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Installation [06/2016 - ]: Procedure

  1. INSTALL IGNITION COIL ASSEMBLY 
    1. Install the 4 ignition coils with the 4 bolts.

      Torque: 8.5 N*m (87 kgf*cm, 75 in.*lbf) 

  2. INSTALL NO. 1 WATER BY-PASS PIPE (for Manual Transmission) 
    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

    2. Connect the water by-pass hose with the hose clamp.
  3. INSTALL NO. 1 WATER BY-PASS PIPE (for Automatic Transmission) 
    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

    2. Connect the 2 water by-pass hoses with the 2 hose clamps.
  4. CONNECT NO. 3 TRANSMISSION OIL COOLER HOSE (for Automatic Transmission) 
    1. Connect the No. 3 transmission oil cooler hose with the hose clamp.
  5. INSTALL NO. 2 WATER BY-PASS HOSE 
    1. Connect the No. 2 water by-pass hose with the clamp.
      GTY727646Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. CONNECT NO. 2 VENTILATION HOSE 
    1. Connect the No. 2 ventilation hose.
  7. INSTALL ENGINE WIRE 
    1. Connect the ground wire with the 2 bolts.

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

    2. Connect each connector and each clamp to fix the engine wire as shown in the illustration, and check that the engine wire is correctly installed.
      GTY695830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Ground Wire - -
      *a Upper side *b Front side
      *c Right side *d Left side
  8. INSTALL PUMP DRIVE CASE ASSEMBLY 

    Refer to PROCEDURE - Step 1

  9. INSTALL VALVE LIFTER 

    Refer to PROCEDURE - Step 2

  10. INSTALL FUEL PUMP ASSEMBLY 

    Refer to PROCEDURE - Step 3

  11. INSTALL FUEL INJECTOR O-RING 

    Refer to PROCEDURE - Step 1

  12. INSTALL FUEL INJECTOR ASSEMBLY 

    Refer to PROCEDURE - Step 2

  13. INSTALL FUEL DELIVERY PIPE LH 

    Refer to PROCEDURE - Step 3

  14. INSTALL FUEL DELIVERY PIPE RH 

    Refer to PROCEDURE - Step 4

  15. INSTALL FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 5

  16. INSTALL NO. 2 FUEL DELIVERY PIPE 

    Refer to PROCEDURE - Step 6

  17. INSTALL INTAKE MANIFOLD 
    1. Install 2 new gaskets to the intake manifold.
    2. Install the intake manifold with the 6 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

    3. Engage the 2 clamps and connect the 4 connectors.
    4. Connect the fuel pump connector.
    5. Connect the No. 1 vacuum switching valve assembly connector.
    6. Connect the vacuum sensor connector.
    7. Connect the 2 water by-pass hoses to the throttle body assembly.
    8. Connect the throttle body assembly connector.
  18. CONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 2

  19. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY 
    1. Install the fuel delivery pipe sub-assembly to the fuel pump assembly with a new gasket and the union bolt.

      Torque: 31 N*m (316 kgf*cm, 23 ft.*lbf) 

    2. Connect the No. 2 fuel vapor feed hose.
    3. Install the bolt and connect the fuel delivery pipe sub-assembly.

      Torque: 6.4 N*m (65 kgf*cm, 57 in.*lbf) 

  20. INSTALL INJECTOR COVER (for Bank 2) 
    1. for Automatic Transmission:
      1. Install the injector cover to the intake manifold with the 2 bolts.

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

    2. for Manual Transmission:
      1. Engage the 2 guides and install the injector cover to the intake manifold with the 2 bolts.

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

  21. INSTALL INJECTOR COVER (for Bank 1) 
    1. for Automatic Transmission:
      1. Install the injector cover to the intake manifoldwith the 2 bolts.

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

    2. for Manual Transmission:
      1. Engage the 2 guides and install the injector cover to the intake manifold with the 2 bolts.

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

  22. INSTALL COMPRESSOR WITH MAGNET CLUTCH 

    Refer to PROCEDURE - Step 2

  23. INSTALL GENERATOR BRACKET 
    1. Temporarily install the generator bracket with the 4 bolts.
    2. Tighten the 4 bolts in the order shown in the illustration.
      GTY773232Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf) 

  24. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Align the stopper pin and the positioning hole, and then install the V-ribbed belt tensioner assembly using an 8 mm hexagon socket wrench.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

      GTY766714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Stopper pin
      *b Positioning hole
    2. Install the cap.
  25. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 5

  26. INSTALL OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 6

  27. INSTALL GENERATOR ASSEMBLY 
    1. Install the generator assembly with the 2 bolts.

      Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) 

  28. INSTALL FAN AND GENERATOR V BELT 

    See step  1

  29. INSTALL BELT GENERATOR COVER 

    See step  2

  30. INSTALL GENERATOR COVER 

    See step  3

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