EXHAUST MANIFOLD W/ 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 and bolt to the turbocharger sub-assembly with the 2 nuts.

      Torque:
      for bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
  2. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


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

      Tech Tips

      It is easier to install the turbo oil inlet pipe sub-assembly if the 3 nuts are only loosely installed.

    2. A01DNFQ

      Set a new gasket on the engine and install the exhaust manifold with turbocharger sub-assembly, the 8 collars and the 8 plate washers with 8 new nuts.

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

      Note

      Install the collars so that the side with the smaller external diameter faces the exhaust manifold.

    3. Temporarily install the turbo oil inlet pipe sub-assembly to the turbocharger sub-assembly.

      Tech Tips

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


      1. 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.

      2. 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.

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

        A01DRR9E03
        Text in Illustration
        *1 Gasket - -
        *a Wide *b Narrow
        *c Claw - -
        A01DQPB Outside - -
      4. Temporarily install the turbocharger stay to the turbocharger sub-assembly and cylinder block sub-assembly with the 2 bolts and nut.

    4. Tighten the 3 nuts of the turbocharger sub-assembly.

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

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

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }
    7. Tighten the 2 bolts labeled C.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    8. A01DQXYE01

      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 }
  3. INSTALL TURBINE OUTLET ELBOW


    1. Install a new gasket and the turbine outlet elbow to the turbocharger sub-assembly with the 3 nuts.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }
  4. CONNECT NO. 1 TURBO WATER HOSE


    1. Connect the No. 1 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.

  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Temporarily install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the bolt.

  6. 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 bolt 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 }
  7. INSTALL COMPRESSOR INLET ELBOW


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

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    2. Connect the No. 2 turbo water hose and No. 3 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the clamp to secure the hose.

    3. Connect the No. 3 turbo water hose and No. 3 turbo water hose to the No. 2 water by-pass pipe, and slide the clamp to secure the hose.

    4. Connect the 2 connectors and attach the wire harness clamp.

    5. Install the wire harness bracket to the water inlet with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    6. Attach the 3 wire harness clamps.

  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a small amount of clean engine oil to the O-ring.

    3. Install the engine oil level dipstick guide to the cylinder block sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. Install the engine oil level dipstick.

  9. INSTALL VENTILATION PIPE


    1. Connect the 2 ventilation hoses and install the ventilation pipe to the cylinder head cover 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, and slide the 2 clamps to secure the hose.

  10. 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 }
  11. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
  12. INSTALL GENERATOR ASSEMBLY


    1. A01DT1PE01

      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.

  13. 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.

  14. 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 }
  15. 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.

  16. 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.

  17. INSTALL NO. 1 AIR HOSE

    Note

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


    1. A01DQL2E01
      Text in Illustration
      *1 Embossed Mark
      *2 Paint Mark
      *a Rear Side of Vehicle
      *b LH Side
      *c Upper

      Align the paint mark of the intercooler air hose with the embossed mark of the intercooler.

    2. Tighten the 2 clamps.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
  18. 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 }
  19. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  20. 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.

  21. INSTALL NO. 1 AIR CLEANER HOSE

    A01DM6NE01
    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

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

      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.

    2. 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.

  22. INSTALL FAN AND GENERATOR V BELT


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

      A01DSGFE01
      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.

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

  23. INSTALL FRONT HEATER BRACKET (for Cold Area Specification Vehicles)


    1. Install the front heater bracket with the 2 bolts.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
  24. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  25. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH


    1. Install the front No. 1 fender apron to frame seal RH with the 5 clips.

  26. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 4 clips.

  27. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }
  28. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  29. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. 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)
      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)
      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.

    4. Press the inlet and 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.

    5. Install the radiator reservoir cap.

    6. Using a wrench, install the vent plug.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    7. 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 2500 to 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.

    8. 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.

  30. 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.

  31. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  32. INSPECT FOR EXHAUST GAS LEAK


    • If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.

  33. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 4 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
  34. INSTALL FRONT BUMPER LOWER COVER


    1. Install the lower front bumper cover with the clip and 5 bolts.

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