Engine Assembly, Intake Manifold, Exhaust Manifold: Installation

1. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.

   Torque: 20 N*m (200 kgf*cm, 14 ft.*lbf) 

   Fig 1: Identifying EFI Engine Coolant Temperature Sensor

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1. Install the engine oil level sensor and a new gasket with the 4 bolts.

   Torque: 8.2 N*m (84 kgf*cm, 73 in.*lbf) 

Fig 2: Locating Oil Level Sensor And Gasket

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1. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure switch.

   Adhesive: 

   Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent 

   Fig 3: Applying Adhesive To Threads Of Oil Pressure Switch

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 24 mm deep socket wrench, install the oil pressure switch.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   NOTE: Do not start the engine within 1 hour after installation to prevent oil leaks.
   Fig 4: Identifying Oil Pressure Switch

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1. Install the No. 1 vacuum switching valve with the bolt.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 5: Identifying No. 1 Vacuum Switching Valve And Bolt

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1. Install the 2 radio setting condensers with the 2 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

   Fig 6: Locating Bolts And Radio Setting Condensers

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1. Install the No. 1 engine mounting bracket front LH with the 6 bolts.

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

Fig 7: Locating Engine Mounting Bracket Front

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1. Install the No. 2 idler pulley sub-assembies and cover plates with the bolts.

   Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

   Fig 8: Identifying Plate And No. 2 Idler Pulley Sub-Assembly

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1. Install the No. 2 timing gear cover with the 2 bolts.

   Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) 

   Fig 9: Locating No. 2 Timing Gear Cover With Bolts

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1. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

   HINT:

   Each bolt length is as follows:

   1. 70 mm (2.76 in.)
   2. 33 mm (1.30 in.)
2. Install the V-ribbed belt tensioner 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) 

3. Tighten the other bolts.

   Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

   Fig 10: Identifying V-Ribbed Belt Tensioner

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1. Install the drive shaft bearing bracket with the 3 bolts.

   Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

   Fig 11: Locating Drive Shaft Bearing Bracket

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1. Install the engine mounting bracket RH with the 3 bolts.

   Torque: 54 N*m (551 kgf*cm, 40 ft.*lbf) 

   Fig 12: Locating Engine Mounting Bracket RH With Bolts

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1. Install a new gasket as shown in the illustration.
   Fig 13: Locating Exhaust Manifold Sub-Assembly RH With Nuts

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2. Install the exhaust manifold sub-assembly LH with the 6 nuts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 14: Locating Exhaust Manifold Sub-Assembly

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 2 insulator with the 3 bolts.

   Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

   Fig 15: Locating Insulator With Nuts

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1. Install the No. 2 manifold stay with the bolt and nut.

   Torque: 34 N*m (347 kgf*cm, 25 ft.*lbf) 

   Fig 16: Locating No. 2 Manifold Stay With Bolt And Nut

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1. Install 2 new O-rings to the oil level gauge guide.
2. Apply a light coat of engine oil to the O-rings.
3. Push in the oil level gauge guide end into the guide hole.
4. Install the oil level gauge guide No. 1 with the bolt.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

5. Install the oil level gauge guide No. 2 with the bolt.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

6. Install the oil level gauge.
   Fig 17: Locating Oil Level Gauge Guide No. 1 With Bolt

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1. Install a new gasket as shown in the illustration.
   Fig 18: Locating Exhaust Manifold Sub-Assembly RH

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2. Install the exhaust manifold sub-assembly RH with the 6 nuts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 19: Locating Exhaust Manifold Sub-Assembly With Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set a new gasket on each cylinder head.
   NOTE:

   • Align the port holes of the gasket and cylinder head.
   • Make sure that the gasket is installed in the correct direction.
2. Set the intake manifold on the cylinder heads.
3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 20: Identifying Cylinder Heads Gasket

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1. Install the No. 2 engine mounting stay RH with the bolt.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

1. Install the 6 ignition coil assemblies with the 6 bolts.

   Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

1. Install a new gasket to the intake air surge tank.
2. Using a 5 mm hexagon socket wrench, install the 4 bolts and 2 nuts.

   Torque: Bolt 

   18 N*m (184 kgf*cm, 13 ft.*lbf) 

   Nut 

   16 N*m (163 kgf*cm, 12 ft.*lbf) 

3. Install the throttle body bracket, No. 1 surge tank stay and 4 bolts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) 

   Fig 21: Locating Throttle Body Bracket, No. 1 Surge Tank Stay And Bolts

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4. Connect the connector.
   Fig 22: Locating Connector

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5. Install the vacuum hose clamp with the bolt.

   Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) 

6. Connect the No. 1 ventilation hose.
   Fig 23: Locating Vacuum Hose Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Install the clamp and connect the throttle with motor body assembly connector.
8. Connect the vapor feed hose.
9. Connect the 2 water by-pass hoses to the throttle with motor body assembly.
Fig 24: Locating Water Bypass Hoses To Throttle Body
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HINT:

See INSTALLATION .

1. Install the engine mounting insulators RH and LH with the 2 nuts.

   Torque: 95 N*m (969 kgf*cm, 70 ft.*lbf) 

   Fig 25: Locating Engine Mounting Insulators RH And LH With Nuts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the engine mounting insulator FR with the bolt.

   Torque: 87 N*m (887 kgf*cm, 64 ft.*lbf) 

3. Connect the cable with the bolt.

   Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf) 

   Fig 26: Locating Engine Mounting Insulator

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Connect the 2 connectors and 2 clamps.
   Fig 27: Locating Connectors And Clamps

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5. Connect the 2 clamps.
   Fig 28: Locating Clamps

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1. Install the vane pump with the 2 bolts.

   Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf) 

2. Install the pressure feed tube clamp bolt.

   Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 

3. Connect the power steering oil pressure switch connector.
   Fig 29: Locating Vane Pump And Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Set the engine assembly with transaxle on the engine lifter.
2. Install the engine assembly to the vehicle.
3. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.

   Torque: A 

   85 N*m (867 kgf*cm, 63 ft.*lbf) 

   B 

   32 N*m (329 kgf*cm, 24 ft.*lbf) 

4. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.

   Torque: C 

   85 N*m (867 kgf*cm, 63 ft.*lbf) 

   D 

   32 N*m (329 kgf*cm, 24 ft.*lbf) 

   Fig 30: Locating Front Suspension Member Brace Rears

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the cooler compressor with the 4 bolts.
2. Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.

   Torque: 25 N*m (250 kgf*cm, 18 ft.*lbf) 

3. Install the 2 connector clamps.

Fig 31: Locating Connector Clamps

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 1 exhaust pipe support bracket with the 2 nuts.

   Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf) (bolt) 

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

HINT:

Use the same procedure described for the LH side.

1. Connect the oil reservoir to pump hose.
   Fig 32: Locating Oil Reservoir To Pump Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the return tube sub-assembly.
   Fig 33: Locating Return Tube Sub-Assembly

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1. Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
   NOTE:

   • Check for damage or contamination on the connected part of the pipe.
   • Check if the pipe and the connector are securely connected by trying to pull them apart.
2. Install the No. 1 fuel pipe clamp.
   Fig 34: Pushing Fuel Tube Connector To Fuel Pipe

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the cable to the transaxle with the clip and nut.

   Torque: 13 N*m (130 kgf*cm, 9 ft.*lbf) 

   Fig 35: Locating Transmission Control Cable Assembly Clip And Nut

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the clamp to the bracket with the bolt.

   Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

   Fig 36: Locating Engine Wire Bolt And Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the 2 clamps to the body with the 2 bolts.

   Torque: Bolt A 

   12 N*m (123 kgf*cm, 9 ft.*lbf) 

   Bolt B 

   8.4 N*m (85 kgf*cm, 74 in.*lbf) 

   Fig 37: Locating Body Bolts And Clamps

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the engine wire connectors to the engine room junction block. Then, install it with the nut.

   Torque: 8.4 N*m (85 kgf*cm, 74 in.*lbf) 

   Fig 38: Locating Engine Wire Connectors

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Connect the heater inlet water hose.

1. Connect the heater outlet water hose.
   Fig 39: Locating Heater Outlet Water Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the oil cooler inlet hose with the clamp.

1. Install the oil cooler outlet hose with the clamp.
   Fig 40: Locating Oil Cooler Outlet Hose Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the radiator hose inlet with the clamp.
   Fig 41: Locating Radiator Hose Inlet Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the radiator hose outlet with the clamp.
   Fig 42: Locating Radiator Hose Outlet

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the check valve to brake booster hose with the clamp.
   Fig 43: Locating Brake Booster Hose Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 1 fuel vapor feed hose with the clamp.
   Fig 44: Locating No. 1 Fuel Vapor Feed Hose

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the engine moving control rod with the 4 bolts.
2. Tighten the 4 bolts.

   Torque: 38 N*m (388 kgf*cm, 28 ft.*lbf) 

   Fig 45: Locating Engine Moving Control Rod Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Temporarily install the No. 2 engine mounting stay RH with the bolt and 2 nuts.
2. Tighten the bolt and 2 nuts.

   Torque: Bolt 

   38 N*m (388 kgf*cm, 28 ft.*lbf) 

   Nut 

   23 N*m (235 kgf*cm, 17 ft.*lbf) 

   Fig 46: Identifying No. 2 Mounting Stay RH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the intake air resonator with the bolt and clip.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

   Fig 47: Locating Intake Air Resonator Sub-Assembly Bolt And Clip

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the battery and battery tray.
2. Install the battery clamp with the bolt and nut.

   Torque: Bolt 

   9.0 N*m (92 kgf*cm, 80 in.*lbf) 

   Nut 

   3.5 N*m (36 kgf*cm, 31 in.*lbf) 

   Fig 48: Locating Battery Bolts

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the No. 1 air cleaner inlet with the bolt.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

   Fig 49: Locating No. 1 Air Cleaner Inlet Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the air cleaner case with the 3 bolts.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

2. Connect the vacuum hose and hose clamp.

Fig 50: Locating Vacuum Hose And Hose Clamp

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the air cleaner inlet with the clamp and 2 bolts.

   Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

   Fig 51: Identifying Bolts, Clamp And Air Cleaner Inlet

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Torque: 103 N*m (1,050 kgf*cm, 76 ft.*lbf) 

Torque: 6.9 N*m (70 kgf*cm, 61 in.*lbf) 

HINT:

See AUTOMATIC TRANSAXLE FLUId

HINT:

See FRONT WHEEL ALIGNMENT .

1. Fit the 3 retainers and install the V-bank cover.
   Fig 53: Identifying V-Bank Cover

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1. Install the engine room side cover LH with the 6 clips.
2. Install the hood hinge cover LH.
   Fig 54: Identifying Hood Hinge Cover LH With Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the engine room side cover RH with the 5 clips.
   NOTE: When installing the engine room side cover RH, make sure that the engine coolant reservoir hose is positioned as shown in the illustration.
2. Install the hood hinge cover RH.
   Fig 55: Identifying Engine Room Side Cover RH With Clips

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Install the intake duct seal with the 7 clips.

Fig 56: Locating Intake Duct Seal With Clips

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HINT:

See TEST MODE PROCEDURE

1. Perform initialization procedure (See INITIALIZATION ).
   NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal.