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Installation [10/2022 - ]: Procedure

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  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. GTY1105303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 2 timing chain cover assembly with the bolt.

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

      2. Using an 8 mm socket wrench, install the wire harness clamp bracket to the crankshaft bearing cap with the bolt.

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

  2. INSTALL CRANKSHAFT POSITION SENSOR 

    Refer to PROCEDURE - Step 1

  3. INSTALL PCV VALVE (VENTILATION VALVE SUB-ASSEMBLY) 

    Refer to PROCEDURE - Step 1

  4. INSTALL KNOCK CONTROL SENSOR 

    Refer to PROCEDURE - Step 1

  5. INSTALL ENGINE COOLANT TEMPERATURE SENSOR (for Cylinder Head Side) 

    Refer to PROCEDURE - Step 1 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 1 [11/2023 - ]

  6. INSTALL HEATER WATER HOSE BRACKET 

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

  7. INSTALL WATER BY-PASS GASKET 
    1. GTY1106238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw - -
      1. Install a new water by-pass gasket to the water by-pass pipe sub-assembly.
        NOTE:

        Make sure that the claws of the water by-pass gasket are toward the water by-pass pipe sub-assembly side.

  8. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY 

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

  9. INSTALL WATER BY-PASS HOSE 
  10. INSTALL EXHAUST PIPE HEAT INSULATOR 

    Refer to PROCEDURE - Step 5

  11. INSTALL NO. 2 MANIFOLD STAY 

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

  12. INSTALL WATER INLET HOUSING 

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

  13. INSTALL WIRE HARNESS 
    1. GTY1105463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using an 8 mm socket wrench, install the wire harness with the bolt.

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

      2. Engage the 2 clamps.
      3. Connect the 4 connectors.
  14. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  15. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 1 [11/2023 - ]

  16. INSTALL NO. 5 ENGINE WIRE 
  17. INSTALL INJECTOR VIBRATION INSULATOR 
  18. INSTALL FUEL DELIVERY SPACER 
  19. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 5 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 5 [11/2023 - ]

  20. INSTALL NO. 2 WATER BY-PASS PIPE 

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

  21. INSTALL FUEL PUMP LIFTER ASSEMBLY 

    Refer to PROCEDURE - Step 1 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 1 [11/2023 - ]

  22. INSTALL FUEL PUMP SPACER GASKET 
  23. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 3 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 3 [11/2023 - ]

  24. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 6 [11/2023 - ]

  25. INSTALL FUEL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 5 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 5 [11/2023 - ]

  26. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 6 [10/2022 - 11/2023] , or refer to PROCEDURE - Step 6 [11/2023 - ]

  27. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1109306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tube sub-assembly to the fuel delivery pipe.

        Refer to PRECAUTION [10/2022 - ]

      2. Connect the fuel tube sub-assembly to the fuel (engine room side) pump assembly.

        Refer to PRECAUTION [10/2022 - ]

      3. Install the EFI fuel pipe clamp (fuel delivery pipe side) to the fuel tube connector.
  28. CONNECT WATER OUTLET STAY 

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

  29. TEMPORARILY INSTALL TURBOCHARGER SUB-ASSEMBLY 
    1. GTY1250251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Install a new exhaust manifold to head gasket.
      2. Temporarily install the turbocharger sub-assembly to the cylinder head sub-assembly by tightening 4 new nuts by 2 or 3 threads.
  30. INSTALL NO. 1 TURBO OIL OUTLET GASKET 
    1. GTY1109139Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw - -
      1. Install a new No. 1 turbo oil outlet gasket to the No. 1 turbo oil pipe.
        NOTE:

        Make sure that the claws of the No. 1 turbo oil outlet gasket are toward the No. 1 turbo oil pipe side.

  31. INSTALL NO. 1 TURBO OIL PIPE 
    1. GTY1250238Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Turbo Oil Inlet Gasket *2 Gasket
      Bolt Nut
      Oil Pipe Union Bolt - -
      1. Install a new turbo oil inlet gasket and gasket.

        HINT: 

        Face the straight part of the turbo oil inlet gasket toward the outside of the engine.

      2. Temporarily install the No. 1 turbo oil pipe to the turbocharger sub-assembly and cylinder block sub-assembly by tightening the oil pipe union bolt, 2 bolts and 2 nuts by 2 or 3 threads.
    2. GTY1249982Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Oil Pipe Union Bolt - -
      1. Temporarily install the turbocharger sub-assembly to the cylinder head sub-assembly by tightening the 4 nuts until the turbocharger sub-assembly is seated.
      2. Temporarily install the No. 1 turbo oil pipe to the turbocharger sub-assembly by tightening the 2 nuts until the No. 1 turbo oil pipe is seated.
      3. Temporarily install the No. 1 turbo oil pipe to the cylinder block sub-assembly by tightening the 2 bolts and oil pipe union bolt until the No. 1 turbo oil pipe is seated.
    3. Fig 1: No. 1 Turbo Oil Pipe Bolts And Nuts Tightening Sequence
      GTY1249983Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt Nut
      Oil Pipe Union Bolt - -
      1. Uniformly tighten the 4 nuts in the order shown in the illustration.

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

      2. Uniformly tighten the 2 bolts, oil pipe union bolt and 2 nuts in the order shown in the illustration.

        Bolt 

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

        Oil Pipe Union Bolt 

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

        Nut 

        Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  32. INSTALL MANIFOLD STAY 

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

  33. INSTALL NO. 1 HEAT INSULATOR BRACKET 

    Refer to PROCEDURE - Step 5

  34. CONNECT NO. 3 TURBO WATER HOSE 

    Refer to PROCEDURE - Step 6

  35. CONNECT NO. 2 TURBO WATER HOSE 

    Refer to PROCEDURE - Step 7

  36. INSTALL NO. 1 TURBO INSULATOR 

    Refer to PROCEDURE - Step 8

  37. INSTALL COMPRESSOR INLET ELBOW SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 11

  38. INSTALL VACUUM REGULATING VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  39. INSTALL WATER OUTLET GASKET 
    1. GTY1105487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw - -
      1. Install a new water outlet gasket to the front water by-pass joint.
        NOTE:

        Make sure that the claws of the water outlet gasket are toward the front water by-pass joint side.

  40. INSTALL FRONT WATER BY-PASS JOINT 

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

  41. INSTALL WATER CONTROL VALVE 

    Refer to PROCEDURE - Step 1

  42. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY 

    Refer to PROCEDURE - Step 4

  43. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1107755Courtesy 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 intake manifold with the bolt.

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

      4. Install the engine oil level dipstick.
  44. CONNECT NO. 5 WATER BY-PASS HOSE 
  45. CONNECT NO. 4 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 7

  46. CONNECT NO. 4 TURBO WATER HOSE 

    Refer to PROCEDURE - Step 9

  47. CONNECT NO. 3 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 11

  48. CONNECT NO. 1 TURBO WATER HOSE 

    Refer to PROCEDURE - Step 13

  49. CONNECT NO. 2 FUEL VAPOR FEED HOSE 
  50. INSTALL AIR TUBE ASSEMBLY 

    Refer to PROCEDURE - Step 15

  51. CONNECT NO. 1 VENTILATION PRESSURE SENSOR HOSE 
  52. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to PROCEDURE - Step 16

  53. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  54. INSTALL DRIVE SHAFT BEARING BRACKET 

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

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