Air Switching Valve: Installation

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.
  
  NOTE: Make sure the claws on the gasket are not caught between the air tube and air switching valve.
  
  Fig 1: Locating No. 3 Air Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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.
  
  NOTE: Make sure the claws on the gasket are not caught between the air tube and air switching valve.
  
  Fig 2: Locating No. 2 Air Tube Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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)
2. Connect the 2 air switching valve connectors.
  
  Fig 3: Locating Air Switching Valve With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the bracket with the bolt.
  Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
4. Connect the knock sensor connector.
  
  Fig 4: Locating Knock Sensor Connector
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL AIR PIPE SUB-ASSEMBLY
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)
  
  Fig 5: Locating No. 1 Air Hoses Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Connect the air pump connector clamp holder.
4. Attach the wire harness claw.
5. Connect the air pump connector.
  
  Fig 6: Locating Air Pump Connector Clamp Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Connect the No. 2 and No. 3 hoses.
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)
2. Connect the engine coolant temperature sensor connector.
  
  Fig 7: Locating Front Water By-Pass Joint Nuts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (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)
  
  Fig 8: Locating No. 2 Water By-Pass Pipe Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT NO. 2 WATER BY-PASS HOSE
1. Connect the No. 2 water by-pass hose to the water by-pass joint.
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.
  
  Fig 9: Locating Water By-Pass Hose Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL 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.
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.

Fig 10: Aligning No. 1 Engine Cover With Air Switching Valve Surface And Cylinder Head Wall
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
CONNECT FUEL TUBE CLAMP
1. Connect the fuel tube clamp to the bracket.
  
  Fig 11: Locating Fuel Tube Clamp
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL NO. 2 ENGINE COVER
HINT:
- Align the No. 2 engine cover cutout with the air tube.
- Align the No. 2 engine cover with the front water bypass joint and cylinder head wall.
  
  Fig 12: Identifying No. 2 Engine Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
NOTE: Make sure that the No. 2 engine cover is flush with the top surface of the intake port of the cylinder head.
INSTALL INTAKE MANIFOLD
1. Install the intake manifold (See INSTALLATION ).
INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY
1. Install the exhaust manifold (See INSTALLATION ).