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INSTALLATION (To 08/2009): Installation

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR  . Refer to INSTALLATION - Step 1
  2. INSTALL KNOCK CONTROL SENSOR  . Refer to INSTALLATION - Step 1
  3. INSTALL KNOCK CONTROL SENSOR WIRE 
    1. Connect the 2 clamps, 2 knock control sensor connectors and knock control sensor wire connector.
      Fig 1: Identifying Knock Control Sensor Connectors & Knock Control Sensor Wire Connector
      GTY248766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      Fig 2: Applying Adhesive To Threads Of Oil Pressure Switch
      GTY289897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 24 mm deep socket wrench, install the oil pressure switch.
      Fig 3: Identifying Engine Oil Pressure Switch Assembly (W & W/O Oil Cooler) & Socket Wrench
      GTY251348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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 ASSEMBLY 
    1. Install the No. 1 vacuum switching valve with the bolt.
      Fig 4: Identifying No. 1 Vacuum Switching Valve & Bolt
      GTY280298Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

  6. INSTALL WATER PUMP PULLEY  . Refer to INSTALLATION - Step 2
  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.
      Fig 5: Identifying No. 2 Idler Pulley Sub-Assembly, Bolt & Idler Pulley Cover Plate
      GTY250799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
      Fig 6: Identifying No. 2 Timing Gear Cover & Bolts
      GTY250760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
      Fig 7: Identifying V-Ribbed Belt Tensioner & Bolts
      GTY257987Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      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.
      Fig 8: Identifying Exhaust Manifold Gasket
      GTY288037Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
      Fig 9: Identifying Exhaust Manifold Sub-Assembly LH & Nuts
      GTY285621Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR  . Refer to INSTALLATION - Step 4
  12. INSTALL NO. 2 MANIFOLD STAY  . Refer to INSTALLATION - Step 5
  13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.
      Fig 10: Identifying No. 2 Engine Oil Level Dipstick Guide & O-Ring
      GTY194015Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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. Install the No. 2 engine oil level dipstick guide with the bolt.
      Fig 11: Identifying No. 2 Engine Oil Level Dipstick Guide & Bolt
      GTY281359Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      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.
      Fig 12: Identifying Exhaust Manifold Sub-Assembly RH Gasket
      GTY288038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
      Fig 13: Identifying Exhaust Manifold Sub-Assembly RH & Nuts
      GTY279471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  15. 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. Set a new gasket on each cylinder head.
      Fig 14: Identifying Intake Manifold, Bolts, Nuts & Gaskets
      GTY146837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
      Fig 15: Identifying No. 2 Engine Mounting Stay RH & Bolt
      GTY281164Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  17. INSTALL IGNITION COIL ASSEMBLY  . Refer to INSTALLATION - Step 2
  18. INSTALL NO. 1 SURGE TANK STAY 
    1. Install the No. 1 surge tank stay with the bolt.
      Fig 16: Identifying No. 1 Surge Tank Stay & Bolt
      GTY255341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  19. INSTALL THROTTLE BODY BRACKET 
    1. Install the throttle body bracket with the bolt.
      Fig 17: Identifying Throttle Body Bracket & Bolt
      GTY281757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY  . Refer to INSTALLATION - Step 5
  21. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
      Fig 18: Identifying No. 1 And No. 2 Engine Hanger & Bolts
      GTY249581Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Part No.

      No. 1 engine hanger 12281-31120

      No. 2 engine hanger 12282-31100

      Bolts 91671-10825

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

    2. Attach the engine sling device and hang the engine with the chain block.
  22. REMOVE ENGINE STAND 
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