Engine Unit: Installation

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)
INSTALL KNOCK CONTROL SENSOR (See INSPECTION )

Fig 1: Identifying EFI Engine Coolant Temperature Sensor
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL KNOCK CONTROL SENSOR WIRE
1. Connect the 2 knock control sensor connectors and 3 clamps.
  
  Fig 2: Locating Knock Control Sensor Connectors And Clamps
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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:
  
  Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
  
  Fig 3: Cleaning Threads Of Oil Pressure Switch
  Courtesy 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: Removing Engine Oil Pressure Switch Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing Bolt And No. 1 Vacuum Switching Valve
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIO SETTING CONDENSER
1. Install the 2 bolts and 2 radio setting condensers.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL WATER PUMP PULLEY (See INSTALLATION )

Fig 6: Removing Bolts And Radio Setting Condensers
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  Torque: 54 N*m (550 kgf*cm, 40 ft.*lbf)
  
  HINT:
  
  Plate diameter:
  
  Idler pulley cover plate: 33.6 mm (1.32 in.)
  
  No. 2 idler pulley cover plate: 37.8 mm (1.49 in.)
  
  Fig 7: Identifying No. 2 Idler Pulley Cover Plate And No. 2 Idler Pulley Sub-Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing Bolts And No. 2 Timing Gear Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 in the illustration.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
  
  Fig 9: Identifying V-Ribbed Belt Tensioner
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Tighten the other bolts.
  Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
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: Removing Bolts And Engine Mounting Bracket RR
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing Drive Shaft Bearing Bracket (For 2WD)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating Engine Mounting Bracket RH With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
1. Install a new gasket as shown in the illustration.
  
  Fig 13: Locating Exhaust Manifold Sub-Assembly RH With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
  
  Fig 14: Installing Exhaust Manifold Sub-Assembly LH With Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Removing No. 2 Exhaust Manifold Heat Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 MANIFOLD STAY
1. Install the No. 2 manifold stay with the bolt and nut in the order shown in the illustration.
  Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf)
  
  Fig 16: Installing No. 2 Manifold Stay With Bolt And Nut
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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: Locating No. 2 Engine Oil Level Dipstick Guide And O-Rings
  Courtesy 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)
5. Install the engine oil level dipstick.
  
  Fig 18: Locating No. 2 Engine Oil Level Dipstick Guide And Bolt
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
1. Install a new gasket as shown in the illustration.
  
  Fig 19: Locating Exhaust Manifold Sub-Assembly RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

INSTALL INTAKE MANIFOLD

NOTE: DO NOT apply oil to the bolts listed below:

TIGHTENING PART SPECIFICATION

Tightening Parts
Intake Manifold and Cylinder Head Sub-assembly RH
Intake Manifold and Cylinder Head Sub-assembly LH

Fig 20: Installing Exhaust Manifold Sub-Assembly RH With Nuts

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.
Set the intake manifold on the cylinder heads.
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: Disconnecting A/F Sensor Connector Clamp
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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)
INSTALL IGNITION COIL ASSEMBLY (See INSTALLATION )
INSTALL ENGINE HANGERS
1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
  
  Fig 22: Removing Bolt And No. 2 Engine Mounting Stay RH
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  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.
REMOVE ENGINE STAND