TURBOCHARGER (for DPF) INSTALLATION


  1. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY


    1. Install a new gasket and the No. 1 turbo water pipe with the 2 nuts and bolt.

      Torque:
      for bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
  2. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. Temporarily install a new gasket with the turbocharger and 3 new nuts.

      Tech Tips

      It is easier to install the turbo oil inlet pipe if the 3 nuts are only loosely installed.

    2. Temporarily install the turbo oil inlet pipe.

      Tech Tips

      Before installing the turbo oil inlet pipe, clean it.


      1. Install a new gasket and the turbo oil inlet pipe with the 2 nuts, but only loosely install the nuts.

        A01DVN9E01
        Text in Illustration
        *1 New Gasket *2 Claw
        *3 Narrow *4 Wide
        A01E2TX Outside - -

        Note

        The notch (narrow part) of the gasket must face the engine.

      2. Install a new gasket and the turbo oil inlet pipe with the 2 bolts, but only loosely install the bolts.

        Note

        The claws of the gasket must face the pipe.

      3. Install a new gasket and the turbo oil inlet pipe with the union bolt, but only loosely install the union bolt.

      4. Temporarily install the turbocharger stay with the 2 bolts and a new nut.

    3. Tighten the 3 nuts of the turbocharger.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    4. Tighten the 2 nuts labeled A.

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

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }
    6. Tighten the 2 bolts labeled C.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    7. A01E1LJE01

      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 }
  3. CONNECT NO. 1 TURBO WATER HOSE


    1. Connect the No. 1 turbo water hose to the cylinder block.

    2. Connect the No. 1 turbo water hose to the No. 2 water by-pass pipe.

  4. INSTALL TURBINE OUTLET ELBOW


    1. Install a new gasket and the No. 4 water by-pass pipe to the turbine outlet elbow with the union bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    2. Install a new gasket and the No. 3 water by-pass pipe to the turbine outlet elbow with the bolt and union bolt.

      Torque:
      for bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for union bolt
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    3. Temporarily install the turbine outlet elbow and a new gasket with 3 new nuts.

      A01E23ZE01
      Text in Illustration
      *1 New Gasket *2 Union Bolt
      *3 No. 3 Water By-pass Pipe *4 No. 4 Water By-pass Pipe
      *5 No. 3 Turbo Water Hose *6 Turbine Outlet Elbow
      *7 No. 1 Fuel Pipe - -
    4. Temporarily install the No. 1 fuel pipe and a new gasket with the union bolt.

    5. Tighten the 3 nuts of the turbine outlet elbow.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }
    6. Connect the No. 3 water by-pass pipe to the No. 3 turbo water hose.

  5. TIGHTEN NO. 1 FUEL PIPE


    1. Tighten the union bolt of the No. 1 fuel pipe.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    2. Attach the clamp and connect the No. 4 turbo water hose to the No. 4 water by-pass pipe.

    3. Connect the exhaust fuel addition injector connector.

  6. INSTALL NO. 2 TURBINE OUTLET ELBOW


    1. Install a new gasket and the No. 2 turbine outlet elbow with 3 new nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
  7. INSTALL TURBINE OUTLET ELBOW STAY


    1. Install the turbine outlet elbow stay with the bolt and nut.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
    2. Attach the wire harness clamp.

  8. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
  9. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
  10. TEMPORARILY INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Temporarily install the No. 1 exhaust manifold heat insulator with the bolt.

  11. INSTALL NO. 1 TURBO INSULATOR


    1. Temporarily install the No. 1 turbo insulator with the 2 bolts.

    2. Tighten the 2 bolts of the No. 1 exhaust manifold heat insulator and the bolt of the No. 1 turbo insulator.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
  12. INSTALL COMPRESSOR INLET ELBOW


    1. Install a new gasket and the compressor inlet elbow with the 2 nuts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    2. Attach the wire harness clamp and connect the 2 connectors.

  13. INSTALL VENTILATION HOSE CLAMP


    1. Install the ventilation hose clamp with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
  14. INSTALL AIR CLEANER ASSEMBLY


    1. Install the air cleaner together with the No. 1 air cleaner hose with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. Connect the No. 1 air cleaner hose and tighten the hose clamp of the compressor inlet elbow.

    3. Install the ventilation hose and attach the ventilation hose clamp.

    4. Connect the mass air flow meter connector and attach the wire harness clamp.

  15. INSTALL FRONT FENDER SEAL


    1. Install the front fender seal with the 5 clips.

  16. INSTALL FRONT FENDER APRON SEAL UPPER


    1. Install the front fender apron seal upper with the 5 clips.

  17. INSTALL INTERCOOLER ASSEMBLY

    Click here

  18. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  19. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  20. ADD ENGINE COOLANT


    1. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Tighten the radiator drain cock plug by hand.

    3. A01DYVNE01

      Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the reservoir tank's B line.

      Standard capacity
      Item Specified Condition
      A/T 11.1 liters (11.7 US qts, 9.8 Imp. qts)
      M/T 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. A01DY58E01

      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. A01E2D9E01

      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.

  21. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

      • The hand pump must be pushed with a full stroke during pumping.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use, and the engine cannot be started.

    2. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

      2. If the engine cannot be started, bleed the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

    5. Turn the ignition switch to ON and turn the intelligent tester on.

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE05
      Text in Illustration
      *a

      Reference

      (Active Test Operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

    11. Enter the following menus: Powertrain / Engine and ECT / DTC.

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs, as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

    15. Enter the following menus: Powertrain / Engine and ECT / DTC.

    16. Read Current DTCs.

      OK
      No DTCs are output.
  22. INSPECT FOR COOLANT LEAK

    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. A01E06UE01

      Fill the radiator with coolant and attach a radiator cap tester to the radiator reservoir.

    2. Warm up the engine.

    3. Using a 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.

  23. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  24. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch to ON.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurize common rail interior and check for fuel leaks Stop/Start
        • The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed.

        • The above conditions are maintained while the Active Test is being performed.

  25. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  26. INSTALL NO. 2 ENGINE UNDER COVER

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }
  27. INSTALL NO. 1 ENGINE UNDER COVER

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }
  28. INSTALL FRONT WHEEL RH