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Installation [11/2016 - ]: Procedure

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  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

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

  2. INSTALL WATER PUMP PULLEY 

    Refer to PROCEDURE - Step 2

  3. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  4. INSTALL SENSOR WIRE 
    1. Engage the 2 clamps and install the sensor wire with the bolt.

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

  5. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  6. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to INSTALLATION [11/2016 - ]

  7. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 2

  8. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  9. INSTALL NO. 2 ENGINE MOUNTING STAY RH 
    1. Install the No. 2 engine mounting stay RH to the intake manifold with the bolt.

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

    2. Connect the wire harness clamp bracket to the No. 2 engine mounting stay RH with the bolt.

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

  10. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  11. INSTALL NO. 6 WATER BY-PASS HOSE 
    1. Install the No. 6 water by-pass hose to the water outlet and slide the clip to secure it.
  12. INSTALL NO. 2 WATER BY-PASS HOSE 
    1. Install the No. 2 water by-pass hose to the water outlet and slide the clip to secure it.
  13. INSTALL NO. 3 WATER BY-PASS HOSE 
    1. Install the No. 3 water by-pass hose to the water inlet pipe and slide the clip to secure it.
  14. INSTALL WATER BY-PASS HOSE ASSEMBLY 
    1. Install the water by-pass hose assembly to the water inlet pipe and slide the clip to secure it.
  15. INSTALL NO. 2 VENTILATION HOSE 
    1. Install the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.
  16. INSTALL VENTILATION HOSE 
    1. Install the ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.
  17. INSTALL NO. 1 ENGINE COVER 
    1. Install the No. 1 engine cover to the cylinder head cover sub-assembly LH.
  18. INSTALL REAR ENGINE MOUNTING BRACKET 
    1. Install the rear engine mounting bracket to the cylinder block sub-assembly with the 3 bolts.

      Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf) 

      NOTE:

      Make sure that there is no oil on the threads of the bolts.

  19. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 15

  20. INSTALL INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 16

  21. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 18

  22. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  23. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  24. INSTALL INJECTOR DRIVER 

    Refer to PROCEDURE - Step 1

  25. INSTALL NO. 5 CYLINDER BLOCK INSULATOR 
    1. Install the No. 5 cylinder block insulator.
      GTY667864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
      *b Positioning Boss
      NOTE:
      • Press the area (A) to confirm that the protrusion on the back side of the timing chain cover assembly is securely installed.
      • Make sure that the No. 5 cylinder block insulator is not covering the positioning bosses.
  26. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET 
    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

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

      NOTE:
      • Make sure to align the bolt holes of the No. 1 compressor mounting bracket with that of the engine assembly and fit the 2 sides securely before tightening the bolts.
      • Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (A) and (D).
      GTY660248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSTALL NO. 4 CYLINDER BLOCK INSULATOR 
    1. Install the No. 4 cylinder block insulator.
  28. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  29. INSTALL V-RIBBED BELT 

    Refer to PROCEDURE - Step 1

  30. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Install a new engine oil level dipstick guide O-ring to the engine oil level dipstick guide.
    2. Apply a light coat of engine oil to the engine oil level dipstick guide O-ring.
    3. Insert the engine oil level dipstick guide end into the oil pan sub-assembly.
    4. Install the engine oil level dipstick guide to the camshaft housing sub-assembly LH with the bolt.

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

    5. Install the engine oil level dipstick to the engine oil level dipstick guide.
  31. INSTALL RADIATOR PIPE CLAMP 
    1. Install the radiator pipe clamp to the camshaft housing sub-assembly LH with the bolt.

      Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) 

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