Exhaust Manifold W/ Turbocharger (W/ Dpf) Installation

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 the No. 7 water by-pass hose and No. 9 water by-pass hose to the compressor inlet elbow.

Install a new gasket and the No. 1 turbo water pipe 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}

Connect the No. 2 water by-pass hose to the compressor inlet elbow.

Temporarily install a new gasket with the turbocharger and 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.

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.
   
   

   
   
   
   
   

   Text in Illustration

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

   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 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 a new nut.
   

Tighten the 3 nuts of the turbocharger.

Torque:

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

Tighten the union bolt labeled B.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Tighten the 2 nuts labeled A.

Torque:

13 N*m{133 kgf*cm, 10 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}

Attach the wire harness clamp and connect the 2 connectors.

Connect the No. 1 turbo water hose and No. 9 water by-pass hose.

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

Torque:

35 N*m{357 kgf*cm, 26 ft.*lbf}

Install a new gasket and the No. 3 water by-pass pipe to the turbine outlet elbow with the bolt and union bolt.

Torque:

for bolt:

21 N*m{214 kgf*cm, 15 ft.*lbf}

for union bolt:

35 N*m{357 kgf*cm, 26 ft.*lbf}

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

Temporarily install the No. 1 fuel pipe and a new gasket with the union bolt.

Tighten the 3 nuts of the turbine outlet elbow.

Torque:

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

Connect the No. 3 water by-pass pipe to the No. 3 turbo water hose.

Tighten the union bolt of the No. 1 fuel pipe.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Attach the clamp and connect the No. 4 turbo water hose to the No. 4 water by-pass pipe.

Connect the exhaust fuel addition injector connector.

Install a new gasket and the No. 2 turbine outlet elbow with 3 new nuts.

Torque:

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

Install the turbine outlet elbow stay with the bolt and nut.

Torque:

60 N*m{612 kgf*cm, 44 ft.*lbf}

Attach the wire harness clamp.

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

Torque:

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

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

Torque:

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

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 2 bolts of the No. 1 exhaust manifold heat insulator and the bolt of the No. 1 turbo insulator.

Torque:

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

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}

Install the air cleaner together with the No. 1 air cleaner hose with the 2 bolts.

Torque:

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

Connect the No. 1 air cleaner hose and tighten the hose clamp of the compressor inlet elbow.

Connect the mass air flow meter connector and attach the wire harness clamp.

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.

Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

NOTICE:

1. Hand pump pumping speed: Max. 2 strokes/ sec.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. 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.
   
5. 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.
   
6. 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.
   

Check if the engine starts.

NOTICE:

1. 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.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. 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 the air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch to ON and turn the intelligent tester on.

Clear the DTCs.

1. for DPF: (HILUX_TGN26 RM000000PDK0X2X.html)
   
2. for i-ART: (HILUX_TGN26 RM000000PDK0X4X.html)
   

Start the engine.*1

Enter the following menus: Powertrain / Engine / Active Test / Test the Fuel Leak.*2

Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

HINT:

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.

Enter the following menus: Powertrain / Engine / DTC.

Read Current DTCs.

Clear the DTCs.

1. for DPF: (HILUX_TGN26 RM000000PDK0X2X.html)
   
2. for i-ART: (HILUX_TGN26 RM000000PDK0X4X.html)
   

HINT:

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.

Repeat steps *1 to *3.

Enter the following menus: Powertrain / Engine / DTC.

Read Current DTCs.

OK:

No DTCs are output.

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.

Perform the Active Test.

1. Connect the intelligent tester to the DLC3.
   

2. Turn the ignition switch to ON.
   

3. Turn the intelligent tester on.
   

4. Enter the following menus: Powertrain / Engine / Active Test.
   

5. 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.