Installation [10/2014 - ]: Procedure

INSTALL IGNITION COIL ASSEMBLY
Refer to PROCEDURE - Step 2
INSTALL SENSOR WIRE
1. Install the sensor wire with the bolt.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
2. Connect the knock control sensor connector.
INSTALL FUEL DELIVERY PIPE
Refer to PROCEDURE - Step 2
INSTALL INTAKE MANIFOLD
1. Install a new gasket to the intake manifold.
2. Set the intake manifold on the engine assembly.
3. Temporarily install the intake manifold with the 6 bolts.
4. Tighten the 6 bolts in the order shown in the illustration.
  
  Fig 1: Intake Manifold Bolts Tightening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  Torque: 28 N*m (286 kgf*cm, 21 ft.*lbf)
5. Connect the No. 2 ventilation hose to the intake manifold, and slide the clip to secure it.
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET
1. Install the No. 1 compressor mounting bracket with the 4 bolts.
  Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf)

INSTALL WATER INLET HOUSING

Using an E5 "TORX" socket wrench, install the stud bolt to the water inlet housing.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Using an E8 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly.
Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf)
Install a new gasket.

Install the water inlet housing with the 3 bolts and nut.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

TEXT IN ILLUSTRATION

*1	Bolt
*2	Nut

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

Install the harness clamp bracket to the water inlet housing with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
Install the harness clamp bracket to the cylinder block sub-assembly with the bolt.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

INSTALL WATER INLET SUB-ASSEMBLY
1. Install a new gasket and the water inlet sub-assembly with the 2 bolts.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
INSTALL ENGINE WATER PUMP ASSEMBLY
1. Install a new gasket and the engine water pump assembly with the 5 bolts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
INSTALL NO. 1 EGR PIPE
1. Install a new gasket and the No. 1 EGR pipe with the 2 bolts and 2 nuts.
  Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

INSTALL EGR COOLER ASSEMBLY

Temporarily install a new gasket and the EGR cooler assembly with the bolt (A) and nut (A).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Temporarily install the bolt (B) and nut (B).
Tighten the 2 bolts and 2 nuts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

NOTE:
Make sure that all installation surfaces of the EGR cooler assembly are in even contact when tightening the bolts and nuts.
Connect the No. 4 water by-pass hose and No. 6 water by-pass hose, and slide the 2 clips to secure it.

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)
Refer to PROCEDURE - Step 2
INSTALL MANIFOLD STAY
Refer to PROCEDURE - Step 3
INSTALL NO. 2 MANIFOLD STAY
Refer to PROCEDURE - Step 4
INSTALL NO. 2 EGR PIPE
Refer to PROCEDURE - Step 5
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 8
CONNECT NO. 1 WATER BY-PASS HOSE
1. Connect the No. 1 water by-pass hose with the clamp, and slide the clip to secure it.
INSTALL THROTTLE BODY GASKET
Refer to PROCEDURE - Step 1
INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
Refer to PROCEDURE - Step 2
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. Install the engine oil level dipstick guide with the bolt.
  Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
4. Install the engine oil level dipstick.

INSTALL ENGINE HANGERS

Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts as shown in the illustration.

TEXT IN ILLUSTRATION

*1	No. 1 Engine Hanger
*2	No. 2 Engine Hanger

PART NO.

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