TURBOCHARGER (w/o DPF) INSTALLATION


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


    1. 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 SUB-ASSEMBLY


    1. A01KGZ9E03
      Text in Illustration
      *1 Claw

      Install a new gasket to the turbocharger sub-assembly.

      Note

      Insert the gasket with its claws facing the turbocharger sub-assembly.

    2. A01KH22

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

  3. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY (w/ EGR Cooler Bypass Valve)


    1. A01KFEDE02
      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 TURBO OIL INLET PIPE SUB-ASSEMBLY (w/o EGR Cooler Bypass Valve)


    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.

  5. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

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

  6. FULLY TIGHTEN TURBOCHARGER SUB-ASSEMBLY


    1. A01KH22

      Tighten the 3 nuts to the specified torque and install the turbocharger sub-assembly.

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

  7. FULLY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Tighten the 2 bolts and nut to the specified torque.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf, w/ EGR Cooler Bypass Valve }
      24 N*m  { 245 kgf*cm, 18 ft.*lbf, w/o EGR Cooler Bypass Valve }

  8. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KFMNE03
      Text in Illustration
      *A w/ EGR Cooler Bypass Valve
      *B w/o EGR Cooler Bypass Valve
      *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 }

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler Bypass Valve)


    1. Install a new gasket and the exhaust manifold converter sub-assembly with the new 3 nuts and 2 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf, for bolt }
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for nut }

  10. INSTALL TURBINE OUTLET ELBOW (w/o EGR Cooler Bypass Valve)


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

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  11. INSTALL COMPRESSOR INLET ELBOW


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

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

  12. CONNECT NO. 1 TURBO WATER HOSE


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

  13. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


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

  14. INSTALL NO. 1 TURBO INSULATOR


    1. 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 }

  15. INSTALL VENTILATION PIPE (w/ EGR Cooler Bypass Valve)


    1. Install the ventilation pipe with the bolt.

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

  16. INSTALL VENTILATION PIPE (w/o EGR Cooler Bypass Valve)


    1. Install a new O-ring to the ventilation pipe.

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

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

  17. INSTALL ENGINE WIRE HARNESS (for LHD)


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

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

  18. INSTALL ENGINE WIRE HARNESS (for RHD)


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

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

  19. CONNECT TURBOCHARGER STROKE SENSOR


    1. Install the turbocharger stroke sensor connector to the turbocharger sub-assembly.

  20. INSTALL NO. 2 AIR CLEANER HOSE


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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A01KIOWE02
      Text in Illustration
      *1 Matchmarks

      w/ EGR Cooler Bypass Valve:

      Connect the No. 2 ventilation hose with the clamp as shown in the illustration.

  21. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. Connect the turbocharger motor connector to the turbocharger sub-assembly.

  22. INSTALL COMPRESSOR OUTLET ELBOW


    1. 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 }

  23. CONNECT NO. 1 AIR HOSE


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

  24. 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. A01KFI7E03
      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. Install the 2 hungers and front exhaust pipe.

    5. Install the 2 bolts and 2 compression springs.

      Torque:
      43 N*m  { 439 kgf*cm, 32 ft.*lbf }

  25. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

  26. 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.

  27. 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.

  28. INSPECT FOR OIL LEAK

  29. INSPECT FOR EXHAUST GAS LEAK

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

    A01KIQM

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

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

    A01KGPT

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

  32. INSTALL REAR FLOOR MAT (for Double Cab)

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

    A01KINS

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

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

    A01KF1Z

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

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


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

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

  36. 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 }