Installation [03/2023 - ]: Procedure

INSTALL CYLINDER HEAD GASKET

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Lot No.	-	-
	Front of Engine	-	-

Clean the cylinder block sub-assembly and cylinder head sub-assembly with solvent.
Place a new cylinder head gasket on the cylinder block sub-assembly as shown in the illustration.
NOTE:
- Make sure that the cylinder head gasket is installed in the correct orientation.
- Remove any oil from the contact surfaces.
- Pay attention to the installation direction.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 17
for PHEV Model:
Refer to PROCEDURE - Step 18

INSTALL VALVE STEM CAP

for HEV Model:
Refer to PROCEDURE - Step 19
for PHEV Model:
Refer to PROCEDURE - Step 20

INSTALL VALVE LASH ADJUSTER ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 20
for PHEV Model:
Refer to PROCEDURE - Step 21

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 21
for PHEV Model:
Refer to PROCEDURE - Step 22

INSTALL EXHAUST CAMSHAFT SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 22
for PHEV Model:
Refer to PROCEDURE - Step 23

INSTALL INTAKE CAMSHAFT SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 23
for PHEV Model:
Refer to PROCEDURE - Step 24

INSTALL CAMSHAFT BEARING CAP

for HEV Model:
Refer to PROCEDURE - Step 24
for PHEV Model:
Refer to PROCEDURE - Step 25

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 25
for PHEV Model:
Refer to PROCEDURE - Step 26

INSTALL FUEL PUMP LIFTER GUIDE

for HEV Model:
Refer to PROCEDURE - Step 26
for PHEV Model:
Refer to PROCEDURE - Step 27

INSTALL TIMING CHAIN COVER ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 29
for PHEV Model:
Refer to PROCEDURE - Step 30

INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 30
for PHEV Model:
Refer to PROCEDURE - Step 31

SET NO. 1 CYLINDER TO TDC (COMPRESSION)

for HEV Model:
Refer to PROCEDURE - Step 31
for PHEV Model:
Refer to PROCEDURE - Step 32

INSTALL NO. 1 CHAIN VIBRATION DAMPER
- for HEV Model:
  Refer to PROCEDURE - Step 32
- for PHEV Model:
  Refer to PROCEDURE - Step 33
INSTALL CHAIN TENSIONER SLIPPER
- for HEV Model:
  Refer to PROCEDURE - Step 33
- for PHEV Model:
  Refer to PROCEDURE - Step 34

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 34
for PHEV Model:
Refer to PROCEDURE - Step 35

INSTALL CHAIN SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 35
for PHEV Model:
Refer to PROCEDURE - Step 36

INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 36
for PHEV Model:
Refer to PROCEDURE - Step 37

INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 37
for PHEV Model:
Refer to PROCEDURE - Step 38

SET NO. 1 CYLINDER TO TDC (COMPRESSION)

for HEV Model:
Refer to PROCEDURE - Step 27
for PHEV Model:
Refer to PROCEDURE - Step 27

INSTALL NO. 2 TIMING CHAIN COVER ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 39
for PHEV Model:
Refer to PROCEDURE - Step 40

INSTALL TIMING CHAIN COVER OIL SEAL

See step 1

INSTALL SPARK PLUG TUBE GASKET

for HEV Model:
Refer to PROCEDURE - Step 42
for PHEV Model:
Refer to PROCEDURE - Step 43

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 43
for PHEV Model:
Refer to PROCEDURE - Step 44

INSTALL WATER OUTLET PIPE GASKET

INSTALL WATER BY-PASS OUTLET

for HEV Model:
Refer to PROCEDURE - Step 45
for PHEV Model:
Refer to PROCEDURE - Step 46

INSTALL WATER OUTLET GASKET

INSTALL WATER OUTLET SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 47
for PHEV Model:
Refer to PROCEDURE - Step 48

INSTALL CRANKSHAFT PULLEY ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 49
for PHEV Model:
Refer to PROCEDURE - Step 50

INSTALL CAM TIMING CONTROL MOTOR O-RING

Refer to PROCEDURE - Step 1
INSTALL CAM TIMING CONTROL MOTOR WITH EDU ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL CAM TIMING OIL CONTROL SOLENOID O-RING

Refer to PROCEDURE - Step 1
INSTALL CAM TIMING OIL CONTROL SOLENOID ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL OIL PRESSURE CONTROL VALVE ASSEMBLY

Refer to PROCEDURE - Step 1

INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

for HEV Model:
Refer to PROCEDURE - Step 5
for PHEV Model:
Refer to PROCEDURE - Step 5

INSTALL IGNITION COIL ASSEMBLY

Refer to PROCEDURE - Step 2
INSTALL FUEL INJECTOR SEAL

Refer to PROCEDURE - Step 1
INSTALL INJECTOR VIBRATION INSULATOR

Refer to PROCEDURE - Step 2
INSTALL C-RING

Refer to PROCEDURE - Step 3
INSTALL NO. 1 FUEL INJECTOR BACK-UP RING

Refer to PROCEDURE - Step 4
INSTALL NO. 3 FUEL INJECTOR BACK-UP RING

Refer to PROCEDURE - Step 5
INSTALL NOZZLE HOLDER CLAMP
INSTALL DIRECT FUEL INJECTOR ASSEMBLY

Refer to PROCEDURE - Step 7
INSTALL FUEL DELIVERY PIPE

Refer to PROCEDURE - Step 8
CONNECT WIRE HARNESS
INSTALL PORT FUEL INJECTOR ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL NO. 5 ENGINE WIRE
INSTALL INJECTOR VIBRATION INSULATOR
INSTALL FUEL DELIVERY SPACER

Refer to PROCEDURE - Step 4
INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 5
INSTALL WATER BY-PASS HOSE ASSEMBLY
- for HEV Model:
  Refer to PROCEDURE - Step 22
- for PHEV Model:
  Refer to PROCEDURE - Step 22
INSTALL FUEL PUMP LIFTER ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL FUEL PUMP SPACER GASKET
TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Refer to PROCEDURE - Step 3
TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 4
INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

Refer to PROCEDURE - Step 5
INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 6

CONNECT FUEL TUBE SUB-ASSEMBLY

for HEV Model:
Refer to PROCEDURE - Step 29
for PHEV Model:
Refer to PROCEDURE - Step 29

INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
INSTALL INTAKE MANIFOLD

Refer to PROCEDURE - Step 3
INSTALL INTAKE MANIFOLD STAY

Refer to PROCEDURE - Step 4

INSTALL NO. 3 WATER BY-PASS PIPE

for HEV Model:
Refer to PROCEDURE - Step 33
for PHEV Model:
Refer to PROCEDURE - Step 33

SET EGR VALVE ASSEMBLY

Refer to PROCEDURE - Step 1
INSTALL NO. 8 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 2
INSTALL NO. 4 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 3
INSTALL NO. 1 EGR COOLER GASKET

Refer to PROCEDURE - Step 3
INSTALL EGR VALVE GASKET

Refer to PROCEDURE - Step 4
INSTALL EGR COOLER ASSEMBLY

Refer to PROCEDURE - Step 5
CONNECT NO. 4 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 6
CONNECT NO. 3 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 7
INSTALL EGR VALVE ASSEMBLY

Refer to PROCEDURE - Step 5
INSTALL EGR INLET GASKET
INSTALL EGR VALVE ADAPTER GASKET
INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

Refer to PROCEDURE - Step 8
INSTALL THROTTLE BODY GASKET

Refer to PROCEDURE - Step 1
CONNECT NO. 8 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 2
INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

Refer to PROCEDURE - Step 3
CONNECT NO. 5 WATER BY-PASS HOSE

Refer to PROCEDURE - Step 4
INSTALL EXHAUST MANIFOLD

Refer to PROCEDURE - Step 1
INSTALL MANIFOLD STAY

Refer to PROCEDURE - Step 3
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Refer to PROCEDURE - Step 4
INSTALL AIR FUEL RATIO SENSOR

Refer to PROCEDURE - Step 1
INSTALL WIRE HARNESS CLAMP BRACKET

Refer to PROCEDURE - Step 2

INSTALL ENGINE HANGERS

for HEV Model:
See step 46
for PHEV Model:
See step 47

REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
- for HEV Model:
  Refer to INSTALLATION [12/2022 - ]
- for PHEV Model:
  Refer to INSTALLATION [03/2023 - ]