Exhaust Manifold W/ Turbocharger Installation

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}

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}

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 the hose clamp with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Install a new gasket.

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

Torque:

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

Install a new gasket.

Using an E8 "TORX" socket wrench, install a new gasket and the compressor inlet elbow with the stud bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

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 the compressor inlet elbow stay with the 2 bolts.

Torque:

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

Install a new gasket.

Temporarily install the turbo water pipe sub-assembly with the bolt and 2 nuts.

Tighten the bolt and 2 nuts.

Torque:

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

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.

Install a new gasket as shown in the illustration.

NOTICE:

Do not install the gasket upside down.

Temporarily install the turbo oil inlet pipe subassembly with the 2 nuts.

Install 2 new gaskets to the exhaust manifold and turbocharger sub-assembly.

Temporarily install the exhaust manifold to turbocharger sub-assembly with 3 new nuts.

Temporarily install the exhaust manifold with turbocharger sub-assembly, 8 collars and the 8 plate washers to the cylinder head sub-assembly with 8 new nuts.

Text in Illustration

*1	Collar
	Engine Side

NOTICE:

Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

Install a new gasket on the union bolt side to turbo oil inlet pipe sub-assembly.

Temporarily install the union bolt.

Install a new gasket to the turbo oil outlet pipe.

NOTICE:

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

Install the turbo oil outlet pipe with the 2 bolts.

Torque:

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

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 the turbocharger stay to the turbocharger sub-assembly, with 3 bolts and nut.

Tighten the exhaust manifold with turbocharger sub-assembly, to the cylinder head sub-assembly with 8 nuts.

Torque:

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

HINT:

Tighten the nuts in the order shown in the illustration.

Tighten the turbocharger sub-assembly, to the exhaust manifold with the 3 nuts.

Torque:

73 N*m{744 kgf*cm, 54 ft.*lbf}

Tighten the 2 nuts and then 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}

NOTICE:

If the connecting part of the union bolt gasket is cracked, remove the connecting part.

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}

Temporarily install the No. 1 viscous heater bracket sub-assembly with 4 bolts.

Tighten the 4 bolts and of the No. 1 viscous heater bracket sub-assembly in the order shown in the illustration.

Torque:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Connect the No. 4 engine harness with the bolt.

Torque:

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

Connect the wire harness.

Connect the wire harness clamp bracket with the bolt.

Torque:

13 N*m{130 kgf*cm, 9 ft.*lbf}

for Automatic Transmission:
Connect the oil cooler tube bracket with the bolt.

Torque:

5.5 N*m{56 kgf*cm, 47 in.*lbf}

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}

Install 2 new gaskets and the No. 1 EGR pipe sub-assembly to the exhaust manifold and EGR valve adapter with 4 new nuts.

Torque:

29 N*m{296 kgf*cm, 21 ft.*lbf}

Connect the No. 1 EGR pipe sub-assembly to the vacuum transmitting pipe sub-assembly with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the No. 1 turbo water hose and No. 2 turbo water hose to the water outlet sub-assembly, engine water pump assembly and slide the 2 hose clips to secure the hoses.

NOTICE:

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.

Install a new gasket to the No. 1 water by-pass pipe as shown in the illustration.

HINT:

Make sure that the claws of the gasket are facing the No. 1 water by-pass pipe.

Connect the No. 1 water by-pass pipe to the engine water pump assembly with the 3 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Attach the wire harness clamp and connect the 2 connectors to the turbocharger sub-assembly.

Attach the clamp and install the PCV hose.

Slide the 2 hose clips to secure the hoses.

Connect the PCV pipe to the compressor inlet elbow, cylinder head cover sub-assembly and slide the 2 hose clips to secure the hoses.

Install the PCV pipe with the bolt to the compressor inlet elbow.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the No. 19 water by-pass hose to the compressor inlet elbow and slide the hose clip to secure the hoses.

Install the No. 20 water by-pass hose to the PCV pipe and No. 1 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Connect the 2 water hoses to the oil cooler assembly and No. 2 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Install the No. 3 water by-pass pipe with the bolt.

Torque:

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

for Cold Area Specification Vehicles:
Install the water hose to the compressor inlet elbow and No. 3 water by-pass pipe, and slide the 2 hose clips to secure the hoses.

Install the water hose sub-assembly B to the No. 2 water pipe and water outlet sub-assembly, slide the 4 clamps secure the hoses.

Connect the water hose sub-assembly B to the water inlet with the bolt.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Temporarily install the viscous heater with magnet clutch assembly with the 2 bolts.

Connect the connector.

Install the air cleaner case sub-assembly with the 3 bolts.

Torque:

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

for Cold Area Specification Vehicles:
Connect the wire harness clamps.

Install the air cleaner filter element sub-assembly to the air cleaner case.

Attach the 4 clips to install the air cleaner cap sub-assembly with air cleaner hose.

Tighten the hose clamp.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the mass air flow meter connector and attach the 2 wire harness clamps.

Install the fan pulley.

Place the fan shroud together with the fan with fluid coupling assembly between the engine and radiator assembly.

NOTICE:

Be careful not to damage the radiator core.

Attach the 2 guides and install the fan shroud with the 2 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Temporarily install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.

NOTICE:

1. Make sure to match the paint mark colors on the fan with fluid coupling assembly with the stud bolts of the same color on the engine water pump assembly.
   
2. When installing the fan and generator V belt, make sure to securely tighten the nuts of the fan with fluid coupling assembly so that the fan pulley is properly aligned.
   

Install the fan and generator V belt (LandCruiser RM00000122V00OX_01_0002.html).

Tighten the 4 nuts holding the fan with fluid coupling assembly.

Torque:

23 N*m{235 kgf*cm, 17 ft.*lbf}

Install the radiator reservoir assembly with the 3 bolts.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Attach the 2 clamps to connect the No. 1 water by-pass hose to the fan shroud.

Connect the No. 1 water by-pass hose to the radiator assembly and slide the hose clamp to secure the hose.

Connect the No. 2 water by-pass hose to the water inlet and slide the hose clamp to secure the hose.

Attach the 2 clamps to connect the No. 2 water by-pass hose to the fan shroud.

Install the No. 1 radiator hose and slide the 2 hose clamps to secure the hose.

Connect the vane pump oil reservoir sub-assembly to the body with the 3 bolts.

Torque:

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

Install the No. 2 intercooler air hose and tighten the 2 hose clamps.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

Connect the oil return hose and slide the 2 clips to secure the hose.

Install the intercooler air hose and tighten the 2 hose bands to secure the hose.

Torque:

5.0 N*m{51 kgf*cm, 44 in.*lbf}

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

Oil Grade:

Oil Grade	Oil Viscosity (SAE)
ACEA C2 (Using engine oil other than ACEA C2 may damage the catalytic converter)	- 0W-30 - 5W-30

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter sub-assembly change	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Drain and refill with oil filter sub-assembly change	7.5 liters (7.9 US qts, 6.6 Imp. qts)
Dry fill	8.0 liters (8.5 US qts, 7.0 Imp. qts)

Add engine coolant through the radiator reservoir filler opening until the engine coolant reaches the "B" line.

Standard Capacity:

Item		Specified Condition
for Manual Transmission	except Cold Area Specification Vehicle	10.1 liters (10.7 US qts, 8.9 Imp. qts)
	for Cold Area Specification Vehicle	11.9 liters (12.6 US qts, 10.5 Imp. qts)
for Automatic Transmission	except Cold Area Specification Vehicle	10.0 liters (10.6 US qts, 8.8 Imp. qts)
	for Cold Area Specification Vehicle	11.8 liters (12.5 US qts, 10.4 Imp. qts)

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

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 is a combination of low phosphates and organic acids).

Press the No. 1 radiator hose and No. 2 radiator hose several times by hand, and then check the level of the engine coolant.
If the coolant level drops below the B line, add engine coolant to the B line.

Install the radiator reservoir cap sub-assembly.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 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.
   

   NOTICE:

   1. Immediately after starting the engine, if the radiator reservoir sub-assembly does not have any engine coolant, perform the following: 1) stop the engine, 2) wait until the engine coolant has cooled down, and 3) add engine coolant.
      
   2. Do not start the engine when there is no coolant in the radiator reservoir sub-assembly.
      
   3. Make sure that the needle does not show an abnormally high temperature.
      
   4. If there is not enough coolant, the engine may overheat.
      

   HINT:

   The thermostat open timing can be confirmed by pressing the No. 2 radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

2. Maintain the engine speed at 2000 to 2500 rpm.
   

3. Press the No. 1 radiator hose and No. 2 radiator hose several times by hand to bleed air.
   

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

Check the coolant level in the radiator reservoir sub-assembly.
If the coolant level is low, add engine coolant to the radiator reservoir sub-assembly full line.

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

Warm up the engine, and then stop the engine and wait 5 minutes.

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.

NOTICE:

Do not fill engine oil above the full level mark.

HINT:

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.

1. When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
   

1. If low quality oil or oil of an inappropriate viscosity is used.
   

1. When driving at a high engine speed or with a heavy load, when towing, or when driving while accelerating or decelerating frequently.
   

1. 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.

Remove the radiator reservoir cap sub-assembly.

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

Warm up the engine.

Using the radiator cap tester, increase the pressure inside the radiator assembly 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 assembly and engine water pump assembly for leaks.
If there are no signs or traces of external engine coolant leakage, check the heater core, cylinder block assembly and cylinder head sub-assembly.

Remove the radiator cap tester and install the radiator reservoir cap sub-assembly.