ENGINE UNIT INSTALLATION


  1. INSTALL RADIO SETTING CONDENSER


    1. Install the radio setting condenser with the bolt.

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

  2. 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.

    3. Connect the engine coolant temperature sensor connector.

  3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A01EWGLE08
      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

    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 engine oil pressure switch connector.

  4. INSTALL KNOCK CONTROL SENSOR


    1. A01EX4TE09
      Text in Illustration
      *a Front of Engine
      *b Up
      *c 10°
      *d 10°

      Install the knock control sensor with the bolt so that the knock control 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 10° upward and 10° downward from the horizontal position.

    2. Connect the knock control sensor connector.

  5. INSTALL IGNITION COIL ASSEMBLY


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

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

    2. Connect the 4 ignition coil assembly connectors.

  6. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new water by-pass pipe 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 }

  7. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

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

  8. INSTALL ENGINE OIL LEVEL DIPSTICK


    1. Install the engine oil level dipstick.

  9. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A01EXWWE07
      Text in Illustration
      *1 Jiggle Valve
      *a Upward

      Install the thermostat with the jiggle valve facing upward.

      Tech Tips

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

  10. INSTALL WATER INLET


    1. A01EWTFE02
      Text in Illustration
      *a 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 }

  11. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Set a new gasket to the cylinder head sub-assembly.

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

    3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.

    4. A01EVVIE05

      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 }

    5. Connect the air fuel ratio sensor connector.

  12. INSTALL NO. 2 MANIFOLD STAY


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

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  13. INSTALL MANIFOLD STAY


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

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

  14. 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 }

  15. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator to the cylinder block.

  16. INSTALL INTAKE MANIFOLD


    1. Install the vacuum hose clamp with the bolt.

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

    2. Install a new No. 1 intake manifold to head gasket to the intake manifold.

    3. Set the intake manifold on the engine assembly.

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

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

    5. Temporarily install the intake manifold with the 5 bolts and 2 nuts.

    6. A01EVP6E03

      Tighten the 5 bolts and 2 nuts in the order shown in the illustration.

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

    7. Connect the oxygen sensor connector and 2 wire harness clamps.

  17. CONNECT UNION TO VACUUM TUBE HOSE


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

  18. CONNECT NO. 2 VENTILATION HOSE


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

  19. INSTALL FUEL DELIVERY PIPE


    1. A01EYQ8

      Install 4 new injector vibration insulators to the cylinder head.

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

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

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

      Note


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

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

    4. Connect the 4 fuel injector connectors.

    5. Install the 2 wire harness clamps.

  20. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01EV9GE01
      Text in Illustration
      *a Groove
      *b Protrusion

      Install a new gasket to the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove on the intake manifold.

    2. Temporarily install the throttle with motor body assembly and fuel tube bracket with the 4 bolts.

    3. Connect the 2 water by-pass hoses.

    4. Connect the purge line hose.

    5. A01EYZD

      Install the fuel tube bracket and the throttle with motor body assembly with the 4 bolts.

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

    6. Connect the throttle with motor body assembly connector to the throttle with motor body assembly.

    7. Connect the wire harness clamp to the fuel tube bracket.

    8. Install the fuel tube to the fuel tube bracket.

  21. INSTALL IDLER PULLEY BRACKET


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

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

  22. INSTALL ENGINE HANGERS


    1. A01ETLPE08
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the 2 engine hangers with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91552-B1020