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Engine Unit: Installation: Installation

  1. INSTALL WIRING HARNESS CLAMP BRACKET 
    1. Install the wiring harness clamp bracket to the cylinder head cover with the bolt.

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

    2. Install the wiring harness clamp bracket to the cylinder head with the bolt.

      Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf) 

    3. Install the wiring harness clamp bracket to the cylinder block with the bolt.

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

  2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    Fig 1: Identifying Belt Tensioner Bolts
    GTY346970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the V-ribbed belt tensioner and engine cover bracket with the 2 bolts.
      TEXT IN ILLUSTRATION

      *1 Stopper
      NOTE:

      Attach stopper of the bracket to the belt tensioner.

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

  3. INSTALL NO. 2 IDLE PULLEY ASSEMBLY WITH BRACKET 
    Fig 2: Identifying No. 2 Idle Pulley Bracket Bolts
    GTY344453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Temporarily install the No. 2 idle pulley with bracket with the 4 bolts.
    2. Fully tighten the 4 bolts in the order shown in the illustration.

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

  4. INSTALL NO. 1 WATER BY-PASS PIPE 
    Fig 3: Identifying No. 2 Water By-Pass Hose, No. 1 Water By-Pass Pipe, And Water By-Pass Hose
    GTY345849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the water by-pass hose to the water inlet with the clip.
      TEXT IN ILLUSTRATION

      *1 Water By-Pass Hose
      *2 No. 1 water by-pass pipe
      *3 No. 2 Water By-Pass Hose
      *4 Protector
      *5 Clip
      NOTE:

      Install the clip so that its claws face away from the engine.

    2. Temporarily install the No. 1 water by-pass pipe with the 3 bolts.
    3. Fully tighten the 3 bolts in the order shown in the illustration.

      Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) 

    4. Engage the No. 2 water by-pass hose to the 3 clamps as shown in the illustration.
  5. INSTALL NO. 2 VENTILATION HOSE 
    Fig 4: Identifying No. 2 Ventilation Hose Clamp
    GTY346772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the ventilation hose to the cylinder head with the clip.
      TEXT IN ILLUSTRATION

      *a View A
      *b Upper
      *c Clip center installation range
      *d Paint mark of the hose
      NOTE:
      • Install the clip so that its claws are within the clip center installation range.
      • The protrusion of the head cover should overlap the paint mark of the hose.
  6. INSTALL VENTILATION HOSE 
    Fig 5: Identifying Ventilation Hose Clamp
    GTY344287Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the ventilation hose to the cylinder head with the clip.
      TEXT IN ILLUSTRATION

      *a View A
      *b Left
      *c Rear
      *d Clip center installation range
      *e Paint mark of the hose
      NOTE:

      Install the clip so that its claws are within the clip center installation range.

  7. INSTALL NO. 1 IGNITION COIL 
    1. Install the 4 ignition coils with the 4 bolts.

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

  8. INSTALL INJECTOR VIBRATION INSULATOR  . Refer to INSTALLATION - Step 1
  9. INSTALL NO. 1 DELIVERY PIPE SPACER  . Refer to INSTALLATION - Step 2
  10. INSTALL FUEL INJECTOR ASSEMBLY  . Refer to INSTALLATION - Step 3
  11. INSTALL FUEL DELIVERY PIPE  . Refer to INSTALLATION - Step 4
  12. INSTALL EGR HOLE COVER PLATE 
    1. Install a new EGR valve gasket onto the cylinder head.
    2. Install the EGR hole cover plate with the 3 nuts.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  13. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the oil level dipstick guide.

      HINT: 

      Apply engine oil to the O-ring and install the oil level dipstick guide into the oil pan.

    2. Temporarily install the engine oil level dipstick guide with the 2 bolts.
      Fig 6: Identifying Engine Oil Level Dipstick Guide Bolts
      GTY345098Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fully tighten the 2 bolts in the order shown in the illustration.

      Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) 

  14. INSTALL ENGINE OIL LEVEL DIPSTICK 
  15. INSTALL NO. 4 ENGINE WIRE 
    1. Engage the 7 clamps and install the No. 4 engine wire.
    2. Install the ground bolt.

      Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf) 

    3. Connect the 4 fuel injector connectors.
    4. Connect the 4 ignition coil connectors.
    5. Connect the 2 camshaft timing oil control valve connectors.
  16. INSTALL INTAKE MANIFOLD ASSEMBLY 
    1. Install a new No. 2 intake manifold to head gasket onto the cylinder head.
    2. Temporarily install the intake manifold with the 3 bolts and 2 nuts.
      Fig 7: Identifying Intake Manifold Nuts And Bolts
      GTY344705Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fully tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  17. INSTALL INTAKE MANIFOLD STAY 
    Fig 8: Identifying Intake Manifold Stay Bolts
    GTY344262Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Temporarily install the intake manifold stay with the 2 bolts.
    2. Fully tighten the 2 bolts in the order shown in the illustration.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  18. CONNECT NO. 4 WATER BY-PASS HOSE 
    Fig 9: Identifying No. 4 Water By-Pass Hose Clip
    GTY346195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the No. 4 water by-pass hose to the EGR hole cover plate with the clip.
      TEXT IN ILLUSTRATION

      *a View A
      *b Upper
      *c Clip center installation range
      *d Paint mark of the hose
      NOTE:

      Install the clip so that its claws are within the clip center installation range.

  19. CONNECT NO. 2 WATER BY-PASS HOSE 
    Fig 10: Identifying No. 2 Water By-Pass Hose Clip
    GTY347361Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the No. 2 water by-pass hose to the throttle body with the clip.
      TEXT IN ILLUSTRATION

      *a View A
      *b Upper
      *c Clip installation range
      *d Paint mark of the hose
      NOTE:
      • Install the clip so that its claws are within the clip installation range.
      • Line up the rib of the throttle with motor body assembly with the center of the paint mark.
  20. CONNECT VENTILATION HOSE 
    Fig 11: Identifying Ventilation Hose Clip
    GTY344382Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Connect the ventilation hose to the intake manifold with the clip.
      TEXT IN ILLUSTRATION

      *a View A
      *b Upper
      *c Left
      *d Clip center installation range
      *e Paint mark of the hose
      NOTE:

      Install the clip so that its claws are within the clip center installation range.

  21. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Install the new exhaust manifold to head gasket onto the cylinder head.
    2. Temporarily install the exhaust manifold converter with the 3 new bolts and 2 new nuts.
      Fig 12: Identifying Exhaust Manifold Converter Nuts And Bolts
      GTY347109Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fully tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  22. INSTALL MANIFOLD STAY 
    Fig 13: Identifying Manifold Stay Nut And Bolt
    GTY346748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Temporarily install the manifold stay with the new bolt and new nut.
    2. Fully tighten the bolt and nut in the order shown in the illustration.

      Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf) 

  23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    Fig 14: Identifying Exhaust Manifold Heat Insulator Nuts And Bolt
    GTY346752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Temporarily install the exhaust manifold heat insulator with the bolt and 2 nuts.
    2. Fully tighten the bolt and 2 nuts in the order shown in the illustration.

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

  24. INSTALL GENERATOR ASSEMBLY 
    Fig 15: Identifying Generator Bolts
    GTY344353Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install the generator with the 2 bolts.

      Bolt A 

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

      Bolt B 

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

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