TURBOCHARGER (w/o DPF) INSTALLATION


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


    1. A01KHXG

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf, for bolt }
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for nut }

  2. TEMPORARILY TIGHTEN TURBOCHARGER


    1. A01KGZ9E03
      Text in Illustration
      *1 Claw

      Install a new gasket to the turbocharger.

      Note

      Insert the gasket with its claws facing the turbocharger.

    2. A01KH22

      Temporarily install the turbocharger with new 3 nuts.

  3. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KG5FE04
      Text in Illustration
      *1 Claw
      *a Wide
      *b Narrow
      *c Outside

      Install a new gasket to the turbo oil inlet pipe sub-assembly.

      Note

      Insert the gasket with its claws facing the turbo oil inlet pipe sub-assembly.

    2. Temporarily tighten the turbo oil inlet pipe sub-assembly with the 2 bolts, 2 nuts and union bolt.

  4. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

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

  5. FULLY TIGHTEN TURBOCHARGER


    1. A01KH22

      Tighten the 3 nuts to the specified torque and install the turbocharger.

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

  6. FULLY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Tighten the 2 bolts and nut to the specified torque.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  7. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KHCKE04
      Text in Illustration
      *1 Union Bolt

      Tighten the 2 bolts, 2 nuts and union bolt to the specified torque and install the turbo oil inlet sub-assembly.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for bolt }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut }
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for union bolt }

  8. INSTALL TURBINE OUTLET ELBOW


    1. A01KEND

      Install a new gasket and the turbine outlet elbow with the new 3 nuts.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  9. INSTALL COMPRESSOR INLET ELBOW


    1. A01KEUC

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

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

  10. CONNECT NO. 1 TURBO WATER HOSE


    1. A01KHWT

      Connect the No. 1 turbo water hose with the 2 clips.

  11. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01KG7W

      Temporarily install the No. 1 exhaust manifold heat insulator with the 2 bolts.

  12. INSTALL NO. 1 TURBO INSULATOR


    1. A01KGR2

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

    2. Tighten the 4 bolts to the specified torque and install the No. 2 turbo insulator and No. 1 exhaust manifold heat insulator.

      Torque:
      12 N*m  { 122 kgf*cm, 9 in.*lbf }

  13. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. A01KGB4

      Install a new O-ring to the ventilation pipe sub-assembly.

    2. Apply a small amount of engine oil to the O-ring and install it to the ventilation pipe sub-assembly with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  14. INSTALL ENGINE WIRE HARNESS (for LHD)


    1. A01KG9Q

      Install the engine wire harness with bracket with the 2 bolts.

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

  15. INSTALL ENGINE WIRE HARNESS (for RHD)


    1. A01KIQT

      Install the engine wire harness with bracket with the 2 bolts.

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

  16. CONNECT TURBOCHARGER STROKE SENSOR


    1. A01KEZH

      Connect the turbocharger stroke sensor connector to the turbocharger.

  17. INSTALL NO. 2 AIR CLEANER HOSE


    1. A01KF86

      Connect the No. 2 air hose and tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  18. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01KHOK

      Connect the turbocharger motor connector to the turbocharger.

  19. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01KEB4

      Install the compressor outlet elbow with No. 2 air hose with the hose clamp and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for bolt }
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf, for hose clamp }

  20. CONNECT NO. 1 AIR HOSE


    1. A01KHAW

      Connect the No. 1 air hose and tighten the hose clamp.

  21. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01KEXT

      Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.594 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. A01KH27E02
      Text in Illustration
      *1 New Gasket
      *a Wooden Block

      Fully insert a new gasket into the turbine outlet elbow by hand.

      Note


      • Install the gasket in the correct direction.

      • Do not damage the outer surface of the gasket.

      • Do not reuse the gasket.

      • Do not push in the gasket with the front exhaust pipe when connecting it.

    3. Using a wooden block, uniformly strike the gasket so that the gasket and the turbine outlet elbow are properly fitted.

    4. A01KIEL

      Install the 2 hungers and the front exhaust pipe.

    5. Install the 2 bolts and the 2 compression springs.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  22. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    6.4 N*m  { 65 kgf*cm, 56 in.*lbf }

  23. ADD ENGINE COOLANT


    1. Pour coolant into the radiator until it overflows.

      Capacity
      Specification Capacity
      w/o Heater 9.8 liters (10.3 US qts, 8.6 Imp. qts)
      w/ Front Heater 10.7 liters (11.3 US qts, 9.4 Imp. qts)
      w/ Front and Rear Heater 11.5 liters (12.2 US qts, 10.1 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    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 securely.

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

    5. Warm up the engine until the thermostat opens.


      1. 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.

    6. Maintain the engine speed at 2000 to 2500 rpm.

    7. Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.

      CAUTION:


        When squeezing the radiator hoses:

      • Wear protective gloves.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

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

    9. Remove the radiator cap and check the coolant level inside the radiator.

    10. If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.

    11. Check the coolant level inside the radiator reservoir tank again.

      If it is below the full level, add coolant.

  24. INSPECT FOR COOLANT LEAK


    1. Remove the radiator cap.

      CAUTION:

      To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator.

    2. A01KH30E02
      Text in Illustration
      *1 Radiator Cap Tester

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

    3. Warm up the engine.

    4. Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi), then check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator and water pump for leakage. If there are no signs of external coolant leakage, check the heater core, cylinder block and head.

    5. Reinstall the radiator cap.

  25. INSPECT FOR OIL LEAK

  26. INSPECT FOR EXHAUST GAS LEAK

  27. INSTALL TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)

    A01KIQM

    1. Install the transmission service hole cover with the 12 bolts.

  28. INSTALL NO. 4 MAT SET PLATE (for Double Cab)

    A01KGPT

    1. Install the mat set plate with the 6 screws.

  29. INSTALL REAR FLOOR MAT (for Double Cab)

  30. INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)

    A01KINS

    1. Install the rear door scuff plate with the 3 screws.

  31. INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)

    A01KF1Z

    1. Install the rear door scuff plate with the 3 screws.

  32. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH (for Double Cab)


    1. Connect the wire harness and install the engine side cover sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 in.*lbf }

  33. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH (for Double Cab)


    1. A01KGS6

      Install the fender side apron sub-assembly RH with the 5 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }