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Installation [10/2015 - ]: 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.

  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 and cylinder block 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 Bolts And Nuts 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

  11. CONNECT INLET HEATER WATER HOSE A 

    Refer to PROCEDURE - Step 43

  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 80

  16. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY 

    See step  24

  17. INSTALL PURGE VALVE (PURGE VSV) 

    Refer to INSTALLATION [10/2015 - ]

  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 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 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 to the 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 [10/2015 - ]

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