TURBOCHARGER (w/ EGR Cooler) INSTALLATION

CLEAN TURBOCHARGER SUB-ASSEMBLY
INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Variable Nozzle Vane Turbocharger)
1. Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly.
2. Text in Illustration
  
  *1 New Gasket
  
  Install a new gasket and No. 1 turbo water pipe sub-assembly with the bolt and 2 nuts.
  
  Torque:
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  for nut
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }

Text in Illustration
*1	New Gasket

INSTALL TURBOCHARGER SUB-ASSEMBLY

Temporarily install a new gasket and the turbocharger sub-assembly with 3 new nuts.

Tech Tips

When installing the turbo oil pipe sub-assembly, loosely tighten the 3 nuts so that the turbocharger sub-assembly and cylinder head can be aligned easily.
Temporarily install the turbo oil inlet pipe sub-assembly.

Tech Tips

Before installing the oil inlet pipe sub-assembly, clean it.
1. Temporarily install a new gasket and the oil inlet pipe sub-assembly with the 2 nuts.
  
  Note
  
  The notch (wide part) of the gasket must face the engine.
2. Temporarily install a new gasket and the oil inlet pipe sub-assembly with the 2 bolts.
  
  Note
  
  The claws of the gasket must face the pipe.
3. Temporarily install a new gasket and the oil inlet pipe sub-assembly with the union bolt.
4. Temporarily install the turbocharger stay with the 2 bolts and nut.

Tighten the 3 nuts of the turbocharger sub-assembly.

Torque:: 52 N*m { 530 kgf*cm, 38 ft.*lbf }

Text in Illustration
*1	New Gasket	*2	Claw
*3	Narrow	*4	Wide
	Outside	-	-

Tighten the 2 nuts labeled A.

Torque:

13 N*m { 133 kgf*cm, 10 ft.*lbf }
Tighten the union bolt labeled B.

Torque:

26 N*m { 265 kgf*cm, 19 ft.*lbf }
Tighten the 2 bolts labeled C.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }

Text in Illustration
*A	for Waste Gate Type Turbocharger
*B	for Variable Nozzle Vane Turbocharger

Tighten the 2 bolts and nut of the turbocharger stay in the order shown in the illustration.

Torque:: 38 N*m { 387 kgf*cm, 28 ft.*lbf }

INSTALL TURBINE OUTLET ELBOW
1. for Waste Gate Type Turbocharger:
  
  Install a new gasket and the turbine outlet elbow with the 4 new nuts.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
2. for Variable Nozzle Vane Turbocharger:
  
  Install a new gasket and the turbine outlet elbow with the 3 new nuts.
  
  Torque:
  
  26 N*m { 260 kgf*cm, 19 ft.*lbf }
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. for Waste Gate Type Turbocharger:
  
  Install the No. 1 exhaust manifold heat insulator with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
2. for Variable Nozzle Vane Turbocharger:
  
  Temporarily install the No. 1 exhaust manifold heat insulator with the bolt.
INSTALL NO. 1 TURBO INSULATOR (for Variable Nozzle Vane Turbocharger)
1. Temporarily install the No. 1 turbo insulator with the 2 bolts.
2. Tighten the bolt of the No. 1 exhaust manifold heat insulator, and the 2 bolts of the No. 1 turbo insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL COMPRESSOR INLET ELBOW (for Waste Gate Type Turbocharger)
1. Install the No. 3 air cleaner hose to the turbocharger sub-assembly.
2. Text in Illustration
  
  *1 Protrusion
  
  Install the air cleaner hose and No. 3 air cleaner hose with the clamp labeled A as shown in the illustration.
  
  Tech Tips
  
  Align the protrusion of the turbocharger sub-assembly and the protrusion of the hose.
3. Install the compressor inlet elbow with the clamp labeled B as shown in the illustration.
  
  Tech Tips
  
  Install the inlet elbow with the clamp labeled B as shown in the illustration.
4. Tighten 2 clamps.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL COMPRESSOR INLET ELBOW (for Variable Nozzle Vane Turbocharger)
1. Install the No. 12 water by-pass hose to the compressor inlet elbow.
2. Install the No. 2 water by-pass hose and No. 7 water by-pass hose to the compressor inlet elbow.
3. Install a new gasket and the compressor inlet elbow with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
4. Connect the No. 13 water by-pass hose to the No. 2 water by-pass pipe sub-assembly.
5. Connect the No. 2 water by-pass hose to the No. 1 turbo water pipe sub-assembly.
6. Connect the No. 1 turbo water hose to the cylinder block.
7. Connect the 2 connectors and attach the wire harness clamp.
INSTALL VENTILATION PIPE
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. for Variable Nozzle Vane Turbocharger:
  
  Connect the No. 12 water by-pass hose and No. 13 water by-pass hose.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Using a vernier caliper, measure the free length of the compression spring.
  
  Minimum length
  
  40 mm (1.57 in.)
  
  If the free length is less than the minimum, replace the compression spring.
2. Install the front pipe to the pipe support.
3. Install a new gasket to the outlet pipe.
  Note
  
  Be careful with the installation direction of the gasket.
  
  Do not reuse the gasket.
  
  To ensure a proper seal, do not use the front pipe to force the gasket onto the outlet pipe.
  Tech Tips
  
  Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.
4. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.
  
  Torque:
  
  43 N*m { 438 kgf*cm, 32 ft.*lbf }
  
  CAUTION:
  
  Do not reuse the gasket.
INSTALL FRONT FENDER SEAL
1. Install the front fender seal with the 5 clips.
INSTALL FRONT FENDER APRON SEAL UPPER
1. Install the front fender apron seal upper with the 5 clips.
INSTALL INTERCOOLER ASSEMBLY

Click here
INSTALL AIR CLEANER ASSEMBLY
1. Install the air cleaner with the 2 bolts.
  
  Torque:
  
  14 N*m { 143 kgf*cm, 10 ft.*lbf }
2. w/ Intake Air Temperature Sensor:
  
  Connect the connector to the intake air temperature sensor.
3. w/ Mass Air Flow Meter:
  
  Connect the connector to the mass air flow meter.
4. Tighten the hose clamp.
5. w/o EGR Cooler:
  
  Connect the ventilation hose.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD ENGINE COOLANT (for Variable Nozzle Vane Turbocharger)
1. Tighten the radiator drain cock plug by hand.
2. Tighten the cylinder block drain cock plug.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.
  
  Standard capacity
  
  9.8 liters (10.4 US qts, 8.6 Imp. qts)
  
  Tech Tips
  
  TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
  
  Note
  
  Never use water as a substitute for engine coolant.
4. Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
  
  If the coolant level drops below the B line, add TOYOTA SLLC to the B line.
5. Install the radiator reservoir cap.
6. Using a wrench, install the vent plug.
  
  Torque:
  
  2.0 N*m { 20 kgf*cm, 18 in.*lbf }
7. Bleed air from the cooling system.
  1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
    
    Tech Tips
    
    The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.
  2. Maintain the engine speed at 2500 to 3000 rpm.
  3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
    CAUTION:
    
    When pressing the radiator hoses:
    
    Wear protective gloves.
    
    Be careful as the radiator hoses are hot.
    
    Keep your hands away from the radiator fan.
  4. Stop the engine and wait until the coolant cools down to ambient temperature.
    
    CAUTION:
    
    Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
8. After the coolant cools down, check that the coolant level is at the F line.
  
  If the coolant level is below the F line, add TOYOTA SLLC to the F line.
INSPECT FOR COOLANT LEAK (for Variable Nozzle Vane Turbocharger)
Note

Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
1. Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.
2. Warm up the engine.
3. Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm²,17.1 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks.
  
  If no external leaks are found, check the cylinder block and head.
INSPECT FOR OIL LEAK
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.
  
  If the oil level is low, check for leakage and add oil up to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.
INSTALL NO. 2 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }
INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

Torque:

28 N*m { 286 kgf*cm, 21 ft.*lbf }