TURBOCHARGER INSTALLATION

INSTALL STUD BOLT
Note

If a stud bolt is deformed or its threads are damaged, replace it.
1. Using an E10 "TORX" socket wrench, install the 3 stud bolts at the positions shown in the illustration.
  
  Torque:
  
  15 N*m { 150 kgf*cm, 11 ft.*lbf }
2. Using an E8 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Using an E5 "TORX" socket wrench, install the 4 stud bolts at the positions shown in the illustration.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 49 in.*lbf }
INSTALL COMPRESSOR OUTLET ELBOW
1. Install a new gasket and the compressor outlet elbow with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL COMPRESSOR INLET ELBOW
1. Install a new gasket.
2. Install the compressor inlet elbow to the turbocharger sub-assembly with the 2 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY
1. Install a new gasket.
2. Temporarily install the No. 1 turbo water pipe sub-assembly with the bolt and 2 nuts.
3. Tighten the bolt and 2 nuts.
  
  Torque:
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
4. Connect 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 hose clips to secure the hoses.
TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *a NG
  
  *b OK
  
  Install a new gasket as shown in the illustration.
  
  Note
  
  Do not install the gasket upside down.
2. Temporarily install the turbo oil inlet pipe sub-assembly with the 2 nuts.
TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY
1. Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.
2. Temporarily install the exhaust manifold to turbocharger sub-assembly with 3 new nuts.
3. Text in Illustration
  
  *1 Collar
  
  Engine Side
  
  Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and 8 plate washers to the cylinder head sub-assembly with 8 new nuts.
  
  Note
  
  Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
4. Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.
5. Temporarily install the union bolt.
INSTALL TURBO OIL OUTLET PIPE
1. Install a new gasket to the turbo oil outlet pipe.
  
  Note
  
  The claws of the gasket must face the turbo oil outlet pipe.
2. Install the turbo oil outlet pipe with the 2 bolts.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
3. Connect the turbo oil outlet hose to the turbo oil outlet pipe, turbo oil inlet pipe and slide the 2 hose clips to secure the hoses.
TEMPORARILY INSTALL TURBOCHARGER STAY
1. Temporarily install the turbocharger stay to the turbocharger sub-assembly with the 3 bolts and nut.
TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY
1. Tighten the exhaust manifold with turbocharger sub-assembly to the cylinder head sub-assembly with the 8 nuts.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
  
  Tech Tips
  
  Tighten the nuts in the order shown in the illustration.
2. Tighten the turbocharger sub-assembly to the exhaust manifold with the 3 nuts.
  
  Torque:
  
  73 N*m { 744 kgf*cm, 54 ft.*lbf }
3. Tighten the 2 nuts and union bolt of the turbo oil inlet pipe sub-assembly.
  
  Torque:
  
  for nut
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  for union bolt
  
  36 N*m { 367 kgf*cm, 27 ft.*lbf }
  
  Note
  
  If the connecting part of the union bolt gasket is cracked, remove the connecting part.
TIGHTEN TURBOCHARGER STAY
1. Tighten the 3 bolts and nut of the turbocharger stay in the order shown in the illustration.
  
  Torque:
  
  24 N*m { 245 kgf*cm, 18 ft.*lbf }
INSTALL OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET
1. Connect the oil cooler tube bracket with the bolt.
  
  Torque:
  
  5.5 N*m { 56 kgf*cm, 47 in.*lbf }
INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly with the bolt and 4 new nuts.
  
  Torque:
  
  for bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  for nut
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
CONNECT TURBO WATER HOSE

Note

The turbocharger sub-assembly may be damaged if the No. 1 turbo water hose and No. 2 turbo water hose are connected to the wrong locations.
1. Connect the No. 2 turbo water hose to the water outlet sub-assembly, and slide the 2 hose clips to secure the hoses.
2. Connect the No. 1 turbo water hose to the engine water pump assembly, and slide the 2 hose clips to secure the hoses.
INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
1. Install the No. 2 water by-pass pipe sub-assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the No. 2 water by-pass hose and No. 3 water by-pass hose to the water outlet sub-assembly and engine oil cooler assembly and slide the 2 hose clips to secure the hoses.
INSTALL PCV HOSE CLAMP
1. Install the PCV hose clamp with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the 2 connectors and attach the wire harness clamp.
INSTALL PCV HOSE
1. Attach the clamp, install the PCV hose and slide the 2 hose clips to secure the hoses.
2. Slide the 2 hose clips to secure the hoses.
INSTALL EXHAUST MANIFOLD CONVERTER SUB-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.

Text in Illustration
*a	NG
*b	OK

Text in Illustration
*1	Collar
	Engine Side

ADD ENGINE OIL

Add new engine oil and install the oil filler cap sub-assembly.

Oil Grade

Oil Viscosity (SAE)

ACEA C2

(Using engine oil other than ACEA C2 may damage the catalytic converter)

- 0W-30

Standard Capacity

Item	Specified Condition
Drain and refill without oil filter sub-assembly change	5.5 liters (5.8 US qts, 4.8 Imp. qts)
Drain and refill with oil filter sub-assembly change	6.1 liters (6.4 US qts, 5.4 Imp. qts)
Dry fill	7.0 liters (7.4 US qts, 6.2 Imp. qts)

ADD ENGINE COOLANT
1. Firmly tighten the drain plugs.
2. Fill the radiator reserve tank assembly with engine coolant to the top of the inlet.
  
  Standard capacity
  
  13.9 liters (14.6 US qts, 12.2 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 (SLLC) 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 water outlet sub-assembly.
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. Add engine coolant up to the B line mark in the radiator reserve tank assembly and install the radiator 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. After the engine cools down, check that the engine coolant level is between the LOW and FULL line.
INSPECT FOR OIL LEAK
1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.
INSPECT ENGINE OIL LEVEL
1. Warm up the engine, and then stop the engine and wait 5 minutes.
2. Check that the engine oil level is between the engine oil level dipstick low level mark and full level mark.
  
  If the engine oil level is low, check for leaks and add engine oil to the full level mark.
  
  Note
  
  Do not fill engine oil above the full level mark.
  Tech Tips
  
  A certain amount of engine oil will be consumed while driving. In the following situations, oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.
  - When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
  - If low quality oil or oil of an inappropriate viscosity is used.
  - When driving at a high engine speed or with a heavy load, when towing, or when driving while accelerating or decelerating frequently.
  - When idling for a long time, or when driving frequently through heavy traffic.
  When judging the amount of oil consumption, keep in mind that the oil may have become diluted, making it difficult to judge the true level accurately.
INSPECT FOR COOLANT LEAK

CAUTION:

Do not remove the radiator cap sub-assembly while the engine assembly and radiator assembly are still hot. Hot, pressurized engine coolant and steam may be released and cause serious burns.
1. Fill the radiator assembly 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 assembly 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 assembly and engine water pump assembly for leaks. If no external leaks are found, check the heater core, cylinder block sub-assembly and cylinder head sub-assembly.
INSPECT FOR EXHAUST GAS LEAK
- If gas is leaking, tighten the areas necessary to stop the leak. Replace damaged parts as necessary.