TURBOCHARGER INSTALLATION


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


    1. w/ DPF:


      1. Install a new gasket and the No. 1 turbo water pipe with the bolt and 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 the turbo water hose, No. 2 turbo water hose and No. 13 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the 3 clamps to secure the hoses.

    2. w/o DPF:


      1. Install a new gasket and the No. 1 turbo water pipe with the bolt and 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 the No. 1 turbo water hose and No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly, and slide the 2 clamps to secure the hoses.

  2. INSTALL COMPRESSOR INLET ELBOW


    1. w/ DPF:


      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. 4 turbo water hose to the compressor inlet elbow, and slide the clamp to secure the hose.

    2. w/o DPF:


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

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

  3. TEMPORARILY INSTALL TURBOCHARGER


    1. w/ DPF:


      1. Set the turbocharger in a safe location.

      2. Temporarily install the exhaust manifold with the 8 plate washers, 8 new nuts and 8 new collars.

      3. Connect the 3 turbo water hoses to the No. 5 water by-pass pipe sub-assembly and No. 2 water by-pass pipe, and slide the 3 clamps to secure the hoses.

    2. w/o DPF:


      1. Install the No. 2 water by-pass pipe with the bolt and 2 nuts.

        Torque:
        for bolt
        23 N*m  { 235 kgf*cm, 17 ft.*lbf }
        for nut
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      2. Connect the 2 turbo water hoses to the No. 2 water by-pass pipe, and slide the 2 clamps to secure the hoses.

    3. A003GLEE04
      Text in Illustration
      *a Claw

      Install a new gasket to the turbocharger.

      Note

      Install the gasket in the correct direction.

    4. Temporarily install the turbocharger with 3 new nuts.

  4. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A003BP0E02
      Text in Illustration
      *a Outside
      *b Narrow
      *c Wide
      *d Claw

      Install 3 new gaskets to the turbo oil inlet pipe sub-assembly.

      Note

      Install the gasket in the correct direction.

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

  5. TEMPORARILY INSTALL TURBOCHARGER STAY


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

  6. TIGHTEN TURBOCHARGER


    1. w/ DPF:

      Tighten the 8 nuts to the specified torque to install the exhaust manifold.

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

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

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

  7. CONNECT TURBOCHARGER STROKE SENSOR CONNECTOR

  8. TIGHTEN TURBOCHARGER STAY


    1. Tighten the 2 bolts and nut to the specified torque to install the turbocharger stay.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  9. TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A003E9GE02
      Text in Illustration
      *1 Union Bolt

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

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for nut
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for union bolt
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

  10. INSTALL NO. 1 AUTOMATIC TRANSMISSION OIL COOLER TUBE CLAMP (for Automatic Transmission)


    1. A003D09E01

      Install the No. 1 automatic transmission oil cooler tube clamp with the 2 bolts.

      Torque:
      for bolt A
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      for bolt B
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  11. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


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

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

  12. TEMPORARILY INSTALL TURBINE OUTLET ELBOW STAY


    1. w/ DPF:


      1. Temporarily install the turbine outlet elbow stay with the 2 bolts.

    2. w/o DPF:


      1. Temporarily install the turbine outlet elbow stay with the 2 bolts and 2 new nuts.

      2. Tighten the 2 bolts.

        Torque:
        62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  13. TEMPORARILY INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Temporarily install the No. 1 exhaust manifold heat insulator with the 3 bolts.

  14. INSTALL TURBO INSULATOR


    1. Temporarily install the turbo insulator with the 2 bolts.

    2. Tighten the 5 bolts to the specified torque to install the turbo insulator and No. 1 exhaust manifold heat insulator.

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

  15. INSTALL TURBINE OUTLET ELBOW (w/ DPF)


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

    2. Temporarily install the No. 3 fuel pipe and a new gasket with the union bolt.

    3. Tighten the 3 nuts of the turbine outlet elbow.

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

    4. Connect the No. 1 turbo water hose to the No. 1 injector holder, and slide the clamp to secure the hose.

    5. Connect the fuel addition injector connector.

    6. w/ Cover:

      Install the fuel addition injector connector cover.

  16. INSTALL NO. 2 FUEL PIPE CLAMP (w/ DPF)


    1. Temporarily install the No. 2 fuel pipe clamp with the 2 bolts.

    2. Tighten the 2 bolts of the No. 2 fuel pipe clamp and the union bolt of the No. 3 fuel pipe.

      Torque:
      for bolt
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for union bolt
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    3. Connect the No. 4 water by-pass pipe to the No. 13 water by-pass hose, and slide the clamp to secure the hose.

    4. Install the No. 4 water by-pass pipe and a new gasket with the union bolt.

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

  17. INSTALL CATALYTIC WITH PIPE CONVERTER ASSEMBLY (w/ DPF)


    1. A003CGU

      Install a new gasket and the catalytic with pipe converter assembly with 3 new nuts.

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

    2. Temporarily install 2 new nuts.

    3. Tighten the 2 bolts of the turbine outlet elbow stay.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  18. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. Install the No. 3 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  19. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)


    1. Install the No. 2 exhaust manifold heat insulator with the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  20. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Attach the 3 clamps.

  21. INSTALL VENTILATION PIPE


    1. w/ DPF:


      1. Connect the 2 ventilation hoses.

      2. Install the ventilation pipe with the bolt.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      3. for Type A:

        Connect the No. 4 turbo water hose to the ventilation pipe, and slide the clamp to secure the hose.

      4. for Type A:

        Install the No. 14 water by-pass hose to the ventilation pipe, and slide the clamp to secure the hose.

    2. w/o DPF:


      1. Connect the 2 ventilation hoses.

      2. Install the ventilation pipe with the bolt.

        Torque:
        18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  22. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A003FEFE02

      Temporarily install the No. 1 compressor mounting bracket with the 4 bolts.

      Tech Tips

      Make sure that the No. 1 compressor mounting bracket is in contact with the cylinder block.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  23. INSTALL COMPRESSOR OUTLET ELBOW


    1. A003G3VE01

      Install the compressor outlet elbow with the 2 hose clamps and bolt.

      Torque:
      for bolt
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for hose clamp A
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      for hose clamp B
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  24. CONNECT TURBOCHARGER MOTOR CONNECTOR

  25. INSTALL AIR TUBE ASSEMBLY


    1. A003ESEE01

      Install the air tube assembly and No. 1 air cleaner hose with the 2 bolts.

      Torque:
      for bolt A
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Tighten the 2 hose clamps.

  26. CONNECT NO. 1 AIR CLEANER HOSE


    1. Connect the No. 1 air cleaner hose to the compressor inlet elbow.

      Note

      Pull the hose to make sure that it is locked and securely connected.

  27. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A003GDEE01

    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.

    2. Tighten the compressor and magnetic clutch with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  28. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE (w/ Air Conditioning System)

  29. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE (w/ Air Conditioning System)

  30. INSTALL FAN AND GENERATOR V BELT (w/ Air Conditioning System)


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

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

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

  31. INSTALL NO. 1 TRANSMISSION CONTROL CABLE BRACKET (for Manual Transmission)


    1. Install the No. 1 transmission control cable bracket with the 2 bolts.

      Torque:
      72 N*m  { 729 kgf*cm, 53 ft.*lbf }

  32. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transmission)


    1. A003GZ9E01

      Install 2 new clips to the No. 1 transmission control cable bracket.

    2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket.

      Note


      • Make sure that A claws of the clips are firmly installed into the bracket grooves.

      • Make sure that the cable is set in the clip with both B claws erected to prevent slippage of the cable in the opposite direction.

    3. A003H3DE02

      Align the matchmarks on the control cable assembly and the shift outer lever.

    4. Align the matchmarks on the control cable assembly and the select outer lever.

    5. Install the transmission control cable assembly to the shift outer lever with the nut.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    6. Install the transmission control cable assembly to the select outer lever with the nut.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/ DPF)

    Click here

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY (w/o DPF)


    1. A003CW9

      Inspect the compression spring.


      1. Using a vernier caliper measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.59 in.)

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

    2. A003BNKE02
      Text in Illustration
      *1 Gasket
      *a Wooden Block

      Fully push a new gasket onto the exhaust manifold converter sub-assembly by hand.

    3. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold converter sub-assembly fit together properly.

      Note


      • Install the gasket in the correct direction.

      • Do not damage the outer surface of the gasket.

      • Do not reuse the removed gasket.

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

    4. Connect the front exhaust pipe assembly to the No. 4 exhaust pipe support.

    5. Install the front exhaust pipe assembly and 2 compression springs with the 2 bolts and 2 nuts.

      Torque:
      for bolt
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      for nut
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

  35. TIGHTEN EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/o DPF)


    1. A003HQH

      Tighten the 2 nuts to the exhaust manifold converter sub-assembly.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  36. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  37. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir assembly with engine coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.2 liters (13.9 US qts, 11.6 Imp. qts)
      w/ Front Heater 14.2 liters (15.0 US qts, 12.5 Imp. qts)
      w/ Front and Rear Heaters 16.2 liters (17.1 US qts, 14.3 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the engine coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A003EJI

      Add engine coolant up to the B line mark in the radiator reservoir assembly and install the radiator reservoir cap sub-assembly.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the engine coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the No. 3 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A003FFY

      After the engine cools down, check that the engine coolant level is between the LOW and FULL level marks.

  38. CHARGE REFRIGERANT (w/ Air Conditioning System)


    1. Perform vacuum purging using a vacuum pump.

    2. Charge with refrigerant HFC-134a (R134a).

      A003DFOE01
      Standard
      Single A/C
      520 to 580g (18.3 to 20.5 oz.)
      Dual A/C
      670 to 730g (23.0 to 25.7 oz.)
      SST
      07110-58060   ( 07117-58090, 07117-78050, 07117-58070, 07117-58060, 07117-58080, 07117-88060, 07117-88070, 07117-88080 )

      Note


      • Do not operate the cooler compressor before charging refrigerant as the cooler compressor does not work properly without any refrigerant, which causes the compressor to overheat.

      • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass.

      Tech Tips

      Prepare a service can to recharge refrigerant if using the refrigerant gas collected with the freon collection/recycling device because the collective rate of the device is approximately 90%.

  39. WARM UP ENGINE


    1. Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging refrigerant.

      Note

      Be sure to warm up the compressor when turning the A/C switch on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

  40. CHECK FOR REFRIGERANT LEAK (w/ Air Conditioning System)


    1. After recharging refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

    2. Carry out the test under the following conditions:


      • Stop the engine.

      • Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

      • Repeat the test 2 or 3 times.

      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

    3. A003I8RE02

      Using a gas leak detector, check for leakage of the refrigerant line.

    4. A003AFME01

      Bring the gas leak detector close to the drain hose with the detector's power off.

      Tech Tips


      • After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.

      • Bring the gas leak detector sensor under the drain hose.

      • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    5. If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

    6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

  41. INSPECT FOR COOLANT LEAK

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.


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

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the pressure does not drop.

      Tech Tips

      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 cylinder head.

  42. INSPECT FOR OIL LEAK


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

  43. INSPECT FOR EXHAUST GAS LEAK

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

  44. INSTALL FENDER APRON MUDGUARD SEAL RH

  45. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  46. INSTALL FRONT SEAT ASSEMBLY RH


    1. A003DBM

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  47. INSTALL FRONT DOOR SCUFF PLATE RH

  48. INSTALL NO. 2 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


    1. Install the No. 2 engine under cover with the 6 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  49. INSTALL NO. 1 ENGINE UNDER COVER (for Cold Area Specification Vehicles)


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

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }