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Installation [08/2015 - ]: Procedure

  1. INSTALL NO. 3 AIR TUBE 
    1. GTY590348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new gasket and the No. 3 air tube with the 2 bolts.

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

      TEXT IN ILLUSTRATION

      *1 Identification Color
      NOTE:

      Make sure that the gasket's claws are not caught between the air tube and electric air control valve assembly.

      HINT: 

      The identification color on the flange is orange.

  2. INSTALL NO. 2 AIR TUBE 
    1. GTY597436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install a new gasket and the No. 2 air tube with the 2 bolts.

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

      TEXT IN ILLUSTRATION

      *1 Identification Color
      NOTE:

      Make sure that the gasket's claws are not caught between the air tube and electric air control valve assembly.

      HINT: 

      The identification color on the flange is blue.

  3. INSTALL ELECTRIC AIR CONTROL VALVE ASSEMBLY 
    1. Install the electric air control valve assembly with the 3 bolts to the No. 1 heat exchanger cover.

      Torque: 21 N.m (214 kgf/cm, 16 ft.lbf) 

    2. Connect the 2 electric air control valve connectors.
    3. Install the bracket to the electric air control valve assembly with the bolt.

      Torque: 8.0 N.m (82 kgf/cm, 71 in.lbf) 

    4. Connect the knock sensor connector.
  4. INSTALL AIR PIPE SUB-ASSEMBLY 
    1. Connect the 2 No. 1 air hoses to the air pipe.
    2. Connect the air pipe to the electric air control valve assembly, and install the air pipe with the 2 bolts to the No. 1 heat exchanger cover.

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

    3. GTY596134Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Connect the air pump connector clamp holder.

      TEXT IN ILLUSTRATION

      *1 No. 2 air injection system hose
      *2 No. 3 air injection system hose
    4. Attach the wire harness claw.
    5. Connect the electric air control valve connector.
    6. Connect the No. 2 air injection system hose and No. 3 air injection system hose, and slide the 2 clamps to secure the hose.
  5. INSTALL NO. 3 WATER BY-PASS PIPE 

    HINT: 

    Perform this procedure only when replacement of the No. 3 water by-pass pipe is necessary.

    1. GTY605901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the No. 3 water by-pass pipe to the front water by-pass joint with the bolt.

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

      TEXT IN ILLUSTRATION

      *a Stopper
      *b Protrusion
      NOTE:

      Align the notch of the stopper with the protrusion of the front water by-pass joint.

  6. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install 2 new gaskets and the front water by-pass joint to the cylinder head with the 4 nuts.

      Torque: 21 N.m (214 kgf/cm, 16 ft.lbf) 

    2. Connect the engine coolant temperature sensor connector.
  7. CONNECT WATER BY-PASS PIPE HOSE (w/ Trailer Towing System) 
    1. Connect the water by-pass pipe hose with the 3 bolts to the timing chain cover and front water by-pass joint.

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

  8. CONNECT NO. 2 WATER BY-PASS HOSE 
    1. Connect the No. 2 water by-pass hose to the water by-pass joint, and slide the clamp to secure the hose.
  9. INSTALL NO. 1 WATER BY-PASS HOSE 
    1. Install the No. 1 water by-pass hose to the front water by-pass joint and water inlet housing, and slide the clamp to secure the hose.
  10. INSTALL NO. 10 WATER BY-PASS HOSE 
    1. GTY601036Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Install the No. 10 water by-pass hose to the separator case and front water by-pass joint, and slide the 2 clamps to secure the hose.

      TEXT IN ILLUSTRATION

      *1 No. 9 Water By-pass Hose
      *2 No. 10 Water By-pass Hose
      *a Paint Mark (Pink)
      *b Paint Mark (White)

      HINT: 

      Make sure that the color on the hose matches with the color on the case separator.

  11. INSTALL NO. 9 WATER BY-PASS HOSE 
    1. Install the No. 9 water by-pass hose to the separator case and front water by-pass joint, and slide the 2 clamps to secure the hose.

      HINT: 

      Make sure that the color on the hose matches with the color on the case separator.

  12. INSTALL NO. 1 ENGINE COVER 
    GTY125605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    Make sure that the No. 1 engine cover is level with the top surface of the intake port of the cylinder head for 1 and 2.

    1. Install the No. 1 engine cover.

      HINT: 

      • Align the No. 1 engine cover cutouts with the air tube.
      • Align the No. 1 engine cover with the air switching valve surface and cylinder head wall.
  13. CONNECT FUEL TUBE CLAMP 
    1. Connect the fuel tube clamp to the bracket.
  14. INSTALL NO. 2 CYLINDER HEAD COVER 
    GTY578728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    NOTE:

    Make sure that the No. 2 cylinder head cover is level with the top surface of the intake port of the cylinder head.

    1. Install the No. 2 cylinder head cover.

      HINT: 

      • Align the No. 2 cylinder head cover cutout with the air tube.
      • Align the No. 2 cylinder head cover with the front water by-pass joint and cylinder head wall.
  15. INSTALL FAN SHROUD 

    (Refer to INSTALLATION [08/2015 - ] )

  16. INSTALL INTAKE MANIFOLD 

    (Refer to INSTALLATION [08/2015 - ] )

  17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY 

    (Refer to INSTALLATION [08/2015 - ] )

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