Installation [10/2020 - ]: Procedure

1. Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

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

Refer to PROCEDURE - Step 1

1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

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

1. Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with 4 bolts.

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

Refer to PROCEDURE - Step 1

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.

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

Refer to PROCEDURE - Step 5

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) 

1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

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

2. Engage the 2 clamps.
3. Connect the 4 connectors.

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.

1. Install the No. 7 water by-pass hose and slide the 2 clips to secure it.

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

1. Using a 17 mm union nut wrench, tighten the union nut on the fuel delivery pipe side of the No. 1 fuel pipe sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	17 mm Union Nut Wrench
   *b	Torque Wrench Fulcrum Length

   Specified tightening torque 

   Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

   NOTE:

   Do not adjust the torque in the loosening direction.

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [03/2020 - ]

   • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
2. Using a 17 mm union nut wrench, tighten the union nut on the fuel pump assembly side of the No. 1 fuel pipe sub-assembly.

   Specified tightening torque 

   Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf) 

   NOTE:

   Do not adjust the torque in the loosening direction.

   HINT: 

   • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

     Refer to PRECAUTION [03/2020 - ]

   • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)
3. Using an 8 mm socket wrench, install the bolt.

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

Refer to PROCEDURE - Step 5

Refer to PROCEDURE - Step 3

Refer to PROCEDURE - Step 4

1. Install the bolt (A).

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

2. Using an 8 mm socket wrench, install the No. 2 water by-pass pipe with the 2 bolts (B) in the order shown in the illustration.
   Fig 1: No. 2 Water By-Pass Pipe Bolts Tightening Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

1. Connect 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, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

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

1. Align and fit the hole of the EGR valve assembly to the pin of the camshaft housing sub-assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Pin
   *b	Hole

2. Using an 8 mm socket wrench, install the EGR valve assembly with the 2 bolts.

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

3. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

1. Connect the water hose to the EGR valve assembly and slide the clip to secure it.

1. Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly, a new EGR inlet gasket and EGR valve adapter gasket with the 4 bolts.

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

1. Install a new EGR cooler gasket to the EGR cooler assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a

   Claw

   NOTE:

   Make sure that the claws of the EGR cooler gasket are toward the EGR cooler assembly side.

2. Install a new EGR valve gasket to the EGR cooler assembly.
   NOTE:

   Make sure that the claws of the EGR valve gasket are toward the EGR valve assembly side.

3. Type A:
   1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 2 bolts and 3 nuts.

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      	Bolt
      	Nut

   2. Tighten the 2 bolts and 3 nuts in the order shown in the illustration.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

4. Type B:
   1. Temporarily install the EGR cooler assembly to the cylinder head sub-assembly and EGR valve assembly with the 3 bolts and 2 nuts.
      Fig 2: EGR Cooler Assembly To Cylinder Head Sub-Assembly Bolts And Nuts Tightening Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      	Bolt
      	Nut

   2. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      Torque: 24 N*m (245 kgf*cm, 18 ft.*lbf) 

5. Connect the No. 3 water by-pass hose to the EGR cooler assembly.
6. Connect the water hose to the EGR cooler assembly.

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

1. Type A:
   1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

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

2. Type B:
   1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 3 bolts.

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

1. Install the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Paint Mark
   *b	45° (Claw of Clip Location)

   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 sub-assembly.
   • Make sure that the claws of the clip are within the location shown in the illustration.
2. Install the water hose clamp bracket with the 2 bolts.

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

3. Connect the flow shutting valve (water by-pass hose assembly) with the bolt.

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

1. Install the No. 2 water by-pass pipe sub-assembly with the bolt.

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

2. Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.

1. Using an 8 mm socket wrench, install the No. 3 timing chain cover and plate washer to the No. 2 timing gear cover assembly with the bolt.

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

1. Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing gear cover assembly with the bolt.

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

1. Install the No. 2 timing chain cover insulator to the 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.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

If oil or grease is on the location indicated by the arrow, replace the V-ribbed belt tensioner assembly.

1. Install the V-ribbed belt tensioner assembly to the No. 2 timing gear cover assembly with the 2 bolts.

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

1. Install the No. 2 engine cover to the No. 2 timing gear cover assembly with the 2 bolts.

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

1. For Type A:
   1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

      Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) 

   2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
      Fig 3: Compressor Assembly With Pulley Bolts And Nuts Tightening Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      	Bolt
      	Nut

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

      HINT: 

      Tighten the bolts and nuts in the order shown in the illustration.

2. For Type B:
   1. Install the compressor assembly with pulley with the 4 bolts.
      Fig 4: Compressor Assembly With Pulley Bolts Tightening Sequence

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

      HINT: 

      Tighten the bolts in the order shown in the illustration.

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 1

1. Install the drive shaft bearing bracket with the 3 bolts.

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

   NOTE:

   Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.