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Installation [10/2015 - ]: Procedure

  1. INSTALL STUD BOLT 
    1. Using an 8 mm socket wrench, install the stud bolt to the front No. 1 engine mounting bracket LH.
      GTY615571Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 63 mm (2.48 in.) *b 27 mm (1.06 in.)
      *c 103 mm (4.06 in.) - -

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

      Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf) 

  3. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 2

  4. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  5. INSTALL SENSOR WIRE 
    1. Engage the 2 clamps and install the sensor wire with the bolt.

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

  6. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  7. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to INSTALLATION [10/2015 - ]

  8. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 2

  9. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  10. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH to the intake manifold with the bolt.

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

    2. Connect the wire harness clamp bracket to the No. 2 engine mounting stay RH with the bolt.

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

  11. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 5 [03/2018 - ]

  12. INSTALL NO. 6 WATER BY-PASS HOSE 
    1. Install the No. 6 water by-pass hose to the water outlet and slide the clip to secure it.
  13. INSTALL NO. 2 WATER BY-PASS HOSE 
    1. Install the No. 2 water by-pass hose to the water outlet and slide the clip to secure it.
  14. INSTALL NO. 3 WATER BY-PASS HOSE 
    1. Install the No. 3 water by-pass hose to the water inlet pipe and slide the clip to secure it.
  15. INSTALL WATER BY-PASS HOSE ASSEMBLY 
    1. Install the water by-pass hose assembly to the water inlet pipe and slide the clip to secure it.
  16. INSTALL NO. 2 VENTILATION HOSE 
    1. Install the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.
  17. INSTALL VENTILATION HOSE 
    1. Install the ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.
  18. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover to the cylinder head cover sub-assembly LH.
  19. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket to the cylinder block sub-assembly with the 3 bolts.

      Torque: 63.7 N*m (650 kgf*cm, 47 ft.*lbf) 

      NOTE:

      Make sure that there is no oil on the threads of the bolts.

  20. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 15

  21. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  22. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 18

  23. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  24. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  25. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 1 [03/2018 - ]

  26. INSTALL NO. 5 CYLINDER BLOCK INSULATOR (w/ Oil Cooler) 
    1. Install the No. 5 cylinder block insulator.
      GTY667864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Positioning Boss
      NOTE:
      • Press the area (A) to confirm that the protrusion on the back side of the timing chain cover assembly is securely installed.
      • Make sure that the No. 5 cylinder block insulator is not covering the positioning bosses.
  27. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 
    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

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

      NOTE:
      • Make sure to align the bolt holes of the No. 1 compressor mounting bracket with that of the engine assembly and fit the 2 sides securely before temporarily tightening the bolts.
      • Temporarily tighten the bolt (B), and then fully tighten the 4 bolts in the order of (A), (D), (B) and (C).
      GTY660248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. INSTALL NO. 4 CYLINDER BLOCK INSULATOR (w/ Oil Cooler) 
    1. Install the No. 4 cylinder block insulator.
  29. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2 [10/2015 - 03/2018] , or refer to PROCEDURE - Step 2 [03/2018 - 08/2019] , or refer to PROCEDURE - Step 2 [08/2019 - ]

  30. INSTALL V-RIBBED BELT 

    Refer to PROCEDURE - Step 1

  31. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new engine oil level dipstick guide O-ring to the engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the engine oil level dipstick guide O-ring.
    3. Insert the engine oil level dipstick guide end into the oil pan sub-assembly.
    4. Install the engine oil level dipstick guide to the camshaft housing sub-assembly LH with the bolt.

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

    5. Install the engine oil level dipstick to the engine oil level dipstick guide.
  32. INSTALL RADIATOR PIPE CLAMP 
    1. Install the radiator pipe clamp to the camshaft housing sub-assembly LH with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

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