TURBOCHARGER (w/ DPF) INSTALLATION

INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
1. Install a new gasket and No. 1 turbo water pipe with the bolt and 2 nuts.
  
  Torque:
  
  Bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  Nut
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL COMPRESSOR INLET ELBOW
1. Install a new gasket and compressor inlet elbow with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }
2. Install the No. 4 turbo water hose.
TEMPORARILY TIGHTEN TURBOCHARGER
1. Text in Illustration
  
  *1 Claw
  
  Install a new gasket to the turbocharger.
  
  Note
  
  Insert the gasket with its claws facing the turbocharger.
2. Temporarily tighten the turbocharger with 3 new nuts.
3. Connect the 3 water hoses.

TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY

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

Install 2 new gaskets to the turbo oil inlet pipe.

Note

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

Temporarily tighten the gasket and turbo inlet pipe with the 2 bolts, 2 nuts and union bolt.

TEMPORARILY TIGHTEN TURBOCHARGER STAY
1. Temporarily tighten the turbocharger stay with the 2 bolts and a new nut.
FULLY TIGHTEN TURBOCHARGER
1. Fully tighten the 3 nuts to the specified torque and install the turbocharger.
  
  Torque:
  
  52 N*m { 530 kgf*cm, 38 ft.*lbf }
FULLY TIGHTEN TURBOCHARGER STAY
1. Fully tighten the 2 bolts and nut to the specified torque and install the turbocharger stay.
  
  Torque:
  
  38 N*m { 387 kgf*cm, 28 ft.*lbf }
FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Union Bolt
  
  Fully tighten the 2 bolts, 2 nuts and union bolt to the specified torque and install the turbo oil inlet pipe.
  
  Torque:
  
  Bolt
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
  
  Nut
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  Union Bolt
  
  26 N*m { 265 kgf*cm, 19 ft.*lbf }
TEMPORARILY TIGHTEN NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Temporarily tighten the No. 1 exhaust manifold heat insulator with the 3 bolts.
INSTALL NO. 1 TURBO INSULATOR
1. Temporarily tighten the No. 1 turbo insulator with the 2 bolts.
2. Fully tighten the 5 bolts to the specified torque and install the No. 1 exhaust manifold heat insulator and No. 1 turbo insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL TURBINE OUTLET ELBOW
1. Connect the No. 4 water by-pass pipe to the No. 13 water by-pass pipe.
2. Temporarily tighten the turbine outlet elbow with a new gasket and 3 new nuts.
3. Temporarily tighten the No. 3 fuel pipe with a new gasket and union bolt.
4. Fully tighten the 3 nuts to the specified torque and install the turbine outlet elbow.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
5. Fully tighten the union bolt to the specified torque and install the No. 3 fuel pipe.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
6. Install a new gasket and No. 4 water by-pass pipe with the union bolt.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
7. Connect the No. 1 turbo water hose.
8. Connect the addition injector connector.

Text in Illustration
*1	Union Bolt

INSTALL NO. 2 FUEL PIPE CLAMP

Text in Illustration
*1	No. 2 Fuel Pipe Clamp
*2	No. 3 Fuel Pipe Clamp

Install the No. 2 fuel pipe clamp with the bolt.

Torque:

8.0 N*m { 82 kgf*cm, 71 in.*lbf }
Install the No. 3 fuel pipe clamp with the bolt.

Torque:

6.5 N*m { 66 kgf*cm, 58 in.*lbf }

TEMPORARILY TIGHTEN CATALYTIC WITH PIPE CONVERTER ASSEMBLY
1. Temporarily tighten the catalytic with pipe converter with a new gasket and 3 new nuts.
TEMPORARILY TIGHTEN TURBINE OUTLET ELBOW STAY
1. Temporarily tighten the turbine outlet elbow stay with the 2 (B) bolts and 2 (C) new bolts.
FULLY TIGHTEN CATALYTIC WITH PIPE CONVERTER ASSEMBLY
1. Fully tighten the 3 (A) nuts to the specified torque and install the catalytic with pipe converter.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
2. Fully tighten the 2 (B) 2 bolts to the specified torque and install the turbine outlet stay.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
3. Fully tighten the 2 (C) 2 bolts to the specified torque and install the turbine outlet stay.
  
  Torque:
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
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 }
INSTALL VENTILATION PIPE SUB-ASSEMBLY
1. Install the ventilation pipe with the bolt.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
INSTALL ENGINE WIRE HARNESS
1. Install the engine wire harness bracket with the 2 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
2. Connect the turbocharger stroke sensor connector.
INSTALL NO. 2 AIR CLEANER HOSE
1. Install the No. 2 air cleaner hose.
  
  Torque:
  
  Hose clamp
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
2. Connect the turbocharger motor connector.
INSTALL COMPRESSOR OUTLET ELBOW
1. Install the compressor outlet elbow with the bolt and hose clamp.
  
  Torque:
  
  Bolt
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Hose clamp
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
CONNECT NO. 1 AIR HOSE
1. Connect the No. 1 air hose.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
INSTALL FRONT EXHAUST PIPE ASSEMBLY

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ADD ENGINE COOLANT

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).

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.
Install the radiator cap securely.
Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
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.
Maintain the engine speed at 2000 to 2500 rpm.
Squeeze the inlet and outlet radiator hoses several times by hand while warming up the engine to bleed the air.
CAUTION:
- Wear protective gloves.
- Be careful as the radiator hoses are hot.
- Keep your hands away from the fan.
Stop the engine and wait until the coolant cools down.
Remove the radiator cap and check the coolant level inside the radiator.
If the coolant level is below the full level, repeat the operation until the coolant level remains at the full level.
Check the coolant level inside the radiator reservoir tank again.

If it is below the full level, add coolant.

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. 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.

Text in Illustration
*1	Radiator Cap Tester

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the ignition switch to ON.
Turn the intelligent tester on.
Enter the following menus: Powertrain / Engine and ECT / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Part	Control Range	Diagnostic Note
Test the Fuel Leak	Pressurize the common rail interior and check for fuel leaks	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when ON is selected. Above conditions preserved while test is ON Tech Tips If this Active Test is performed when the engine is cold, combustion may become unstable. However, this is not a malfunction. It is only necessary to confirm that the pressure rises to the target pressure and that there are no fuel leaks.

INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
INSTALL FRONT FENDER APRON SUB-ASSEMBLY RH
INSTALL TRANSMISSION SERVICE HOLE COVER SUB-ASSEMBLY (for Double Cab)
INSTALL NO. 4 MAT SET PLATE (for Double Cab)
1. Install the mat set plate with the 8 screws.
INSTALL REAR FLOOR MAT (for Double Cab)
INSTALL REAR DOOR SCUFF PLATE LH (for Double Cab)
1. Install the rear door scuff plate with the 3 screws.
INSTALL REAR DOOR SCUFF PLATE RH (for Double Cab)
1. Install the rear door scuff plate with the 3 screws.
INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (for Double Cab)

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