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Installation [10/2018 - ]: Procedure

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  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the stiffening crankcase assembly with the bolt.

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

    2. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

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

  2. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the 2 bolts.

      Torque: 16 N.m (163 kgf/cm, 12 ft.lbf) 

  3. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 
    1. Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

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

  4. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

  5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Apply a light coat of engine oil to a new O-ring.
    2. Install the O-ring to the engine oil level dipstick guide.
    3. Using an 8 mm socket wrench, install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

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

    4. Install the engine oil level dipstick.
  6. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  7. INSTALL FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 1

  8. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  9. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  10. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  11. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  12. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  13. INSTALL FUEL DELIVERY SPACER 

    Refer to PROCEDURE - Step 4

  14. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  15. INSTALL NO. 6 ENGINE WIRE 
    1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

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

    2. Engage the 2 clamps.
    3. Connect the 4 connectors.
  16. INSTALL SENSOR WIRE 
    1. Install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

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

    2. Engage the 3 clamps.
    3. Connect the 4 connectors.
  17. INSTALL WATER BY-PASS HOSE ASSEMBLY 
    1. Install the water by-pass hose assembly to the water inlet with thermostat sub-assembly and cylinder head sub-assembly and slide the 2 clips to secure them.
    2. Install the bolt.

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

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

    Refer to PROCEDURE - Step 1

  19. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

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

    Refer to PROCEDURE - Step 3

  21. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.
      GTY811256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 17 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [10/2018 - 07/2022] , or refer to PRECAUTION [07/2022 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
    2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

      Specified tightening torque 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      NOTE:

      Do not adjust the torque in the loosening direction.

      HINT: 

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Refer to PRECAUTION [10/2018 - 07/2022] , or refer to PRECAUTION [07/2022 - ]

      • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N.m (306 kgf/cm, 22 ft.lbf)
    3. Install the bolt.

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

  22. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. Connect the fuel tube sub-assembly to the fuel delivery pipe with sensor assembly.

      Refer to PRECAUTION [10/2018 - ]

    2. Install the fuel pipe clamp to the fuel tube connector.
    3. Connect the fuel tube sub-assembly to the fuel pump assembly.

      Refer to PRECAUTION [10/2018 - ]

  23. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 2

  24. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  25. INSTALL INTAKE MANIFOLD STAY 

    Refer to PROCEDURE - Step 4

  26. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.
    2. Using an 8 mm socket wrench, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

  27. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  28. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  29. INSTALL EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  30. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  31. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  33. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 3

  34. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 4

  35. INSTALL FUEL HOSE BRACKET 
    1. Install the fuel hose brackets to the cylinder head sub-assembly with the 2 bolts

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

      GTY820301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. CONNECT NO. 2 RADIATOR HOSE 
    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
  37. INSTALL DRIVE SHAFT BEARING BRACKET 
    1. Install the drive shaft bearing bracket with the 3 bolts.

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

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