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Installation [03/2023 - ]: Procedure

  1. INSTALL WIRE HARNESS CLAMP BRACKET 
    1. GTY1147503Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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) 

      2. Using an 8 mm socket wrench, install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

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

  2. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR 

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

  3. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING) 

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

  4. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 1
  5. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. GTY1154471Courtesy 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 camshaft housing sub-assembly with the bolt.

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

      4. Install the engine oil level dipstick.
  6. INSTALL IGNITION COIL ASSEMBLY 
    Refer to PROCEDURE - Step 2
  7. INSTALL FUEL INJECTOR SEAL 
    Refer to PROCEDURE - Step 1
  8. INSTALL INJECTOR VIBRATION INSULATOR 
    Refer to PROCEDURE - Step 2
  9. INSTALL C-RING 
    Refer to PROCEDURE - Step 3
  10. INSTALL NO. 1 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 4
  11. INSTALL NO. 3 FUEL INJECTOR BACK-UP RING 
    Refer to PROCEDURE - Step 5
  12. INSTALL NOZZLE HOLDER CLAMP 
  13. INSTALL DIRECT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 7
  14. INSTALL FUEL DELIVERY PIPE 
    Refer to PROCEDURE - Step 8
  15. INSTALL PORT FUEL INJECTOR ASSEMBLY 
    Refer to PROCEDURE - Step 1
  16. INSTALL NO. 5 ENGINE WIRE 
  17. INSTALL INJECTOR VIBRATION INSULATOR 
  18. INSTALL FUEL DELIVERY SPACER 
    Refer to PROCEDURE - Step 4
  19. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 5
  20. INSTALL NO. 6 ENGINE WIRE 

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

  21. INSTALL SENSOR WIRE 
    1. GTY1159883Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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 3 connectors.
  22. INSTALL WATER BY-PASS HOSE ASSEMBLY 

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

  23. INSTALL FUEL PUMP LIFTER ASSEMBLY 
    Refer to PROCEDURE - Step 1
  24. INSTALL FUEL PUMP SPACER GASKET 
  25. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 
    Refer to PROCEDURE - Step 3
  26. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 4
  27. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure) 
    Refer to PROCEDURE - Step 5
  28. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 6
  29. CONNECT FUEL TUBE SUB-ASSEMBLY 
    1. GTY1148718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Connect the fuel tube sub-assembly to the fuel delivery pipe sub-assembly.

        Refer to PRECAUTION [03/2023 - ]

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

        Refer to PRECAUTION [03/2023 - ]

      3. Install the fuel pipe clamp to the fuel tube connector.
  30. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET 
  31. INSTALL INTAKE MANIFOLD 
    Refer to PROCEDURE - Step 3
  32. INSTALL INTAKE MANIFOLD STAY 
    Refer to PROCEDURE - Step 4
  33. INSTALL NO. 3 WATER BY-PASS PIPE 
    1. GTY1140232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. 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) 

      2. Connect the No. 3 water by-pass pipe to the water outlet sub-assembly and slide the clip to secure it.
  34. SET EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 1
  35. INSTALL NO. 8 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 2
  36. INSTALL NO. 4 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 3
  37. INSTALL NO. 1 EGR COOLER GASKET 
    Refer to PROCEDURE - Step 3
  38. INSTALL EGR VALVE GASKET 
    Refer to PROCEDURE - Step 4
  39. INSTALL EGR COOLER ASSEMBLY 
    Refer to PROCEDURE - Step 5
  40. CONNECT NO. 4 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 6
  41. CONNECT NO. 3 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 7
  42. INSTALL EGR VALVE ASSEMBLY 
    Refer to PROCEDURE - Step 5
  43. INSTALL EGR INLET GASKET 
  44. INSTALL EGR VALVE ADAPTER GASKET 
  45. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY 
    Refer to PROCEDURE - Step 8
  46. INSTALL THROTTLE BODY GASKET 
    Refer to PROCEDURE - Step 1
  47. CONNECT NO. 8 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 2
  48. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 
    Refer to PROCEDURE - Step 3
  49. CONNECT NO. 5 WATER BY-PASS HOSE 
    Refer to PROCEDURE - Step 4
  50. INSTALL EXHAUST MANIFOLD 
    Refer to PROCEDURE - Step 1
  51. INSTALL MANIFOLD STAY 
    Refer to PROCEDURE - Step 3
  52. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    Refer to PROCEDURE - Step 4
  53. INSTALL AIR FUEL RATIO SENSOR 
    Refer to PROCEDURE - Step 1
  54. INSTALL WIRE HARNESS CLAMP BRACKET 
    Refer to PROCEDURE - Step 2
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