Installation
3UR-FE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION
1. INSTALL NOISE FILTER
(a) RH:
Install the noise filter to the cylinder head cover with the bolt.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
(b) LH:
Install the noise filter to the cylinder head cover with the bolt.
Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)
2. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 8 ignition coils with the 8 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 4 bolts.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
4. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Install the mounting bracket with the 4 bolts.
Torque : 35 Nm (357 kgf-cm, 26 ft-lbf)
5. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
(a) Apply adhesive to 2 or 3 threads of the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
(b) Install the water drain cocks as shown in the illustration.
Torque : 30 Nm (306 kgf-cm, 22 ft-lbf)
NOTICE:
* Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.
* Do not loosen the drain cocks to adjust them. If an adjustment is necessary, remove the drain cocks and reinstall them.
(c) Install the water drain cock plugs to the water drain cocks.
Torque : 13 Nm (133 kgf-cm, 10 ft-lbf)
6. INSTALL KNOCK SENSOR
(a) Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
NOTICE:
The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position.
7. INSTALL SEPARATOR CASE
(a) After inserting the pipe on the rear of the separator case into the oil return pipe and the pipe on the front into the ventilation pipe, temporarily install bolt A.
(b) Temporarily install bolt B and tighten bolt A.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(c) Install the bolts labeled C.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Tighten bolt B.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
Standard Bolt:
8. INSTALL ENGINE WIRE
(a) Connect the 3 clamps and 4 knock sensor connectors.
9. INSTALL NO. 3 AIR TUBE Installation
10. INSTALL NO. 2 AIR TUBE Installation
11. INSTALL AIR SWITCHING VALVE ASSEMBLY Installation
12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install the water by-pass pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
13. INSTALL WATER INLET HOUSING Installation
14. INSTALL AIR PIPE SUB-ASSEMBLY
(a) Install the 2 No. 1 air hoses and air pipe with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
15. INSTALL FRONT WATER BY-PASS JOINT Installation
16. INSTALL NO. 1 WATER BY-PASS HOSE Installation
17. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler) Installation
18. INSTALL NO. 1 ENGINE COVER Installation
19. INSTALL NO. 2 ENGINE COVER Installation
20. INSTALL NO. 1 FUEL TUBE
21. INSTALL NO. 2 FUEL TUBE
(a) Install the No. 2 fuel tube with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
22. INSTALL INTAKE MANIFOLD
(a) Place 2 new gaskets on the intake manifold.
(b) Place the intake manifold on the cylinder head.
(c) Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(d) Install the wire bracket to the intake manifold with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(e) Connect the No. 1 ventilation hose.
(f) Connect the 2 water by-pass hoses.
(g) Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
23. INSTALL FUEL INJECTOR ASSEMBLY Installation
24. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH Installation
25. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH Installation
26. CONNECT NO. 1 FUEL TUBE Installation
27. CONNECT NO. 2 FUEL TUBE Installation
28. INSTALL NO. 1 FUEL HOSE
(a) Install the fuel hose Service Precautions.
29. INSTALL NO. 3 ENGINE COVER Installation
30. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY Installation
31. INSTALL ENGINE WIRE
(a) Install the engine wire.
(b) Engine Rear Side:
(1) Install the 3 bolts as shown in the illustration.
Torque : 8.5 Nm (87 kgf-cm, 75 in-lbf)
(2) Connect the 5 clamps.
(3) Connect the 2 air switching valve connectors.
(c) Engine RH Side:
(1) Connect the 7 clamps.
(2) Connect the oil pressure sender gauge connector.
(3) Connect the throttle sensor connector.
(4) Connect the noise filter connector.
(5) Connect the fuel injector connector.
(6) Connect the 2 VVT sensor connectors.
HINT
The wire harnesses on the exhaust side are wrapped with white tape.
(7) Connect the 4 ignition coil connectors.
(8) Connect the 2 camshaft timing control valve connectors.
HINT
The wire harnesses on the exhaust side are wrapped with white tape.
(d) Engine LH Side:
(1) Connect the 7 clamps and install the engine wire with the bolt.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)
(2) Connect the noise filter connector.
(3) Connect the fuel injector connector.
(4) Connect the engine coolant temperature sensor connector.
(5) Connect the purge VSV connector.
(6) Connect the vacuum switching valve connector (for ACIS).
(7) Connect the camshaft position sensor connector.
(8) Connect the 2 VVT sensor connectors.
HINT
The wire harnesses on the exhaust side are wrapped with white tape.
Connect the 4 ignition coil connectors.
Connect the 2 camshaft timing control valve connectors.
HINT
The wire harnesses on the exhaust side are wrapped with white tape.