Exhaust Manifold W/ Turbocharger (W/O Dpf) Installation

Install a new gasket and 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}

Install a new gasket, manifold, 8 new collars and 8 plate washers to the cylinder head with 8 new nuts.

Torque:

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

Text in Illustration

*1	Collar
	Engine Side

NOTICE:

1. Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
   
2. Tighten the nuts in the order shown in the illustration.
   

Temporarily install a new gasket and the turbocharger with 3 new nuts.

HINT:

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

Temporarily install the turbo oil inlet pipe.

Text in Illustration

*1	New Gasket	*2	Claw
*3	Narrow	*4	Wide
	Outside	-	-

HINT:

Before installing the turbo oil inlet pipe, clean it.

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

   NOTICE:

   The notch (narrow part) of the gasket must face the engine.

2. Install a new gasket and the turbo oil inlet pipe with the 2 bolts, but only loosely install the bolts.
   

   NOTICE:

   The claws of the gasket must face the turbo oil inlet pipe.

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

4. Temporarily install the turbocharger stay with the 2 bolts and nut.
   

Tighten the 3 nuts of the turbocharger.

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:

26 N*m{265 kgf*cm, 19 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 a new gasket and the turbine outlet elbow with the 3 new nuts.

Torque:

26 N*m{260 kgf*cm, 19 ft.*lbf}

Install the 2 No. 1 turbo water hoses.

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

Temporarily install the No. 1 turbo insulator with the 2 bolts.

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}

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

Torque:

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

Connect the 2 connectors to the turbocharger.

Attach the wire harness clamp.

Connect the 2 ventilation hoses to the cylinder head cover and compressor inlet elbow.

Install the ventilation pipe to the cylinder head with the bolt.

Torque:

20 N*m{204 kgf*cm, 15 ft.*lbf}

Connect the air cleaner hose.

Install the cleaner with the 2 bolts.

Torque:

14 N*m{143 kgf*cm, 10 ft.*lbf}

Tighten the hose clamp.

Connect the connector to the mass air flow meter connector.

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

Minimum length:

40 mm (1.57 in.)

Install the front exhaust pipe to the exhaust pipe support.

Install a new gasket to the turbine outlet elbow.

NOTICE:

1. Be careful with the installation direction of the gasket.
   

1. Do not reuse the gasket.
   

1. To ensure a proper seal, do not use the front exhaust pipe to force the gasket onto the turbine outlet elbow.
   

HINT:

Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.

Install the front exhaust pipe and 2 compression springs with the 2 bolts. Alternately tighten the bolts in several passes.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf}

Install the front fender seal with the 5 clips.

Install the front fender apron seal upper with the 5 clips.

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 radiator reservoir.

Standard Capacity:

Item	Specified Condition
for Automatic Transmission	11.1 liters (11.7 US qts, 9.8 Imp. qts)
for Manual Transmission	9.8 liters (10.4 US qts, 8.6 Imp. qts)

NOTICE:

Never use water as a substitute for engine coolant.

HINT:

1. 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).
   
2. Please contact your TOYOTA dealer for further details.
   

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.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 17 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 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:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. 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 F line.
If the coolant level is below the F line, add TOYOTA SLLC to the F line.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm², 17 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.

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

Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.
If low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill engine oil above the full level mark.