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Installation [08/2015 - ]: Procedure

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  1. INSTALL NO. 9 WATER BY-PASS HOSE 
    1. Install the No. 9 water by-pass hose to the intercooler assembly and slide the clip to secure it.
      GTY658045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b RH
      *c Front

      HINT: 

      Engage the clip within the area shown in the illustration.

  2. INSTALL NO. 8 WATER BY-PASS HOSE 
    1. Install the No. 8 water by-pass hose to the intercooler assembly and slide the clip to secure it.
      GTY665502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b RH
      *c Front

      HINT: 

      Engage the clip within the area shown in the illustration.

    2. Install the intercooler assembly to the vehicle.
  3. SET INTERCOOLER ASSEMBLY 
    1. Set the intercooler assembly to the engine assembly.
  4. INSTALL INTAKE MANIFOLD 
    1. Install 2 new intake manifold gaskets to the intake manifold.
    2. Temporarily install the intake manifold to the cylinder head sub-assembly with the 4 bolts and 2 nuts.
    3. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.
      Fig 1: Intake Manifold Tightening sequence
      GTY681966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Bolt
      Nut

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

  5. CONNECT INLET HEATER WATER HOSE B 

    See step  12

  6. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY 

    See step  13

  7. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY 

    See step  14

  8. CONNECT NO. 3 WATER BY-PASS HOSE 

    See step  15

  9. CONNECT ENGINE WIRE 

    See step  16

  10. CONNECT OUTLET HEATER WATER HOSE A 

    Refer to PROCEDURE - Step 42 [08/2015 - 10/2016] , or refer to PROCEDURE - Step 42 [10/2016 - 09/2020] , or refer to PROCEDURE - Step 42 [09/2020 - ]

  11. CONNECT INLET HEATER WATER HOSE A 

    Refer to PROCEDURE - Step 43 [08/2015 - 10/2016] , or refer to PROCEDURE - Step 43 [10/2016 - 09/2020] , or refer to PROCEDURE - Step 43 [09/2020 - ]

  12. INSTALL NO. 2 WATER BY-PASS PIPE 

    See step  19

  13. INSTALL NO. 2 VENTILATION HOSE 

    See step  20

  14. INSTALL AIR CLEANER HOSE ASSEMBLY 

    See step  3

  15. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 81 [08/2015 - 10/2016] , or refer to PROCEDURE - Step 80 [10/2016 - 09/2020] , or refer to PROCEDURE - Step 80 [09/2020 - ]

  16. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY 

    See step  24

  17. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to INSTALLATION [08/2015 - ]

  18. INSTALL INTERCOOLER ASSEMBLY 
    1. Install the intercooler assembly to the intercooler support bracket sub-assembly with the 3 bolts.

      Torque: 9.3 N.m (95 kgf/cm, 82 in.lbf) 

  19. CONNECT NO. 1 AIR TUBE 
    1. Connect the No. 1 air tube to the intercooler assembly and tighten the hose clamp.

      Torque: 6.3 N.m (64 kgf/cm, 56 in.lbf) 

  20. CONNECT ENGINE WIRE 
    1. Connect the engine wire with the bolt.

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

    2. Engage the 2 clamps.
  21. INSTALL HEATER WATER PUMP ASSEMBLY 
    1. Install the heater water pump assembly to the heater water pump bracket with the 2 bolts.

      Torque: 9.8 N.m (100 kgf/cm, 87 in.lbf) 

  22. CONNECT NO. 9 WATER BY-PASS HOSE 
    1. Connect the No. 9 water by-pass hose to the No. 6 water by-pass pipe and slide the clip to secure it.
      GTY625714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Rear
      *c Lower

      HINT: 

      Engage the clip within the area shown in the illustration.

  23. CONNECT NO. 8 WATER BY-PASS HOSE 
    1. Connect the No. 8 water by-pass hose to the No. 2 water by-pass pipe and slide the clip to secure it.
      GTY654434Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Upper
      *c RH

      HINT: 

      Engage the clip within the area shown in the illustration.

  24. CONNECT NO. 1 VACUUM TRANSMITTING HOSE 
    1. Connect the No. 1 vacuum transmitting hose assembly to the intercooler assembly and slide the clip to secure it as shown in the illustration.
      GTY644456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 2 to 5 mm (0.0787 to 0.197 in.)
  25. CONNECT NO. 2 TURBO WATER HOSE 
    1. Connect the No. 2 turbo water hose sub-assembly to the No. 6 water by-pass pipe and slide the clip to secure it.
      GTY675880Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a View A
      *b Front
      *c RH

      HINT: 

      Engage the clip within the area shown in the illustration.

  26. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to INSTALLATION [08/2015 - ]

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