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Engine Unit: Installation

  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 
    1. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.

      Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

      Fig 1: Using Deep Socket Wrench To Install Engine Coolant Temperature Sensor & New Gasket
      G04974495Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSTALL KNOCK CONTROL SENSOR  (See INSTALLATION )
  3. INSTALL KNOCK CONTROL SENSOR WIRE 
    1. Connect the 2 knock control sensor connectors and 3 clamps.
      Fig 2: Identifying Knock Control Sensor Connectors & Clamps
      G05414532Courtesy 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.

      Adhesive: Part No. 08833-00080, Three Bond 1344, LOCTITE 242 or equivalent 

      Fig 3: Cleaning Threads Of Oil Pressure Switch
      G04974196Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 after installation to prevent oil leaks.
      Fig 4: Using Deep Socket Wrench To Install Oil Pressure Switch
      G05136532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. INSTALL NO. 1 VACUUM SWITCHING VALVE 
    1. Install the bolt and No. 1 vacuum switching valve.

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

      Fig 5: Identifying No. 1 Vacuum Switching Valve Bolt
      G04974493Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. INSTALL RADIO SETTING CONDENSER 
    1. Install the 2 bolts and 2 radio setting condensers.

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

      Fig 6: Identifying Radio Setting Condensers & Bolts
      G04974492Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSTALL WATER PUMP PULLEY  (See INSTALLATION )
  8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the No. 2 idler pulley sub-assembly and cover plate with the bolt.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 7: Identifying No. 2 Idler Pulley Sub-Assembly & Cover Plate With Bolt
      G04974490Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 2 TIMING GEAR COVER 
    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

      Fig 8: Identifying No. 2 Timing Gear Cover Bolts
      G04974489Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      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 below.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

      Fig 9: Identifying V-Ribbed Belt Tensioner Assembly Bolts
      G04974508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the other bolts.

      Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

  11. INSTALL GENERATOR ASSEMBLY  (See INSTALLATION )
  12. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (for 4WD) 
    1. Install the transverse engine mounting bracket with the 3 bolts.

      Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Fig 10: Identifying Transverse Engine Mounting Bracket Bolts (4WD)
      G05136525Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (for 2WD) 
    1. Install the transverse engine mounting bracket with the 3 bolts.

      Torque: 64 N*m (650 kgf*cm, 47 ft.*lbf) 

      Fig 11: Identifying Transverse Engine Mounting Bracket Bolts (2WD)
      G05136524Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET 
    1. Install the transverse engine mounting bracket with the 3 bolts.

      Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

      Fig 12: Identifying Transverse Engine Mounting Bracket With Bolts
      G04974486Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket as shown below.
      Fig 13: Identifying Exhaust Manifold Gasket
      G04974511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown below.

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

      Fig 14: Identifying Exhaust Manifold Sub-Assembly LH Nuts
      G05136551Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

      Fig 15: Identifying No. 2 Exhaust Manifold Heat Insulator Bolts
      G05136521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL NO. 2 MANIFOLD STAY 
    1. Install the No. 2 manifold stay with the bolt and nut in the order shown below.

      Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

      Fig 16: Identifying No. 2 Manifold Stay With Bolt And Nut
      G05136553Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. 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-rings.
    3. Push in the No. 2 engine oil level dipstick guide end into the No. 1 engine oil level dipstick guide.
      Fig 17: Identifying No. 2 Engine Oil Level Dipstick Guide
      G05414519Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

      Fig 18: Identifying No. 2 Engine Oil Level Dipstick Guide With Bolt
      G05414518Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Install the engine oil level dipstick.
  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown below.
      Fig 19: Identifying Exhaust Manifold Sub-Assembly RH
      G04974516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown below.

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

      Fig 20: Identifying Exhaust Manifold Sub-Assembly RH Nuts
      G05136556Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. INSTALL INTAKE MANIFOLD 
    NOTE: DO NOT apply oil to the bolts listed below:
    BOLT LENGTH SPECIFICATION

    Tightening Parts
    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.
      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) 

      Fig 21: Identifying Intake Manifold Bolts & Nuts
      G04974480Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 mounting stay RH with the bolt.

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

      Fig 22: Identifying No. 2 Engine Mounting Stay RH Bolt
      G05136516Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL IGNITION COIL ASSEMBLY  (See INSTALLATION )
  23. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 4 bolts.

      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.
  24. REMOVE ENGINE STAND 
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