INSTALLATION

PROCEDURE

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

2. INSTALL KNOCK SENSOR

3. INSTALL KNOCK SENSOR WIRE

(a) Connect the 2 clamps, 2 knock sensor connectors and knock sensor wire connector.

4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

(a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch assembly. Text in Illustration *1 Adhesive Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

(b) Using a deep socket wrench, install the oil pressure switch.

Torque:

15 N·m {153 kgf·cm, 11 ft·lbf}

NOTICE:

Do not start the engine within 1 hour after installation to prevent oil leaks.

5. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

(a) Install the No. 1 vacuum switching valve with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. INSTALL WATER PUMP PULLEY

7. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

(a) 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}

8. INSTALL NO. 2 TIMING GEAR COVER

(a) Install the No. 2 timing gear cover with the 2 bolts.

Torque:

6.0 N·m {61 kgf·cm, 53 in·lbf}

9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) 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.)

(b) 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}

(c) Tighten the other bolts.

Torque:

43 N·m {438 kgf·cm, 32 ft·lbf}

10. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

(a) Install a new gasket as shown in the illustration.

Text in Illustration

Engine Front

(b) 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}

11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

12. INSTALL NO. 2 MANIFOLD STAY

13. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

(a) Install a new O-ring to the No. 2 engine oil level dipstick guide.

(b) Apply a light coat of engine oil to the O-ring.

(c) Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

(d) Install the No. 2 engine oil level dipstick guide with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(e) Install the engine oil level dipstick.

14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

(a) Install a new gasket as shown in the illustration.

Text in Illustration

Engine Front

(b) 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}

15. INSTALL INTAKE MANIFOLD

NOTICE:

DO NOT apply oil to the bolts listed below:

(a) Set a new gasket on each cylinder head.

(b) Set the intake manifold on the cylinder heads.

(c) 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 FUEL HOSE PROTECTOR

(a) Install the fuel hose protector with the 2 bolts and nut.

Torque:

Bolt :

21 N·m {214 kgf·cm, 15 ft·lbf}

Nut :

10 N·m {102 kgf·cm, 7 ft·lbf}

17. INSTALL NO. 2 ENGINE MOUNTING STAY RH

(a) Install the No. 2 engine mounting stay RH with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

18. INSTALL IGNITION COIL ASSEMBLY

19. INSTALL NO. 1 SURGE TANK STAY

(a) Install the No. 1 surge tank stay with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

20. INSTALL THROTTLE BODY BRACKET

(a) Install the throttle body bracket with the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

22. INSTALL ENGINE HANGERS

(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.

Part No.

Torque:

33 N·m {337 kgf·cm, 24 ft·lbf}

(b) Attach the engine sling device and hang the engine with the chain block.

23. REMOVE ENGINE STAND