1. INSTALL NOISE FILTER |
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Install the 2 noise filters to the cylinder head cover with the 2 bolts.
Torque:
7.0 N*m{ 71 kgf*cm , 62 in.*lbf }
2. INSTALL IGNITION COIL ASSEMBLY |
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Install the 8 ignition coils with the 8 bolts.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH |
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Install the mounting bracket with the 4 bolts.
Torque:
35 N*m{ 357 kgf*cm , 26 ft.*lbf }
4. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH |
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Install the mounting bracket with the 4 bolts.
Torque:
35 N*m{ 357 kgf*cm , 26 ft.*lbf }
5. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY |
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Apply adhesive to 2 or 3 threads of the drain cocks.
Adhesive:
Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
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Install the water drain cocks as shown in the illustration.
Torque:
30 N*m{ 306 kgf*cm , 22 ft.*lbf }
Text in Illustration *A LH *B RH *a Front 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.
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Install the water drain cock plugs to the water drain cocks.
Torque:
13 N*m{ 133 kgf*cm , 10 ft.*lbf }
6. INSTALL KNOCK SENSOR |
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Install the 4 sensors with the 4 bolts so that the sensors are angled as shown in the illustration.
Torque:
20 N*m{ 204 kgf*cm , 15 ft.*lbf }
Text in Illustration *1 Bank 2 Sensor 1 *2 Bank 1 Sensor 1 *3 Bank 2 Sensor 2 *4 Bank 1 Sensor 2 *a Front *b Rear *c Top NOTICE:
The acceptable installation angle of the sensor is between 10° upward and downward from the horizontal position.
7. INSTALL SEPARATOR CASE |
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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.
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Temporarily install bolt B and tighten bolt A.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
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Install the bolts labeled C.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
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Tighten bolt B.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
Standard Bolt:
Item Length Thread Diameter Bolt A 25 mm (0.984 in.) 6 mm (0.236 in.) Bolt B and C 16 mm (0.630 in.) 6 mm (0.236 in.)
8. INSTALL SENSOR WIRE |
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Connect the 3 clamps and 4 knock sensor connectors.
9. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY |
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Install the water by-pass pipe with the 2 bolts.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
10. INSTALL WATER INLET HOUSING |
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Install a new gasket to the timing chain cover.
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Install the water inlet with the 3 bolts.
Torque:
21 N*m{ 214 kgf*cm , 15 ft.*lbf }
Text in Illustration *1 Gasket
11. INSTALL FRONT WATER BY-PASS JOINT |
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Install 2 new gaskets and the water by-pass joint with the 4 nuts.
Torque:
21 N*m{ 214 kgf*cm , 15 ft.*lbf }
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Connect the No. 2 water by-pass hose to the water by-pass joint.
12. INSTALL NO. 1 WATER BY-PASS HOSE |
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Install the No. 1 water by-pass hose by connecting the hose to the water inlet housing and front water by-pass joint.
13. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY |
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Connect the 4 hoses.
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Install the water by-pass pipe with the 3 bolts.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
14. INSTALL NO. 1 ENGINE COVER |
15. INSTALL NO. 2 ENGINE COVER |
16. INSTALL NO. 1 FUEL TUBE |
17. INSTALL NO. 2 FUEL TUBE |
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Install the No. 2 fuel tube with the 2 bolts.
Torque:
10 N*m{ 102 kgf*cm , 7 ft.*lbf }
18. INSTALL INTAKE MANIFOLD |
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Place 2 new gaskets on the intake manifold.
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Place the intake manifold on the cylinder head.
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Install and uniformly tighten the 8 bolts and 2 nuts in several steps.
Torque:
21 N*m{ 214 kgf*cm , 15 ft.*lbf }
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Install the wire bracket to the intake manifold with the bolt.
Torque:
8.0 N*m{ 82 kgf*cm , 71 in.*lbf }
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Connect the No. 1 ventilation hose.
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Connect the 2 water by-pass hoses.
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Connect the ventilation hose to the ventilation pipe of the cylinder head cover LH and RH.
19. INSTALL FUEL INJECTOR ASSEMBLY |
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Attach the 3 clamps to install the No. 6 wire harness to the delivery pipe RH.
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Attach the 3 clamps to install the No. 7 wire harness to the delivery pipe LH.
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Apply gasoline or spindle oil to a new O-ring and install it to the injector.
NOTICE:
Make sure that there is no damage or foreign material in the groove of the injector when installing the O-ring.
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Connect the injector connector.
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Install the injector to the delivery pipe as shown in the illustration.
Text in Illustration *a CORRECT *b INCORRECT NOTICE:
- Make sure that there are no scratches or foreign matter in or around the insertion hole of the delivery pipe.
- When inserting the injector, be careful not to damage the O-ring.
- Attach the part of the injector labeled B between the parts of the delivery pipe labeled A.
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Check that each injector is installed to the delivery pipe facing the direction shown in the illustration.
Text in Illustration *A Fuel Delivery Pipe RH *B Fuel Delivery Pipe LH
20. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY RH |
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Install the 2 delivery pipe spacers and 4 insulators to the cylinder head RH.
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Install the delivery pipe (with injectors) to the cylinder head RH.
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Install the 2 bolts.
Torque:
21 N*m{ 214 kgf*cm , 15 ft.*lbf }
NOTICE:
Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A.
Text in Illustration *1 Delivery Pipe *2 Injector *a CORRECT *b INCORRECT
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Connect the No. 6 wire harness connector.
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Connect the ventilation hose.
21. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY LH |
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Install the 2 delivery pipe spacers and 4 insulators to the cylinder head LH.
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Install the delivery pipe (with injectors) to the cylinder head LH.
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Install the 2 bolts.
Torque:
21 N*m{ 214 kgf*cm , 15 ft.*lbf }
NOTICE:
Make sure that the part of the injector labeled B is between the parts of the delivery pipe labeled A.
Text in Illustration *1 Delivery Pipe *2 Injector *a CORRECT *b INCORRECT
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Connect the No. 7 wire harness connector.
22. CONNECT NO. 1 FUEL TUBE |
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LH Side:
Connect the No. 1 fuel tube to the delivery pipe LH .
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Connect the No. 1 fuel tube to the delivery pipe RH (for metallic type) .
23. CONNECT NO. 2 FUEL TUBE |
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Connect the No. 2 fuel tube to the fuel pressure regulator .
24. INSTALL NO. 1 FUEL HOSE |
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Install the fuel hose .
25. INSTALL NO. 3 ENGINE COVER |
26. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY |
27. INSTALL ENGINE WIRE |
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Install the engine wire.
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Engine Rear Side:
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Install the 3 bolts as shown in the illustration.
Torque:
8.5 N*m{ 87 kgf*cm , 75 in.*lbf }
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Connect the 5 clamps.
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Connect the sensor wire connector.
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Engine RH Side:
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Connect the 9 clamps.
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Connect the oil pressure sender gauge connector.
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Connect the throttle sensor connector.
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Connect the noise filter connector.
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Connect the fuel injector connector.
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Connect the 2 VVT sensor connectors.
HINT:
The wire harnesses on the exhaust side are wrapped with white tape.
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Connect the 4 ignition coil connectors.
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Connect the 2 camshaft timing control valve connectors.
HINT:
The wire harnesses on the exhaust side are wrapped with white tape.
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Engine LH Side:
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Connect the 7 clamps and install the engine wire with the bolt.
Torque:
20 N*m{ 204 kgf*cm , 15 ft.*lbf }
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Connect the noise filter connector.
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Connect the fuel injector connector.
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Connect the engine coolant temperature sensor connector.
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Connect the purge VSV connector.
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Connect the vacuum switching valve connector (for ACIS).
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Connect the camshaft position sensor connector.
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Connect the 2 VVT sensor connectors.
HINT:
The wire harnesses on the exhaust side are wrapped with white tape.
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Connect the 4 ignition coil connectors.
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Connect the 2 camshaft timing control valve connectors.
HINT:
The wire harnesses on the exhaust side are wrapped with white tape.
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