TURBOCHARGER (w/o EGR Cooler) INSTALLATION

CLEAN TURBOCHARGER SUB-ASSEMBLY
INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (w/ Intercooler)
1. Connect the No. 1 turbo water hose to the No. 1 turbo water pipe.
2. Text in Illustration
  
  *1 New Gasket
  
  Install a new gasket and No. 1 turbo water pipe 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 with 3 new nuts.

Tech Tips

When installing the turbo oil pipe, loosely tighten the 3 nuts so that the turbocharger and cylinder head can be aligned easily.

w/o Intercooler:

Temporarily install the turbo oil pipe and manifold stay.

Tech Tips

Wash the oil pipe before installing it.

Temporarily install a new gasket and the oil pipe with the 2 nuts, but only loosely install the nuts.

Note

The notch (wide part) of the gasket must face the engine.
Temporarily install a new gasket and the oil pipe with the 2 bolts (labeled: A), but only loosely install the bolts.

Note

The claws of the gasket must face the pipe.
Temporarily install a new gasket and the oil pipe with the union bolt (labeled: B), but only loosely install the union bolt.
Temporarily install the stay with the 2 bolts.

Tech Tips

The stay's indented area must face the turbocharger.
Tighten the 3 nuts of the turbocharger.

Torque:

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

Tighten the 2 nuts of the oil pipe.

Torque:: 13 N*m { 133 kgf*cm, 10 ft.*lbf }

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

Tighten the 2bolts labeled A.

Torque:

12 N*m { 122 kgf*cm, 9 ft.*lbf }
Tighten the union bolt labeled B.

Torque:

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

Torque:

19 N*m { 194 kgf*cm, 14 ft.*lbf }

w/ Intercooler:

Temporarily install the turbo oil inlet pipe sub-assembly.

Tech Tips

Before installing the oil inlet pipe sub-assembly, clean it.

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.
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.
Temporarily install a new gasket and the oil inlet pipe sub-assembly with the union bolt.
Temporarily install the turbocharger stay with the 2 bolts and nut.

Tighten the 3 nuts of the turbocharger.

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 }
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. w/o Intercooler:
  1. Temporarily install a new gasket and the outlet elbow (with turbocharger stay) to the turbocharger with the 4 new nuts.
  2. Temporarily install the stay with the 2 bolts.
  3. Tighten the 4 nuts of the turbocharger.
    
    Torque:
    
    26 N*m { 265 kgf*cm, 19 ft.*lbf }
  4. Tighten the 2 bolts of the stay.
    
    Torque:
    
    24 N*m { 245 kgf*cm, 18 ft.*lbf }
2. w/ Intercooler:
  
  Install a new gasket and the outlet elbow with the 3 new nuts.
  
  Torque:
  
  26 N*m { 265 kgf*cm, 19 ft.*lbf }
CONNECT NO. 1 TURBO WATER HOSE (w/ Intercooler)
1. Connect the 2 No. 1 turbo water hoses.
INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ Intercooler)
1. Temporarily install the heat insulator with the 2 bolts.
2. Tighten the bolt of the turbo insulator, and the 2 bolts of the heat insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL NO. 1 TURBO INSULATOR (w/ Intercooler)
1. Temporarily install the turbo insulator with the bolt.
INSTALL COMPRESSOR INLET ELBOW (w/ Intercooler)
1. Install a new gasket and inlet elbow with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
2. Connect the 2 connectors and attach the wire harness clamp.
INSTALL VENTILATION PIPE (w/ Intercooler)
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY (w/o Intercooler)
1. Connect the pipe (with the 2 air hoses) and install the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
2. Tighten the 2 clamps.
3. Connect the vacuum hose to the gas filter.
4. Connect the manifold absolute pressure sensor connector.
INSTALL VENTILATION HOSE HEAT INSULATOR (w/o Intercooler)
1. Install the insulator with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL INTERCOOLER ASSEMBLY

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

Note

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

Minimum length
40 mm (1.57 in.)

ADD ENGINE COOLANT (w/ Intercooler)

Tighten the radiator drain cock plug by hand.
Tighten the cylinder block drain cock plug.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }

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

Standard Capacity

Item	Specified Condition
for Automatic Transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)
for Manual Transmission	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).

Please contact your TOYOTA dealer for further details.

Note

Never use water as a substitute for engine coolant.

Press the radiator hose inlet and radiator hose outlet 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.
Install the radiator reservoir cap.
Using a wrench, install the vent plug.

Torque:

2.0 N*m { 20 kgf*cm, 18 in.*lbf }
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.
2. Maintain the engine speed at 2500 to 3000 rpm.
3. Press the radiator hose inlet and radiator hose outlet 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.
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 ENGINE COOLANT (w/ Intercooler)
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.
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 ENGINE OIL LEAKS
INSPECT ENGINE OIL LEVEL
CHECK FOR EXHAUST LEAKS

If gas is leaking, tighten the problem areas to stop the leak. Replace damaged parts as necessary.
INSTALL FRONT FENDER APRON SEAL UPPER
1. Install the apron seal with the 5 clips.
INSTALL FRONT FENDER SEAL
1. Install the fender seal with the 5 clips.
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 }