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Installation [08/2015 - ]: Procedure

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  1. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY 
    1. Install a new inlet turbo oil gasket to the turbocharger sub-assembly as shown in the illustration.
      GTY647197Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a NG
      NOTE:

      Make sure that the inlet turbo oil gasket is installed in the correct direction.

    2. Install the inlet turbo oil pipe sub-assembly to the turbocharger sub-assembly with the 2 nuts.

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  2. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY 
    1. Install a new water by-pass gasket to the turbocharger sub-assembly.
    2. Temporarily install the No. 1 turbo water pipe sub-assembly to the turbocharger sub-assembly with the bolt and 2 nuts.
    3. Tighten the bolt and 2 nuts in the order shown in the illustration.
      Fig 1: No. 1 Turbo Water Pipe Sub-Assembly Tightening Sequence
      GTY647085Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 12 N.m (122 kgf/cm, 9 ft.lbf) 

  3. INSTALL INLET COMPRESSOR ELBOW 

    See step  3

  4. CONNECT NO. 3 TURBO WATER HOSE 
    1. Connect the No. 3 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.
  5. CONNECT NO. 4 TURBO WATER HOSE 
    1. Connect the No. 4 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.
  6. INSTALL TURBOCHARGER SUB-ASSEMBLY 
    1. Install a new outlet No. 1 turbo oil gasket to the inlet turbo oil pipe sub-assembly as shown in the illustration.
      NOTE:

      Make sure that the claws of the outlet No. 1 turbo oil gasket are facing the inlet turbo oil pipe sub-assembly.

      GTY613767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Claw
    2. Install a new exhaust manifold to head gasket to the cylinder head sub-assembly.
      NOTE:

      Make sure that the protrusion of the exhaust manifold to head gasket is facing the cylinder head sub-assembly as shown in the illustration.

      GTY620546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protrusion
    3. Temporarily install the turbocharger sub-assembly to the cylinder head sub-assembly with 4 new nuts.
    4. Tighten the 4 nuts in the order shown in the illustration.
      Fig 2: Turbocharger Sub-Assembly Tightening Sequence
      GTY640708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Torque: 43 N.m (438 kgf/cm, 32 ft.lbf) 

    5. Connect the vacuum transmitting hose assembly to the waste gate valve actuator with bracket assembly.
      GTY657843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the vacuum transmitting hose assembly is installed all the way to the bent portion of the pipe of the waste gate valve actuator.

    6. Connect the intake air control valve (air by-pass valve assembly) connector and wire harness clamp to the turbocharger sub-assembly.
  7. CONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY 
    1. Install a new No. 1 union bolt gasket to the union bolt.
    2. Connect the inlet turbo oil pipe sub-assembly to the cylinder block sub-assembly with the 2 bolts and union bolt.
    3. Tighten the 2 bolts and union bolt.

      Bolt 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Union Bolt 

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

      NOTE:

      If the link that connects the gaskets is broken, remove the link by using side cutters or a similar tool.

  8. TIGHTEN HEAT INSULATOR BRACKET 
    1. Temporarily install the No. 2 heat insulator bracket to the turbocharger sub-assembly and No. 1 heat insulator bracket with the 2 bolts.
    2. Temporarily install the No. 1 heat insulator bracket to the cylinder head sub-assembly with the 2 bolts.
    3. Tighten the 4 bolts in several steps in the order shown in the illustration.

      Bolt (A) 

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      Bolt (B) 

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      Fig 3: Heat Insulator Bracket Tightening Sequence
      GTY614749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. INSTALL NO. 3 TURBO WATER HOSE 
    1. Install the No. 3 turbo water hose to the No. 1 turbo water pipe and slide the clip to secure it.
      NOTE:

      The turbocharger sub-assembly may be damaged if the No. 3 turbo water hose is connected to the wrong locations.

  10. INSTALL NO. 4 TURBO WATER HOSE 
    1. Connect the No. 4 turbo water hose to the No. 1 turbo water pipe and slide the clip to secure it.
      NOTE:

      The turbocharger sub-assembly may be damaged if the No. 4 turbo water hose is connected to the wrong locations.

  11. INSTALL OUTLET COMPRESSOR ELBOW 
    1. Install a new outlet compressor gasket to the turbocharger sub-assembly.
    2. Install the outlet compressor elbow with intake air resonator to the turbocharger sub-assembly with the 2 nuts.

      Torque: 24 N.m (245 kgf/cm, 18 ft.lbf) 

    3. Connect the vacuum transmitting hose assembly to the outlet compressor elbow with the clamp.
  12. CONNECT NO. 1 AIR TUBE 
    1. Connect the No. 1 air hose to the intake air resonator.
    2. Connect the No. 1 air tube to the cylinder head sub-assembly with the bolt.

      Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    3. Tighten the hose clamp.

      Torque: 6.3 N.m (64 kgf/cm, 56 in.lbf) 

  13. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Type A:
      GTY654460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 5 exhaust manifold heat insulator with the 3 bolts.
      2. Install the bolt (A).

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

        GTY642546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Tighten the 2 bolts (B) and bolt (C).

        Bolt (B) 

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        Bolt (C) 

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      4. Install the bolt (D).

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

    2. Type B:
      GTY791879Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Temporarily install the No. 5 exhaust manifold heat insulator with the 2 bolts.
      2. Install the bolt (A).

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

        GTY835132Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      3. Tighten the bolt (B) and bolt (C).

        Bolt (B) 

        Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

        Bolt (C) 

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

      4. Install the bolt (D).

        Torque: 21 N.m (214 kgf/cm, 15 ft.lbf) 

  14. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH 
    1. Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

      Torque: 43 N.m (438 kgf/cm, 32 ft.lbf) 

    2. Connect the front engine mounting insulator to the front No. 1 engine mounting bracket LH with the bolt.

      Torque: 35 N.m (357 kgf/cm, 26 ft.lbf) 

  15. INSPECT WASTE GATE VALVE ACTUATOR WITH BRACKET ASSEMBLY 

    See step  1

  16. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front and Rear Catalyst) 

    Refer to INSTALLATION [08/2015 - ]

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