ENGINE UNIT INSTALLATION


  1. 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 }

    2. Connect the 4 ignition coil assembly connectors.

  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 formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench Click here.

    3. Connect the engine coolant temperature sensor connector.

    4. Install the wire harness with the 2 bolts.

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

    5. Connect the air fuel ratio sensor connector clamp.

  3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A019JNPE12
      Text in Illustration
      *1 Adhesive

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

      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 oil pressure switch connector.

  4. INSTALL KNOCK CONTROL SENSOR


    1. A019P44E04
      Text in Illustration
      *a Front of Engine
      *b Up
      *c 7°
      *d 10°

      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 }

      Note

      The acceptable installation angle of the sensor is between 7° upward and 10° downward from the horizontal position.

    2. Connect the sensor connector.

  5. INSTALL SENSOR WIRE


    1. A019L0V

      Install the sensor wire with the bolt.

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

    2. Connect the knock control sensor connector.

  6. INSTALL INTAKE MANIFOLD


    1. A019LWK

      Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. A019P6SE01
      Text in Illustration
      *a Black

      Connect the 2 vacuum hoses and check that the check valve is installed as shown in the illustration.

    3. A019OHRE01
      Text in Illustration
      *a Condition: Closed

      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 gasket to the intake manifold.

    5. A019P4FE02

      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. A019OX7

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

    7. Install the wire harness clamp with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    8. A019MFA

      Install the wire harness clamp bracket with the bolt.

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

    9. Connect the wire harness clamp and connector.

    10. Connect the fuel vapor feed hose and vacuum hose.

    11. A019L4L

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

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

  7. CONNECT NO. 2 VENTILATION HOSE


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

  8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A019ND5E01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Cylinder Head Side

      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.

    2. A019NP2

      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.

  9. INSTALL WATER BY-PASS HOSE


    1. A019L1U

      Install the No. 1 and No. 2 water by-pass hoses.

  10. INSTALL THROTTLE BODY ASSEMBLY


    1. Install the fuel tube bracket with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

    2. Install a new gasket to the intake manifold.

    3. Install the throttle body assembly with the 4 bolts.

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

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

    5. Connect the throttle body assembly connector.

    6. Connect the fuel tube to the clamp.

  11. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. A019OT7

      Install the bracket with the 4 bolts.

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

  12. 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. A019N1JE05

      Tighten the 5 nuts in the sequence shown in the illustration.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  13. 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 }

  14. INSTALL MANIFOLD STAY


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

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

  15. 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 }

  16. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A019LVP

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

    2. Install the O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Install the engine oil level dipstick.