Engine Unit: Installation

INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the 4 wire harness clamp brackets with the 4 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
  
  13 N*m (130 kgf*cm, 9 ft.*lbf) for bolt B
  
  Fig 1: Locating Wire Harness Clamp Brackets And Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD
1. Install a new exhaust manifold gasket and exhaust manifold with the 5 nuts in the sequence shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 2: Locating Nuts And Exhaust Manifold
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL MANIFOLD STAY
1. Install the manifold stay with the 3 bolts.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  Fig 3: Locating Bolts And Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 4: Locating Bolts And No. 1 Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR TUBE ASSEMBLY
1. Install the air tube assembly with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
  
  Fig 5: Locating Bolts And Air Tube Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 WATER BY-PASS PIPE
1. Install the water by-pass pipe with the 2 bolts.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 6: Locating Bolts And Water By-Pass Pipe
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the No. 3 water by-pass hose with the clip.
INSTALL WATER INLET HOSE
1. Install the water inlet hose with the 2 clips.
  
  Fig 7: Locating Clips And Water Inlet Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL WATER BY-PASS HOSE
1. Install the water by-pass hose with the clip.
  
  Fig 8: Locating Clip And Water By-Pass Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL LEVEL GAGE GUIDE
1. Install a new O-ring.
2. Install the oil level gage guide with the bolt.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
  
  Fig 9: Locating Bolt And Oil Level Gage Guide
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL OIL LEVEL DIPSTICK
INSTALL VENTILATION HOSE
1. Install the ventilation hose.
  
  Fig 10: Locating Ventilation Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL FAN BELT ADJUSTING BAR
1. Install the fan belt adjusting bar with the bolt.
  Torque: 19 N*m (189 kgf*cm, 14 ft.*lbf)
  
  Fig 11: Locating Bolt And Fan Belt Adjusting Bar
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
INSTALL FUEL INJECTOR (See INSTALLATION )
INSTALL INJECTOR VIBRATION INSULATOR (See INSTALLATION )
INSTALL NO. 1 DELIVERY PIPE SPACER (See INSTALLATION )
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
1. Install the fuel delivery pipe with the 4 fuel injectors, then provisionally install the 3 bolts.
  NOTE:
  - Do not drop the fuel injectors when installing the fuel delivery pipe.
  - Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.
2. Tighten the 3 bolts to the specified torque.
  Torque: 21 N*m (214 kgf*cm, 16 ft.*lbf)
INSTALL INTAKE MANIFOLD
1. Install a new gasket onto the intake manifold.
2. Provisionally tighten the intake manifold and manifold stay with the 4 bolts and 2 nuts in the order shown in the illustration, and then tighten them to the specified torque.
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
  
  Fig 13: Locating Bolt And Nuts And Intake Manifold And Manifold Stay
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the wire harness clamp onto the intake manifold.
4. Install the ventilation hose into the intake manifold.
5. Install the No. 1 vacuum transmitting hose with the clip.
6. Install the No. 1 fuel vapor feed hose into the throttle body manifold.
7. Install the 2 water by-pass hoses with the 2 clips.
  
  Fig 15: Locating Clips And Water By-Pass Hoses
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 1 RADIATOR HOSE
1. Install the No. 1 radiator hose with the clip.
  
  Fig 16: Locating Clip And No. 1 Radiator Hose
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER WATER INLET HOSE A
1. Install heater water inlet hose A with the clip.
  
  Fig 17: Locating Clip And Heater Water Inlet Hose A
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
1. Install heater water outlet hose A with the clip.
  
  Fig 18: Locating Clip And Heater Water Outlet Hose A
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 VENTILATION HOSE
1. Install the No. 2 ventilation hose.
INSTALL ENGINE WIRE
INSTALL RADIO SETTING CONDENSER
1. Install the radio setting condenser with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
2. Connect the radio setting condenser connector.
  
  Fig 20: Locating Radio Setting Condenser Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
  
  Fig 21: Locating Bolts And Ignition Coil Assemblies
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Connect the 4 ignition coil assembly connectors.