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Installation [08/2015 - ]: Procedure

  1. INSTALL NO. 3 AIR TUBE 
    1. Install a new gasket and the No. 3 air tube with the 2 bolts.

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

      HINT: 

      The identification color on the flange is orange.

      GTY555038Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the claws on the gasket are not caught between the air tube and air switching valve.

  2. INSTALL NO. 2 AIR TUBE 
    1. Install a new gasket and the No. 2 air tube with the 2 bolts.

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

      HINT: 

      The identification color on the flange is blue.

      GTY601773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure the claws on the gasket are not caught between the air tube and air switching valve.

  3. INSTALL AIR SWITCHING VALVE ASSEMBLY 
    1. Install the air switching valve with the 3 bolts.

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

      GTY608818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the 2 air switching valve connectors.
    3. Install the bracket with the bolt.

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

      GTY611362Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Connect the knock sensor connector.
  4. INSTALL AIR PIPE SUBASSEMBLY 
    1. Connect the 2 No. 1 air hoses to the air pipe.
    2. Connect the air pipe to the air switching valve, and install the air pipe with the 2 bolts.

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

      GTY589048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Connect the air pump connector clamp holder.
      GTY596133Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Attach the wire harness claw.
    5. Connect the air pump connector.
    6. Connect the No. 2 and No. 3 hoses.
  5. INSTALL FRONT WATER BY-PASS JOINT 
    1. Install 2 new gaskets and the front water by-pass joint with the 4 nuts.

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

      GTY589050Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Connect the engine coolant temperature sensor connector.
  6. CONNECT NO. 2 WATER BY-PASS PIPE SUBASSEMBLY (w/ Oil Cooler) 
    1. Connect the No. 2 water by-pass pipe with the 3 bolts.

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

      GTY611620Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. CONNECT NO. 2 WATER BY-PASS HOSE 
    1. Connect the No. 2 water by-pass hose to the water by-pass joint.
      GTY588210Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. CONNECT NO. 1 WATER BY-PASS HOSE 
    1. Connect the No. 1 water by-pass hose to the water by-pass joint and water inlet housing.
  9. INSTALL NO. 1 ENGINE COVER 
    GTY125605Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    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.
    NOTE:

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

  10. CONNECT FUEL TUBE CLAMP 
    1. Connect the fuel tube clamp to the bracket.
      GTY608815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL NO. 2 ENGINE COVER 
    GTY125767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT: 

    • Align the No. 2 engine cover cutout with the air tube.
    • Align the No. 2 engine cover with the front water by-pass joint and cylinder head wall.
    NOTE:

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

  12. INSTALL INTAKE MANIFOLD 
    1. Install the intake manifold (Refer to INSTALLATION [08/2015 - ] ).
  13. INSTALL EXHAUST MANIFOLD SUBASSEMBLY 
    1. Install the exhaust manifold (Refer to INSTALLATION [08/2015 - ] ).
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