Installation [08/2023 - ]: Procedure

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INSTALL CYLINDER HEAD GASKET

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Lot No.	-	-
	Front of Engine	-	-

Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
NOTE:
- Make sure that the cylinder head gasket is installed in the correct orientation.
- Remove any oil from the contact surfaces.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

Refer to PROCEDURE - Step 19
INSTALL NO. 2 CAMSHAFT

Refer to PROCEDURE - Step 23
INSTALL CAMSHAFT

Refer to PROCEDURE - Step 24
INSTALL CAMSHAFT BEARING CAP

Refer to PROCEDURE - Step 25
INSTALL VALVE STEM CAP

Refer to PROCEDURE - Step 26
INSTALL VALVE LASH ADJUSTER ASSEMBLY

Refer to PROCEDURE - Step 27
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Refer to PROCEDURE - Step 28
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

Refer to PROCEDURE - Step 29
INSTALL FUEL PUMP LIFTER GUIDE

Refer to PROCEDURE - Step 30
INSTALL TIMING CHAIN COVER ASSEMBLY

Refer to PROCEDURE - Step 33
INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Refer to PROCEDURE - Step 34
SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Refer to PROCEDURE - Step 35
INSTALL NO. 1 CHAIN VIBRATION DAMPER
Refer to PROCEDURE - Step 36
INSTALL CHAIN TENSIONER SLIPPER
Refer to PROCEDURE - Step 37
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

Refer to PROCEDURE - Step 38
INSTALL CHAIN SUB-ASSEMBLY

Refer to PROCEDURE - Step 39
INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

Refer to PROCEDURE - Step 40
INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

Refer to PROCEDURE - Step 41
SET NO. 1 CYLINDER TO TDC (COMPRESSION)

Refer to PROCEDURE - Step 42
INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

Refer to PROCEDURE - Step 43
INSTALL TIMING CHAIN COVER OIL SEAL

See step 1
INSTALL SPARK PLUG TUBE GASKET

Refer to PROCEDURE - Step 46
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

Refer to PROCEDURE - Step 47
INSTALL WATER OUTLET PIPE GASKET
INSTALL WATER BY-PASS OUTLET

Refer to PROCEDURE - Step 49
INSTALL WATER OUTLET GASKET
INSTALL WATER OUTLET

Refer to PROCEDURE - Step 51
INSTALL CRANKSHAFT PULLEY ASSEMBLY

Refer to PROCEDURE - Step 52
CONNECT NO. 2 WATER BY-PASS HOSE
CONNECT NO. 1 WATER BY-PASS HOSE
INSTALL CAM TIMING CONTROL MOTOR O-RING

Refer to PROCEDURE - Step 1
INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL CAM TIMING OIL CONTROL SOLENOID O-RING

Refer to PROCEDURE - Step 1
INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Refer to PROCEDURE - Step 2
INSTALL IGNITION COIL ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL FUEL INJECTOR SEAL

Refer to PROCEDURE - Step 1
INSTALL INJECTOR VIBRATION INSULATOR

Refer to PROCEDURE - Step 2
INSTALL C-RING

Refer to PROCEDURE - Step 3
INSTALL NO. 1 FUEL INJECTOR BACK-UP RING

Refer to PROCEDURE - Step 4
INSTALL NO. 3 FUEL INJECTOR BACK-UP RING

Refer to PROCEDURE - Step 5
INSTALL NOZZLE HOLDER CLAMP
INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Refer to PROCEDURE - Step 7
INSTALL FUEL DELIVERY PIPE

Refer to PROCEDURE - Step 8
CONNECT WIRE HARNESS
INSTALL PORT FUEL INJECTOR ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL NO. 5 ENGINE WIRE
INSTALL INJECTOR VIBRATION INSULATOR
INSTALL NO. 1 DELIVERY PIPE SPACER

Refer to PROCEDURE - Step 4
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 5
INSTALL NO. 7 WATER BY-PASS HOSE
INSTALL FUEL PUMP LIFTER ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL FUEL PUMP SPACER GASKET
TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

Refer to PROCEDURE - Step 3
TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 4
INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY

Refer to PROCEDURE - Step 5
INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 26
CONNECT FUEL TUBE SUB-ASSEMBLY

Refer to PROCEDURE - Step 7
INSTALL FUEL PIPE CLAMP
INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
INSTALL INTAKE MANIFOLD

Refer to PROCEDURE - Step 4
INSTALL NO. 2 WATER BY-PASS PIPE

Refer to PROCEDURE - Step 31
INSTALL NO. 3 WATER BY-PASS PIPE

Refer to PROCEDURE - Step 32
SET EGR VALVE ASSEMBLY

Refer to PROCEDURE - Step 1
CONNECT NO. 8 WATER BY-PASS HOSE
CONNECT NO. 4 WATER BY-PASS HOSE
INSTALL NO. 1 EGR COOLER GASKET

Refer to PROCEDURE - Step 3
INSTALL EGR VALVE GASKET

Refer to PROCEDURE - Step 4
INSTALL EGR COOLER ASSEMBLY

Refer to PROCEDURE - Step 5
CONNECT NO. 4 WATER BY-PASS HOSE
CONNECT NO. 3 WATER BY-PASS HOSE
INSTALL EGR VALVE ASSEMBLY

Refer to PROCEDURE - Step 9
INSTALL EGR INLET GASKET
INSTALL EGR VALVE ADAPTER GASKET
INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 12
INSTALL THROTTLE BODY GASKET

Refer to PROCEDURE - Step 1
CONNECT NO. 6 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 2
INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Refer to PROCEDURE - Step 3
CONNECT NO. 5 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 4
INSTALL EXHAUST MANIFOLD TO HEAD GASKET
INSTALL EXHAUST MANIFOLD

Refer to PROCEDURE - Step 3
INSTALL MANIFOLD STAY

Refer to PROCEDURE - Step 4
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 52
INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

Refer to PROCEDURE - Step 53
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 54
INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

Refer to PROCEDURE - Step 55
INSTALL ENGINE HANGERS

See step 44 [10/2022 - 10/2024], or see step 41 [10/2024 - ]
REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
- for HEV Model:
  Refer to INSTALLATION [10/2022 - 10/2024] , or refer to INSTALLATION [10/2024 - ]
- for PHEV Model:
  Refer to INSTALLATION [08/2023 - ]