Part 1
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):
COMPONENTS (Part 13):
COMPONENTS (Part 14):
COMPONENTS (Part 15):
COMPONENTS (Part 16):
INSTALLATION
1. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT LH
(a) Install the mounting bracket with the 4 bolts.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
HINT: The LH mounting bracket is marked with an "L".
2. INSTALL NO. 1 ENGINE MOUNTING BRACKET FRONT RH
(a) Install the mounting bracket with the 4 bolts.
Torque: 36 N*m (370 kgf*cm, 27 ft.*lbf)
HINT: The RH mounting bracket is marked with an "R".
3. INSTALL NO. 2 WIRING HARNESS HEAT INSULATOR
4. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
5. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
6. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
(b) Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf)
7. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Install the heat insulator with the 4 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
8. INSTALL ENGINE WIRE
9. INSTALL ENGINE OIL LEVEL SENSOR
10. INSTALL CRANKSHAFT POSITION SENSOR
11. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
12. INSTALL IGNITION COIL
(a) Install the 8 ignition coils with the 8 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
13. INSTALL NO. 2 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
14. INSTALL NO. 1 ENGINE HANGER
(a) Install the engine hanger with the 2 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf)
15. INSTALL VVT SENSOR
(a) Install the 2 sensors with the 2 bolts.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
16. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the sensor with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
17. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY RH
(a) Install a new O-ring to the oil control valve.
(b) Install the oil control valve with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(c) Connect the oil control valve connector.
18. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY LH
(a) Install a new O-ring to the oil control valve.
(b) Install the oil control valve with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(c) Connect the oil control valve connector.
19. INSTALL OIL DIPSTICK AND GUIDE
20. INSTALL STARTER ASSEMBLY
21. INSTALL KNOCK SENSOR
(a) Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf)
(b) Connect the 2 knock sensor connectors.
22. 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 (184 kgf*cm, 13 ft.*lbf)
(e) Install the wire clamp to the bracket of the water bypass pipe.
23. INSTALL REAR WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
24. INSTALL FRONT WATER BY-PASS JOINT
(a) Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(b) Connect the ECT sensor connector.
25. INSTALL WATER INLET HOUSING
26. INSTALL GENERATOR ASSEMBLY
27. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY LH
28. INSTALL NO. 3 TIMING BELT COVER SUB-ASSEMBLY RH
29. INSTALL INTAKE MANIFOLD
(a) Place 2 new gaskets on the cylinder heads with the white mark facing outward.
NOTICE: Be careful of the installation direction.
(b) Install the intake manifold assembly with the 6 bolts and 4 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(c) Connect the 8 injector connectors.
(d) Install the engine wire protector (rear side) with the 2 bolts.
(e) Install the engine wire protector (LH side) with the 4 bolts.
(f) Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
(g) Install the No. 4 V-bank cover with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(h) Install the No. 1 V-bank cover bracket with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(i) Connect the VSV connector for ACIS.
(j) Install the No. 3 V-bank cover bracket with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(k) Install the No. 2 V-bank cover bracket with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(l) Install the purge VSV to the intake manifold with the bolt.
Torque: 7.5 N*m (76 kgf*cm, 66 in.*lbf)
(m) Connect the purge hose to the purge VSV.
(n) Connect the purge VSV connector.
30. INSTALL THROTTLE BODY ASSEMBLY
(a) Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
(b) Connect the water by-pass hoses.
31. REMOVE ENGINE STAND
32. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
HINT: If any one of the mounting bolts is broken or deformed, replace it.
(a) Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
(b) Install the front spacer, drive plate and rear spacer on the crankshaft.
(c) Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque: 49 N*m (500 kgf*cm, 36 ft.*lbf)
If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.
(d) Mark the mounting bolt with paint.
(e) Retighten the mounting bolt by 90° in the numerical order shown.
(f) Check that the painted mark is now at a 90° angle.
33. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
(a) Check the torque converter clutch installation.
(b) Install the automatic transmission to the engine with the 9 bolts.
Torque: 37 N*m (377 kgf*cm, 27 ft.*lbf) for bolt A
71 N*m (724 kgf*cm, 52 ft.*lbf) for bolt B
HINT:
^ Make sure that the mark is positioned as shown in the illustration.
^ Bolt head size: 14 mm for bolt A 17 mm for bolt B
^ Bolt (B) will be tightened with the wire harness clamp.
(c) Hold the crankshaft pulley bolt with a wrench and install the 6 torque converter clutch mounting bolts.
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)
HINT: First install the black colored bolt and then the remaining 5 bolts.
34. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover with the 2 bolts.
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
35. INSTALL OIL COOLER TUBE
(a) Temporarily install the oil cooler outlet tube.
(b) Temporarily install the oil cooler inlet tube.
(c) Install the 3 clamps with the 3 bolts.
SST 09023-12701
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(d) Using SST, tighten the oil cooler outlet tube.
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) for use without SST
39 N*m (398 kgf*cm, 29 ft.*lbf) for use with SST
HINT:
^ Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
^ Make sure SST and a wrench are connected in a straight line.
(e) Using SST, tighten the oil cooler inlet tube.
SST 09023-12701
Torque: 44 N*m (449 kgf*cm, 32 ft.*lbf) for use without SST
39 N*m (398 kgf*cm, 29 ft.*lbf) for use with SST
HINT:
^ Use a torque wrench with a fulcrum length of 460 mm (18.11 in.).
^ Make sure SST and a wrench are connected in a straight line.
36. CONNECT WIRE HARNESS
(a) Connect the 2 speed sensor connectors.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch connector.
(d) Install the wire harness clamps with the 5 bolts.
Torque: 71 N*m (724 kgf*cm, 52 ft.*lbf) for bolt A 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt B
HINT: Bolt (A) is tightened to the transmission housing.