EXHAUST MANIFOLD W/ TURBOCHARGER (w/ DPF) INSTALLATION

INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
1. Install a new gasket and the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the 2 nuts and bolt.
  
  Torque:
  
  for bolt
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
  
  for nut
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL COMPRESSOR INLET ELBOW
1. Type B
  
  Install the No. 3 turbo water hose to the compressor inlet elbow and slide the clamp to secure the hose.
2. Type A
  
  Install the No. 4 turbo water hose to the compressor inlet elbow and slide the clamp to secure the hose.
3. Install a new gasket and the compressor inlet elbow to the turbocharger sub-assembly with the 2 nuts.
  
  Torque:
  
  19 N*m { 194 kgf*cm, 14 ft.*lbf }

INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

Temporarily install a new gasket and the turbocharger sub-assembly with 3 new nuts to the exhaust manifold.

Tech Tips

It is easier to install the turbo oil inlet pipe sub-assembly if the 3 nuts are only loosely installed.
Set a new gasket on the engine and install the exhaust manifold with turbocharger and the 8 plate washers with 8 new nuts.

Torque:

40 N*m { 408 kgf*cm, 30 ft.*lbf }

Temporarily install the turbo oil inlet pipe sub-assembly.

Tech Tips

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

Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 nuts, but only loosely install the nuts.

Note

The notch (narrow part) of the gasket must face the engine.
Install a new gasket and the turbo oil inlet pipe sub-assembly with the 2 bolts, but only loosely install the bolts.

Note

The claws of the gasket must face the pipe.

Install a new gasket and the turbo oil inlet pipe sub-assembly with the union bolt, but only loosely install the union bolt.

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

Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts and a new nut.

Tighten the 3 nuts of the turbocharger sub-assembly.

Torque:

52 N*m { 530 kgf*cm, 38 ft.*lbf }
Tighten the 2 nuts labeled A.

Torque:

13 N*m { 133 kgf*cm, 10 ft.*lbf }
Tighten the union bolt labeled B.

Torque:

33 N*m { 337 kgf*cm, 24 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 WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket with the bolt.
  
  Torque:
  
  51 N*m { 520 kgf*cm, 38 ft.*lbf }
INSTALL NO. 3 TURBO WATER HOSE
1. Install the No. 3 turbo water hose to the No. 2 water by-pass pipe and slide the clamp to secure the hose.
CONNECT NO. 1 TURBO WATER HOSE
1. Type B
  
  Connect the No. 3 turbo water hose to the compressor inlet elbow and slide the clamp to secure the hose.
2. Connect the No. 1 turbo water hose to the No. 2 water by-pass pipe and slide the 2 clamps to secure the hoses.
CONNECT ENGINE OIL LEVEL DIPSTICK GUIDE
1. Connect the engine oil level dipstick guide to the cylinder block sub-assembly.
2. Install the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
TEMPORARILY INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
1. Temporarily install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 2 bolts.
INSTALL NO. 1 TURBO INSULATOR
1. Temporarily install the No. 1 turbo insulator to the turbocharger sub-assembly with the 2 bolts.
2. Tighten the 2 bolts of the No. 1 exhaust manifold heat insulator and the 2 bolts of the No. 1 turbo insulator.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL VENTILATION PIPE
1. Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head sub-assembly with the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
2. Type A
  
  Connect the No. 3 turbo water hose and No. 4 turbo water hose to the ventilation pipe.
INSTALL FUEL PIPE CLAMP
1. Install the fuel pipe clamp to the turbine outlet elbow with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 in.*lbf }

INSTALL TURBINE OUTLET ELBOW

Temporarily install the turbine outlet elbow to the turbocharger sub-assembly with a new gasket and 3 new nuts.
Temporarily install the No. 1 fuel pipe with the 2 bolts.
Temporarily install the No. 1 fuel pipe with a new gasket and the union bolt.

Text in Illustration
*1	No. 4 Water By-pass Pipe
*2	No. 12 Water By-pass Hose
*3	Turbine Outlet Elbow
*4	Gasket
*5	No. 1 Fuel Pipe
*6	Union Bolt

Tighten the 3 nuts of the turbine outlet elbow.

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

Connect the No. 4 water by-pass pipe to the No. 12 water by-pass hose and slide the 2 clamps to secure the hose.
Install a new gasket and the union bolt to the turbine outlet elbow.

Torque:

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

CONNECT NO. 1 FUEL PIPE
1. Tighten the 2 bolts and union bolt of the No. 1 fuel pipe in the order shown in the illustration.
  
  Torque:
  
  for union bolt
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
  
  for bolt
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
  
  Text in Illustration
  
  Union Bolt
INSTALL NO. 11 WATER BY-PASS HOSE
1. Install the No. 11 water by-pass hose to the turbine outlet elbow and slide the 2 clamps to secure the hose.
2. Connect the exhaust fuel addition injector connector.
INSTALL NO. 2 TURBINE OUTLET ELBOW
1. Install a new gasket and the No. 2 turbine outlet elbow to the turbine outlet elbow with 3 new nuts.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
INSTALL TURBINE OUTLET ELBOW STAY
1. Temporarily install the turbine outlet elbow stay to the No. 2 turbine outlet elbow and cylinder block sub-assembly with the 2 bolts.
2. Tighten the 2 bolts of the turbine outlet elbow stay in the order shown in the illustration.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
1. Install the No. 2 exhaust manifold heat insulator to the turbine outlet elbow with the 2 bolts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET
1. Install the No. 1 compressor mounting bracket with the 5 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  Firmly press and hold the No. 1 compressor mounting bracket against the cylinder block to eliminate any gaps. Then uniformly tighten the 5 bolts.
INSTALL GENERATOR BRACKET
1. Install the generator bracket with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
1. Install the generator with the 2 bolts.
  
  Torque:
  
  for bolt A
  
  62 N*m { 632 kgf*cm, 46 ft.*lbf }
  
  for bolt B
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Install the generator wire with the nut.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
3. Install the terminal cap.
4. Connect the generator connector.
CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
1. Connect the cooler compressor with the 4 bolts.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
2. Connect the compressor connector.
INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)
1. Install the No. 1 viscous heater bracket with the 4 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)
1. Install the viscous heater with magnet clutch with the 2 bolts.
  
  Torque:
  
  45 N*m { 459 kgf*cm, 33 ft.*lbf }
2. Connect the water by-pass hose and water hose.
3. Connect the viscous heater connector.
INSTALL COMPRESSOR OUTLET ELBOW
1. Install the compressor outlet elbow with the 2 bolts and tighten the hose clamp.
  
  Torque:
  
  for bolt
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  for hose clamp
  
  6.5 N*m { 66 kgf*cm, 58 in.*lbf }
2. Install the wire harness bracket with the bolt.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
3. Attach the 3 wire harness clamps.

Text in Illustration
	Union Bolt

INSTALL NO. 1 AIR HOSE

Note

Before installation, remove any oil residue from the inside of the inlet pipe and intercooler.

Text in Illustration
*1	Embossed Mark
*2	Paint Mark
*a	Rear Side of Vehicle
*b	LH Side
*c	Top

Align the paint mark of the No. 1 air hose with the embossed mark of the intercooler and install the No. 1 air hose.

Tighten the 2 clamps.

Torque:

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

INSTALL HEATER HOSE (w/o Rear Air Conditioning System)
1. Text in Illustration
  
  *a Upper Side
  
  *b Paint Mark
  
  Install the heater hose to the heater pipe and slide the 2 clamps to secure the hose.
  Tech Tips
  - When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
  - The direction of each hose clamp is indicated in the illustration.
CONNECT HEATER HOSE AND PIPE (w/ Rear Air Conditioning System)
1. Text in Illustration
  
  *a Upper Side
  
  *b Paint Mark
  
  Install the bolt to the heater hose and pipe.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
2. Connect the 3 heater hoses to the heater pipe, and slide the 3 clamps to secure the hoses.
  Tech Tips
  - When connecting the hoses, make sure the paint marks and clips are as shown in the illustration.
  - The direction of each hose clamp is indicated in the illustration.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
1. Install the air cleaner case sub-assembly with the 3 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Attach the 4 clamps to install the air cleaner cap sub-assembly.
2. except Cold Area Specification Vehicles:
  
  Attach the 2 clamps and connect the mass air flow meter connector.
3. for Cold Area Specification Vehicles:
  
  Attach the 3 clamps and connect the mass air flow meter connector.

Text in Illustration
*a	Upper Side
*b	Paint Mark

Text in Illustration
*a	Upper Side
*b	Paint Mark

INSTALL NO. 1 AIR CLEANER HOSE

Install the No. 1 air cleaner hose with the 2 hose clamps.

Text in Illustration
*1	No. 1 Air Cleaner Hose	*2	Compressor Inlet Elbow
*3	Air Cleaner Cap	-	-
*a	Upper Side	*b	Front Side of Vehicle
*c	Protrusion	*d	Groove

Note

When installing the No. 1 air cleaner hose, align the protrusion of the No. 1 air cleaner hose with the protrusion of the compressor inlet elbow as shown in the illustration.
When installing the No. 1 air cleaner hose, align the groove of the No. 1 air cleaner hose with the protrusion of the air cleaner cap as shown in the illustration.

Tighten the 2 hose clamps.

Torque:

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

Note

When tightening the 2 hose clamps, make sure that they are positioned as shown in the illustration.

INSTALL FAN AND GENERATOR V BELT

Use the pulley set bolt of the tensioner to rotate the tensioner pulley clockwise, and then install the V belt.

Text in Illustration
*1	Crankshaft Pulley	*2	Fan Pulley
*3	Generator	*4	No. 2 Idler Pulley
*5	No. 3 Idler Pulley	*6	Cooler Compressor
*7	Viscous Heater	-	-
*a	Type A	*b	Type C
*c	Type B	*d	Type D

Note

Make sure that the V belt is set properly on each pulley.

Check that the indicator mark of the V-ribbed belt tensioner Click here.

INSTALL FRONT HEATER BRACKET (for Cold Area Specification Vehicles)
INSTALL UPPER RADIATOR SUPPORT SEAL
1. Install the upper radiator support seal with the 13 clips.
INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH
1. Install the front No. 1 fender apron to frame seal RH with the 4 clips.
INSTALL FRONT FENDER APRON SEAL RH
1. Install the front fender apron seal RH with the 5 clips.
INSTALL FRONT EXHAUST PIPE ASSEMBLY

Click here
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

Note

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

ADD ENGINE COOLANT

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 B line of the reservoir tank.

Standard Capacity

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
for Automatic Transmission	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
for Manual Transmission	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 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.
for Cold Area Specification Vehicles:

Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.

Note

Never use water as a substitute for engine coolant.

Press the No. 1 and No. 2 inlet and No. 1 and No. 2 outlet radiator hoses 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 a speed between 2500 and 3000 rpm.
3. Press the inlet and outlet radiator hoses 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 FULL line.

If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

BLEED AIR FUEL SYSTEM
1. Using the hand pump mounted on the fuel filter cap, bleed air from the fuel system. Continue pumping until the pump resistance increases.
  Note
  
  The maximum hand pump pumping speed is 2 strokes per second.
  
  The hand pump must be pushed with a full stroke during pumping.
  
  When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
  
  If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.
  
  If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.
  
  If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.
2. Check if the engine starts.
  Note
  - Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.
  - Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
  - Use a fully-charged battery.
  1. When the engine can be started, proceed to the next step.
  2. If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
3. Turn the engine switch off.
4. Connect the intelligent tester to the DLC3.
5. Turn the engine switch on (IG) and turn the intelligent tester on.
6. Clear the DTCs Click here.
7. Start the engine.*1
8. Text in Illustration
  
  *a
  Reference
  
  (Active Test Operation)
  
  Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2
9. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3
10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.
  
  Tech Tips
  
  When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.
11. Enter the following menus: Powertrain / Engine and ECT / DTC.
12. Read Current DTCs.
13. Clear the DTCs Click here.
  
  Tech Tips
  
  It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.
14. Repeat steps *1 to *3.
15. Enter the following menus: Powertrain / Engine and ECT / DTC.
16. Read Current DTCs.
  
  OK
  
  No DTCs are output.
INSPECT FOR COOLANT LEAK

Note

Before each inspection, turn the A/C switch off.

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.
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 123 kPa (1.3 kgf/cm², 18 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 head.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

Text in Illustration
*a	Reference (Active Test Operation)

OK
No DTCs are output.

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Turn the engine switch on (IG).
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 common rail interior and check for fuel leaks	Stop/Start	The fuel pressure inside the common rail increases to the specified value and the engine speed increases to 2000 rpm when the Active Test is performed. The above conditions are maintained while the Active Test is being performed.

INSPECT FOR EXHAUST GAS LEAK
- If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 engine under cover with the 4 bolts.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
INSTALL FRONT BUMPER LOWER COVER
1. Install the front bumper lower cover with the clip and 5 bolts.
  
  Torque:
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }