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Installation [03/2022 - ]: Procedure

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  1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

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

  2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1075143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 camshaft housing sub-assembly with the bolt.

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

      4. Install the engine oil level dipstick.
  3. INSTALL IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  4. INSTALL FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 1
  5. INSTALL INJECTOR VIBRATION INSULATOR 
    Refer to PROCEDURE - Step 2
  6. INSTALL C-RING 
    Refer to PROCEDURE - Step 3
  7. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 4
  8. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 5
  9. INSTALL NOZZLE HOLDER CLAMP 
  10. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 7
  11. INSTALL FUEL DELIVERY PIPE 
    Refer to PROCEDURE - Step 8
  12. INSTALL PORT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 1
  13. INSTALL NO. 5 ENGINE WIRE 
  14. INSTALL INJECTOR VIBRATION INSULATOR 
  15. INSTALL NO. 1 DELIVERY PIPE SPACER 
    Refer to PROCEDURE - Step 4
  16. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  17. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. GTY1075255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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) 

  18. INSTALL NO. 6 ENGINE WIRE 

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

  19. INSTALL SENSOR WIRE 
    1. GTY1076791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, 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 3 connectors.
  20. INSTALL NO. 7 WATER BY-PASS HOSE 
  21. INSTALL FUEL PUMP LIFTER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  22. INSTALL FUEL PUMP SPACER GASKET 
  23. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 3
  24. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  25. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 5
  26. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6

  27. CONNECT FUEL TUBE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 7
  28. INSTALL FUEL PIPE CLAMP 
  29. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
  30. INSTALL INTAKE MANIFOLD 
    Refer to PROCEDURE - Step 4
  31. INSTALL NO. 2 WATER BY-PASS PIPE 
    1. GTY1075473Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, temporarily install the No. 2 water by-pass pipe with the 2 bolts (B).
      2. Install the bolt (A).

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

      3. Using an 8 mm socket wrench, tighten the 2 bolts (B).

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

  32. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. GTY1075500Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install 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, connect the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

  33. SET EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 1
  34. CONNECT NO. 8 WATER BY-PASS HOSE 
  35. CONNECT NO. 4 WATER BY-PASS HOSE 
  36. INSTALL NO. 1 EGR COOLER GASKET 
    Refer to PROCEDURE - Step 3
  37. INSTALL EGR VALVE GASKET 
    Refer to PROCEDURE - Step 4
  38. INSTALL EGR COOLER ASSEMBLY 
    Refer to PROCEDURE - Step 5
  39. CONNECT NO. 4 WATER BY-PASS HOSE 
  40. CONNECT NO. 3 WATER BY-PASS HOSE 
  41. INSTALL EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 9
  42. INSTALL EGR INLET GASKET 
  43. INSTALL EGR VALVE ADAPTER GASKET 
  44. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 12
  45. INSTALL THROTTLE BODY GASKET 
    Refer to PROCEDURE - Step 1
  46. CONNECT NO. 6 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 2
  47. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 3
  48. CONNECT NO. 5 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 4
  49. INSTALL EXHAUST MANIFOLD TO HEAD GASKET 
  50. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 
    Refer to PROCEDURE - Step 3
  51. INSTALL MANIFOLD STAY 
    Refer to PROCEDURE - Step 6
  52. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

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

  53. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 
    1. GTY1074953Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Paint Mark *b 45° (Claw of Clip Location)
      *c Upper Side *d Front of Engine
      *e 2.0 to 7.0 mm (0.0787 to 0.276 in.) - -
      1. Install the water hose clamp bracket with the 2 bolts as shown in the illustration.

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

        NOTE:

        Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

      2. Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet and slide the clip to secure it.
        NOTE:
        • Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      3. Install the flow shutting valve (water by-pass hose assembly) with the bolt.

        Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

  54. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. GTY1075580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 45° (Claw of Clip Location) *b Paint Mark
      *c Upper Side *d Front of Engine
      *e 2.0 to 7.0 mm (0.0787 to 0.276 in.) - -
      1. Connect the No. 2 water by-pass pipe sub-assembly to the water by-pass outlet and slide the clip to secure it.
        NOTE:
        • Make sure to slide the No. 2 water by-pass pipe sub-assembly until it contacts the hose stopper of the water by-pass outlet.
        • Make sure that the claws of the clip are within the location shown in the illustration.
      2. Install the No. 2 water by-pass pipe sub-assembly with the bolt.

        Torque: 19 N.m (194 kgf/cm, 14 ft.lbf) 

  55. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 
    1. GTY1075163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      1. Using an E8 "TORX" socket wrench, temporarily install the compressor with motor assembly with the 2 stud bolts.

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

      2. Install the compressor with motor assembly with the bolt and 2 nuts in the order shown in the illustration.

        Torque: 24.5 N.m (250 kgf/cm, 18 ft.lbf) 

  56. INSTALL DRIVE SHAFT BEARING BRACKET 

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

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