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Installation [10/2022 - ]: Procedure

  1. INSTALL CYLINDER HEAD GASKET 
    1. Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
    2. Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
      GTY767586Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lot No.
      Front of Engine
      NOTE:
      • Make sure that the cylinder head gasket is installed in the correct orientation.
      • Remove any oil from the contact surfaces.
  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 19

  3. INSTALL NO. 2 CAMSHAFT 

    Refer to PROCEDURE - Step 21

  4. INSTALL CAMSHAFT 

    Refer to PROCEDURE - Step 22

  5. INSTALL CAMSHAFT BEARING CAP 

    Refer to PROCEDURE - Step 23

  6. INSTALL VALVE STEM CAP 

    Refer to PROCEDURE - Step 24

  7. INSTALL VALVE LASH ADJUSTER ASSEMBLY 

    Refer to PROCEDURE - Step 25

  8. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  9. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 27

  10. INSTALL FUEL PUMP LIFTER GUIDE 

    Refer to PROCEDURE - Step 28

  11. INSTALL TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 31

  12. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 32

  13. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 

    Refer to PROCEDURE - Step 33

  14. INSTALL NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 34

  15. INSTALL CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 35

  16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 36

  17. INSTALL CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 37

  18. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY 

    Refer to PROCEDURE - Step 38

  19. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 39

  20. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 

    Refer to PROCEDURE - Step 31

  21. INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY 

    Refer to PROCEDURE - Step 41

  22. INSTALL TIMING CHAIN COVER OIL SEAL 

    See step  1

  23. INSTALL SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 44

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 45

  25. INSTALL WATER BY-PASS OUTLET 

    Refer to PROCEDURE - Step 46

  26. INSTALL WATER OUTLET 

    Refer to PROCEDURE - Step 47

  27. INSTALL CRANKSHAFT PULLEY ASSEMBLY 

    Refer to PROCEDURE - Step 48

  28. CONNECT NO. 2 WATER BY-PASS HOSE 
    1. Connect the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.
  29. CONNECT NO. 1 WATER BY-PASS HOSE 
    1. Connect the No. 1 water by-pass hose to the cylinder block sub-assembly and slide the clip to secure it.
  30. INSTALL CAM TIMING CONTROL MOTOR O-RING 

    Refer to PROCEDURE - Step 1

  31. INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY 

    Refer to PROCEDURE - Step 2

  32. INSTALL O-RING 

    Refer to PROCEDURE - Step 1

  33. INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY 

    Refer to PROCEDURE - Step 2

  34. INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  35. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 2

  36. INSTALL IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 2

  37. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  38. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 3

  39. INSTALL PORT FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 1

  40. INSTALL NO. 5 ENGINE WIRE 

    Refer to PROCEDURE - Step 2

  41. INSTALL INJECTOR VIBRATION INSULATOR 

    Refer to PROCEDURE - Step 3

  42. INSTALL NO. 1 DELIVERY PIPE SPACER 

    Refer to PROCEDURE - Step 4

  43. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  44. INSTALL NO. 7 WATER BY-PASS HOSE 

    Refer to PROCEDURE - Step 14

  45. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 1

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

    Refer to PROCEDURE - Step 2

  47. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 

    Refer to PROCEDURE - Step 3

  48. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 18

  49. CONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 10

  50. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 2

  51. INSTALL INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 3

  52. INSTALL NO. 2 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 22

  53. INSTALL NO. 3 WATER BY-PASS PIPE 

    Refer to PROCEDURE - Step 23

  54. SET EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  55. INSTALL EGR COOLER ASSEMBLY 

    Refer to PROCEDURE - Step 1

  56. INSTALL EGR VALVE ASSEMBLY 

    Refer to PROCEDURE - Step 3

  57. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 4

  58. INSTALL THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 1

  59. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  60. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst) 

    Refer to PROCEDURE - Step 2

  61. INSTALL MANIFOLD STAY 

    Refer to PROCEDURE - Step 4

  62. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 

    Refer to PROCEDURE - Step 6

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

    Refer to PROCEDURE - Step 33

  64. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 34

  65. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 35

  66. INSTALL ENGINE HANGERS 

    See step  41

  67. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND 

    Refer to INSTALLATION [07/2020 - ] 

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