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Installation [08/2015 - ]: Procedure

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  1. INSTALL THERMOSTAT (for Cylinder Block) 

    Refer to PROCEDURE - Step 1

  2. INSTALL WATER INLET HOUSING 

    Refer to PROCEDURE - Step 2

  3. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  4. INSTALL NO. 4 WATER BY-PASS PIPE 
    1. Install a new gasket to the water inlet housing.
    2. Install the No. 4 water by-pass pipe to the cylinder block sub-assembly and water inlet housing with the bolt and 2 nuts.

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

    3. Connect the No. 4 water by-pass pipe to the oil cooler assembly and slide the clip to secure it.
  5. INSTALL WATER BY-PASS PIPE ASSEMBLY 

    Refer to PROCEDURE - Step 4

  6. INSTALL NO. 9 ENGINE WIRE 
    1. Install the No. 9 engine wire to the No. 1 water by-pass pipe and water inlet housing with the 3 clamps.
    2. Connect the oil pressure switching valve assembly connector.
  7. INSTALL VACUUM PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 1

  8. INSTALL FUEL INJECTOR SEAL (for Direct Injection) 

    Refer to PROCEDURE - Step 1

  9. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  10. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 3

  11. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  12. INSTALL FUEL DELIVERY PIPE (for Port Injection) 

    Refer to PROCEDURE - Step 2

  13. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

  14. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 2

  15. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  16. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 4

  17. INSTALL AIR CLEANER BRACKET 

    Refer to PROCEDURE - Step 8

  18. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 5

  20. INSTALL IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  21. INSTALL OIL FILLER CAP GASKET 
    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.
  22. INSTALL OIL FILLER CAP SUB-ASSEMBLY 
    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
  23. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. for Engine Front Side:
      1. Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

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

      2. Connect the oil pressure sender gauge assembly connector.
    2. for Engine Upper Side:
      1. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

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

    3. for Engine RH Side:
      1. Install the 2 wire harness clamp brackets to the stiffening crankcase assembly with the 2 bolts.

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

    4. for Engine Rear Side:
      1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

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

  24. INSTALL SENSOR WIRE 
    1. Install the sensor wire to the fuel delivery pipe sub-assembly with the 2 bolts.

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

    2. Connect the 4 direct fuel injector assembly connectors.
    3. Connect the fuel pressure sensor connector.
  25. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  26. INSTALL TURBOCHARGER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  27. CONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  28. TIGHTEN HEAT INSULATOR BRACKET 

    Refer to PROCEDURE - Step 8

  29. INSTALL OUTLET COMPRESSOR ELBOW 
    1. Install a new gasket to the turbocharger sub-assembly.
    2. Install the compressor outlet elbow to the turbocharger sub-assembly with the 2 nuts.

      Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

  30. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 13

  31. CONNECT NO. 4 VENTILATION HOSE 

    Refer to PROCEDURE - Step 2

  32. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  33. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new O-ring to the engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the O-ring.
    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Install the engine oil level dipstick.
  34. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH 
    1. Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

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

  35. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

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

  36. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY 
    1. Install 2 new No. 1 intake manifold to head gaskets to the intake manifold with intercooler assembly and throttle with motor body assembly.
    2. Temporarily install the intake manifold with intercooler assembly and throttle with motor body assembly with the 4 bolts and 2 nuts.
      Fig 1: Intake Manifold With Intercooler Assembly And Throttle With Motor Body Assembly Tightening Sequence
      GTY679937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Tighten the 4 bolts and 2 nuts in the order shown in the illustration to install the intake manifold with intercooler assembly and throttle with motor body assembly.

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

    4. Install the wire harness clamp bracket to the intake manifold with intercooler assembly and throttle with motor body assembly with the bolt.

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

  37. CONNECT NO. 3 WATER BY-PASS HOSE 
    1. Connect the No. 3 water by-pass hose to the water outlet sub-assembly and slide the clip to secure it.
    2. Engage the clamp to the engine oil level dipstick guide.
  38. INSTALL NO. 2 VENTILATION HOSE 

    Refer to PROCEDURE - Step 20

  39. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 13

  40. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY 

    Refer to PROCEDURE - Step 14

  41. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  42. INSTALL WATER BY-PASS PIPE ASSEMBLY 
    1. Install the water by-pass pipe assembly to the intercooler assembly and No. 2 air tube with the 2 bolts.

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

    2. Connect the No. 9 water by-pass hose to the intercooler assembly and slide the clip to secure it.
    3. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.
  43. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 19

  44. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 

    Refer to PROCEDURE - Step 6

  45. INSTALL COMPRESSOR AND MAGNETIC CLUTCH 

    Refer to PROCEDURE - Step 3 [08/2015 - 10/2017] , or refer to PROCEDURE - Step 3 [10/2017 - 09/2020] , or refer to PROCEDURE - Step 3 [09/2020 - 11/2021] , or refer to PROCEDURE - Step 4 [11/2021 - 09/2022] , or refer to PROCEDURE - Step 4 [09/2022 - ]

  46. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

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