TURBOCHARGER INSTALLATION


  1. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. Install the 7 stud bolts.

      Note


      • If the bolts are not securely tightened, they will fall out.

      • Excessively tightening the bolts may crack the female screw section.

    2. Install a new gasket and the turbocharger with 4 new nuts and the 4 spacers.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    3. Connect the connector.

  2. INSTALL INTAKE PIPE


    1. Install a new gasket and the intake pipe with the bolt and 2 nuts.

      Torque:
      Bolt
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }
      Nut
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

    2. Connect the No. 2 air hose with the new hose band.

  3. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install 4 new gaskets and No. 2 water by-pass pipe sub-assembly, temporarily tighten the 2 union bolts.

    2. Temporarily tighten the No. 2 water by-pass pipe sub-assembly bracket with the nut.

    3. Tighten the 2 union bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Tighten the nut.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

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


    1. A01CHX1E01
      Text in Illustration
      *1 Union Bolt
      *2 Bolt

      Install a new O-ring onto the No. 1 turbo water pipe.

    2. Install 2 new gaskets and the No. 1 turbo water pipe sub-assembly with the union bolt and bolt.

      Torque:
      Union Bolt
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Bolt
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  5. INSTALL TURBO OIL OUTLET PIPE


    1. Install 2 new gaskets and the turbo oil outlet pipe with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  6. INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01CGM4E01
      Text in Illustration
      *1 Union Bolt
      *2 Bolt

      Install 4 new gaskets and the turbo oil inlet pipe sub-assembly, and temporarily tighten the 2 union bolts.

    2. Temporarily tighten the turbo oil inlet pipe sub-assembly bracket with the bolt.

    3. Tighten the 2 union bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  7. INSTALL NO. 1 TURBO INSULATOR


    1. Install the No. 1 turbo insulator with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  8. INSTALL INTAKE PIPE OR HOSE STAY


    1. Install the intake pipe or hose stay with the 2 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  9. INSTALL EGR COOLER SUB-ASSEMBLY


    1. A01CIUEE01

      Install the EGR cooler sub-assembly, wire harness clamp bracket and 2 new gaskets with the 6 bolts.

      Torque:
      Bolt A
      69 N*m  { 700 kgf*cm, 51 ft.*lbf }
      Bolt B
      55 N*m  { 561 kgf*cm, 40 ft.*lbf }

    2. Connect the 3 water by-pass hoses.

  10. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe assembly, and temporarily tighten 3 new nuts.

    2. Temporarily tighten a new bolt.

    3. Tighten the 3 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    4. Tighten the bolt.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  11. INSTALL EXHAUST RETARDER ASSEMBLY


    1. Install 2 new gaskets and exhaust retarder assembly with 4 new bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. Connect the vacuum hose.

  12. INSTALL NO. 2 INTAKE PIPE AND NO. 1 AIR HOSE


    1. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  13. INSTALL FRONT MUDGUARD RH

  14. INSTALL ENGINE SIDE COVER RH

  15. ADD ENGINE COOLANT


    1. Add engine coolant.

      Specified capacity
      14.7 liters (15.5 US qts, 12.9 Imp. qts)

      Note

      Never use water as a substitute for engine coolant.

      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 is a combination of low phosphates and organic acids).

      • Contact your TOYOTA dealer for further details.

    2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.

    3. Install the radiator cap sub-assembly.

    4. Slowly pour coolant into the radiator reservoir until it reaches the full line.

    5. 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. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Be careful as the radiator hoses are hot.

        • Keep your hands away from the radiator fan.

    6. Stop the engine and wait until the coolant cools down.

    7. Remove the radiator cap sub-assembly and check the coolant level.

    8. If the coolant level has dropped, add coolant.

    9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.

  16. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap sub-assembly.

      CAUTION:

      Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE02
      Text in Illustration
      *1 Radiator Cap Tester

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

    3. Warm up the engine.

    4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 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 heater core, cylinder block and cylinder head.

    5. Install the radiator cap sub-assembly.

  17. INSPECT FOR EXHAUST GAS LEAK