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Installation [11/2021 - 03/2022]: Procedure

  1. INSTALL STUD BOLT 
    NOTE:

    If a stud bolt is deformed or its threads are damaged, replace it.
    1. GTY1076928Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 33.1 mm (1.30 in.) *b 15 mm (0.591 in.)
      *c 95 mm (3.74 in.) - -
      1. Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

        Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  2. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. GTY1075256Courtesy 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) 

  3. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET 
    1. GTY1076840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the camshaft housing sub-assembly with the 2 bolts.

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

  4. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 1

  5. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

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

  6. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1077421Courtesy 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.
  7. INSTALL IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  8. INSTALL FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 1
  9. INSTALL INJECTOR VIBRATION INSULATOR 
    Refer to PROCEDURE - Step 2
  10. INSTALL C-RING 
    Refer to PROCEDURE - Step 3
  11. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 4
  12. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 5
  13. INSTALL NOZZLE HOLDER CLAMP 
  14. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 7
  15. INSTALL FUEL DELIVERY PIPE 
    Refer to PROCEDURE - Step 8
  16. INSTALL PORT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 1
  17. INSTALL NO. 5 ENGINE WIRE 
  18. INSTALL INJECTOR VIBRATION INSULATOR 
  19. INSTALL NO. 1 DELIVERY PIPE SPACER 
  20. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  21. INSTALL NO. 6 ENGINE WIRE 

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

  22. INSTALL SENSOR WIRE 
    1. GTY1075877Courtesy 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 4 connectors.
  23. INSTALL NO. 7 WATER BY-PASS HOSE 
  24. INSTALL FUEL PUMP LIFTER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  25. INSTALL FUEL PUMP SPACER GASKET 
  26. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 3
  27. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  28. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY 
    Refer to PROCEDURE - Step 5
  29. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 6
  30. CONNECT FUEL TUBE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 7
  31. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
  32. INSTALL INTAKE MANIFOLD 
    Refer to PROCEDURE - Step 4
  33. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 6

  34. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. GTY1077164Courtesy 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) 

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

    Refer to PROCEDURE - Step 6

  54. INSTALL NO. 2 WATER HOSE CLAMP BRACKET 

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

  55. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY) 

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

  56. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 
    1. GTY1076427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2.0 to 7.0 mm (0.0787 to 0.276 in.) *b 120°(Claw of Clip Location)
      *c Paint Mark *d Protrusion
      *e RH Side - -
      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 protrusion 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) 

  57. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR 
  58. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    NOTE:
    • Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
    • Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.
    GTY743260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

  59. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY 
    Refer to PROCEDURE - Step 2
  60. INSTALL GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  61. INSTALL V-RIBBED BELT 
    Refer to PROCEDURE - Step 1
  62. INSTALL NO. 2 ENGINE COVER 

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

  63. INSTALL DRIVE SHAFT BEARING BRACKET 

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

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