake Manifold and Cylinder Head Sub-assembly RH
    Intake Manifold and Cylinder Head Sub-assembly LH

    1. A01NG3U

      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 }

  17. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. A01NFDW

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

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

  18. INSTALL IGNITION COIL ASSEMBLY


    1. A01NDWZE01

      Install the 6 ignition coils with the 6 bolts.

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

    2. Connect the 6 ignition coil connectors.

  19. INSTALL NO. 1 SURGE TANK STAY


    1. A01NDV9

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

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

  20. INSTALL EGR DELIVERY CHAMBER


    1. A01NGB1

      Set a new No. 2 intake manifold gasket.

    2. A01NHNVE01
      Text in Illustration
      *A w/ EGR System
      *B w/o EGR System

      Install the EGR delivery chamber.

    3. A01NCSW

      Connect the 2 water hoses and connector (w/ EGR System).

  21. INSTALL NO. 1 EGR COOLER BRACKET (w/ EGR System)


    1. A01NFV7

      Install the No. 1 EGR cooler bracket with the 3 bolts.

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

  22. INSTALL EGR COOLER ASSEMBLY (w/ EGR System)


    1. A01ND0Z

      Install a new gasket and the EGR cooler assembly with the 4 nuts.

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

    2. Connect the 2 water hoses.

  23. INSTALL NO. 1 EGR PIPE (w/ EGR System)


    1. A01NHTU

      Install 2 new gaskets and No. 1 EGR pipe with the bolt and 4 nuts.

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

  24. INSTALL NO. 2 EGR PIPE (w/ EGR System)


    1. A01NG7P

      Install 2 new gaskets and the No. 2 EGR pipe with the 2 nuts and 2 bolts.

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

  25. INSTALL THROTTLE BODY BRACKET


    1. A01NH8I

      Install the throttle body bracket with the bolt.

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

  26. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    NOTICE
    DO NOT apply oil to the bolts listed below:
    Tightening Part
    Surge Tank and Intake Manifold
    No. 1 Surge Tank Stay and Surge Tank
    Throttle Body Bracket and Surge Tank

    1. A01NDLR

      Install 3 new air surge tank to intake manifold gaskets to the intake air surge tank.

    2. A01NE93E01
      Text in Illustration
      *1 Bolt
      *2 Nut

      Using a 5 mm hexagon socket wrench, install the intake air surge tank assembly with the 4 bolts and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }
    3. A01NHZZ

      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 }
    4. A01NCZR

      Connect the connector to the manifold absolute pressure sensor.

    5. A01NGGD

      Connect the ventilation hose.

    6. A01NHMY

      Install the 5 clamps and connect the main wire to the body.

    7. A01NG7C

      Connect the 2 water by-pass hoses to the throttle body assembly.

    8. A01NF4U

      Connect the fuel vapor feed hose.

    9. A01ND1X

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

  27. INSTALL ENGINE HANGERS


    1. A01NEC7E13
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-31120
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825

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

  28. REMOVE ENGINE STAND


    1. Remove the engine assembly from the engine stand.