Installation
ENGINE ASSEMBLYCOMPONENTS (Part 1):
COMPONENTS (Part 2):
COMPONENTS (Part 3):
COMPONENTS (Part 4):
COMPONENTS (Part 5):
COMPONENTS (Part 6):
COMPONENTS (Part 7):
COMPONENTS (Part 8):
COMPONENTS (Part 9):
COMPONENTS (Part 10):
COMPONENTS (Part 11):
COMPONENTS (Part 12):
INSTALLATION
1. INSTALL VENTILATION VALVE SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the ventilation valve.
Torque: 27 N*m (275 kgf*cm, 20 ft.*lbf)
HINT: After tightening the valve to the specified torque, turn the ventilation valve clockwise with the port facing in the direction indicated in the illustration.
(c) Install the ventilation valve cover to the ventilation valve.
(d) Connect the ventilation hose to the ventilation valve.
2. INSTALL OIL COOLER ASSEMBLY
(a) Place a new gasket into the groove of the oil cooler.
(b) Apply a light coat of engine oil to the gasket.
(c) Install the oil cooler assembly with the 2 bolts and nut.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
3. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Place a new gasket on the cylinder head.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in diagonally.
Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf)
(c) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Place a new gasket on the cylinder head.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts diagonally.
Torque: 44 N*m (450 kgf*cm, 33 ft.*lbf)
(c) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
5. INSTALL WATER BY-PASS JOINT FR
(a) With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.
(b) Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
6. INSTALL WATER INLET HOUSING
7. INSTALL KNOCK SENSOR
8. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly with the 2 bolts.
Torque: 39 N*m (400 kgf*cm, 29 ft.*lbf)
(b) Connect the No. 2 engine wire.
Torque: 9.8 N*m (100 kgf*cm, 7.2 ft.*lbf)
9. INSTALL AIR PUMP ASSEMBLY WITH BRACKET
10. INSTALL WATER BY-PASS JOINT RR
(a) With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.
(b) Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
11. INSTALL NO. 2 AIR SWITCHING VALVE
12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install a new O-ring to the water by-pass pipe.
(b) Apply soapy water to the O-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the bolt.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)
13. INSTALL VVT SENSOR
(a) Install the VVT sensors with the 2 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
14. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 6.5 N*m (65 kgf*cm, 58 in.*lbf)
15. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt and the stud bolt.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
16. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 8 ignition coils with the 8 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
17. INSTALL FAN BRACKET SUB-ASSEMBLY
(a) Install the fan bracket with the 2 bolts and 2 nuts.
Torque:
12 mm head 16 N*m (160 kgf*cm, 12 ft.*lbf)
14 mm head 32 N*m (326 kgf*cm, 24 ft.*lbf)
18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the v-ribbed belt tensioner with the bolt and 2 nuts.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
19. INSTALL NO. 2 TIMING BELT COVER SUBASSEMBLY
(a) Install the No. 2 timing belt cover sub-assembly with the 2 bolts.
Torque: 16 N*m (160 kgf*cm, 12 ft.*lbf)
20. INSTALL NO. 2 TIMING CHAIN OR BELT COVER
(a) Install the timing chain or belt cover with the nut and 3 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
21. INSTALL NO. 3 TIMING BELT COVER SUBASSEMBLY LH
(a) Install the timing belt cover sub-assembly with the 4 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
(b) Install the camshaft position sensor connector and grommet to the timing belt cover.
22. INSTALL PUMP BRACKET
(a) Install the pump bracket with the 4 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
23. INSTALL OIL COOLER PIPE
(a) Install the oil cooler pipe with the bolt and nut.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
(b) Connect the 3 hoses.
24. INSTALL DRIVE PLATE & RING GEAR SUBASSEMBLY
25. INSTALL HEATER HOSE
26. INSTALL GENERATOR ASSEMBLY
27. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a) Install the engine-mounting bracket and engine-mounting insulator with the 4 bolts.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
28. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH
(a) Install the engine-mounting bracket and engine-mounting insulator with the 4 bolts.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
29. INSTALL NO. 2 ENGINE WIRE
(a) Install the engine wire protector with the nut and 2 bolts.
(b) Connect the ground cable wire clamp with the bolt.
30. INSTALL NO. 2 WIRING HARNESS HEAT INSULATOR
(a) Install the wiring harness heat insulator with the 2 bolts.
Torque: 17 N*m (175 kgf*cm, 13 ft.*lbf)
31. INSTALL INTAKE MANIFOLD ASSEMBLY
32. INSTALL ENGINE WIRE
33. INSTALL ENGINE ASSEMBLY
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the engine assembly into the engine compartment.
(c) Attach the engine mounting brackets to the frame brackets.
(d) Install the engine mounting brackets with the 4 nuts and 4 bolts.
Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf)
(e) Remove the engine chain hoist.
34. INSTALL ENGINE WIRE
35. CONNECT HEATER HOSE
36. INSTALL OIL LEVEL GAUGE GUIDE
(a) Install a new O-ring to the oil level gauge guide.
(b) Install the oil level gauge guide with the bolt.
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)
37. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY
(a) Install a new O-ring to the oil filler tube subassembly.
(b) Install the transmission oil filler tube sub-assembly with the bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
38. INSTALL FAN WITH FLUID COUPLING
(a) Install the fan pulley to the engine.
(b) Install the fan with fluid coupling with the 4 nuts.
Torque: 29 N*m (296 kgf*cm, 21 ft.*lbf)
39. INSTALL COMPRESSOR
(a) Install the compressor with the stay, nut and 3 bolts.
Torque:
Bolt 47 N*m (475 kgf*cm, 34 ft.*lbf)
Nut 25 N*m (255 kgf*cm, 18 ft.*lbf)
(b) Connect the compressor connector.
40. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly with the nut and 2 bolts.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)
41. INSTALL FAN AND GENERATOR V BELT
42. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
43. CONNECT FUEL HOSE
44. CONNECT NO. 2 FUEL HOSE
45. INSTALL FAN SHROUD
(a) Install the fan shroud with the fan into the engine room.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
46. INSTALL RADIATOR ASSEMBLY
47. ADD ENGINE COOLANT
48. ADD ENGINE OIL
49. INSTALL ENGINE UNDER COVER ASSEMBLY REAR
50. INSTALL NO. 1 ENGINE UNDER COVER SUBASSEMBLY
51. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner assembly with the 3 bolts.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(b) Connect the wire harness clamp and the ground cable.
Torque: 8.3 N*m (85 kgf*cm, 73 in.*lbf)
52. INSTALL AIR CLEANER HOSE ASSEMBLY
53. INSTALL ENGINE ROOM SIDE COVER LH
54. INSTALL ENGINE ROOM COVER SIDE
55. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Install the V-bank cover sub-assembly with the 2 nuts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)
56. INSTALL HOOD SUB-ASSEMBLY
(a) Install the hood with the 4 bolts.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(b) Connect the hood damper.
Torque: 18 N*m (180 kgf*cm, 13 ft.*lbf)
(c) Connect the windshield washer hose.
57. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
58. CHECK FOR ENGINE COOLANT LEAKAGE
59. CHECK FOR EXHAUST GAS LEAKAGE
60. CHECK FOR FUEL LEAK
61. INSPECT AUTOMATIC TRANSMISSION FLUID
62. CHECK FOR ENGINE OIL LEAKAGE