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Installation [07/2015 - ]: Procedure

  1. INSTALL ENGINE OIL LEVEL SENSOR 
    1. Install the engine oil level sensor with the 4 bolts and a new gasket.
      GTY631759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR 

    Refer to PROCEDURE - Step 1

  3. INSTALL KNOCK SENSOR WIRE 
    1. Connect the 3 clamps, 2 knock sensor connectors and knock sensor wire connector.
  4. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY 
    1. Clean the threads of the engine oil pressure switch assembly. Apply adhesive to 2 or 3 threads of the engine oil pressure switch assembly.
      GTY574993Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Adhesive

      Adhesive

      Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent

    2. Using a 24 mm deep socket wrench, install the engine oil pressure switch assembly.

      Torque: 15 N*m (153 kgf*cm, 11 ft.*lbf) 

      NOTE:

      Do not start the engine within 1 hour after installation to prevent oil leaks.

  6. INSTALL NO. 1 VACUUM SWITCHING VALVE 
    1. Install the No. 1 vacuum switching valve with the bolt.

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

  7. INSTALL WATER PUMP PULLEY 
    1. Temporarily install the water pump pulley with the 4 bolts.
    2. Using SST, hold the water pump pulley.
      • SST: 09960-10010 
        1. 09962-01000
        2. 09963-00700
    3. Tighten the 4 bolts.

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

  8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 
    1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

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

  9. INSTALL NO. 2 TIMING GEAR COVER 
    1. Install the No. 2 timing gear cover with the 2 bolts.

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

  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.
      GTY624084Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Each bolt length is as follows:

      A: 70 mm (2.76 in.)

      B: 33 mm (1.30 in.)

    2. Install the V-ribbed belt tensioner assembly 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) 

  11. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Install a new gasket as shown in the illustration.
      GTY295908Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Engine Front
    2. Install the exhaust manifold sub-assembly LH with the 6 nuts in the order shown in the illustration.
      GTY627497Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  12. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 3

  13. INSTALL NO. 2 MANIFOLD STAY 

    Refer to PROCEDURE - Step 2

  14. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Push in the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.
    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.
  15. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Install a new gasket as shown in the illustration.
      GTY295910Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      Engine Front
    2. Install the exhaust manifold sub-assembly RH with the 6 nuts in the order shown in the illustration.
      GTY591144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  16. INSTALL INTAKE MANIFOLD 
    1. Set 2 new gaskets on each cylinder head sub-assembly.
      NOTE:
      • Align the port holes of the gasket and cylinder head sub-assembly.
      • Make sure that the gasket is installed in the correct direction.
    2. Set the intake manifold on the cylinder head sub-assembly.
    3. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.

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

  17. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH with the bolt.

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

  18. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. INSTALL NO. 1 SURGE TANK STAY 
    NOTE:

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for No. 1 surge tank stay and cylinder head cover
    1. Install the No. 1 surge tank stay with the bolt.

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

  20. INSTALL THROTTLE BODY BRACKET 
    NOTE:

    Do not apply oil to the bolt as listed below:

    Oil Application Prohibited Bolt
    Bolt for throttle body bracket and cylinder head cover
    1. Install the throttle body bracket with the bolt.

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

  21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 6

  22. INSTALL ENGINE HANGERS 
    1. Install the 2 engine hangers with the 4 bolts.
      PART NO.

      Item Part No.
      No. 1 Engine Hanger 12281-31120
      No. 2 Engine Hanger 12282-31100
      Bolt 91671-10825

      Torque: 33 N*m (337 kgf*cm, 24 ft.*lbf) 

    2. Attach an engine sling device and hang the engine with a chain block.
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