Turbocharger installation (4JK1-TCY) Page 1 of 27

Turbocharger installation (4JK1-TCY)

1. Component views

Low pressure turbocharger

Part name

1. Low pressure turbocharger

2. Low pressure turbocharger water feed and return pipe
3. Low pressure turbocharger heat protector
4. Oil drain pipe
5. Turbocharger bracket

Tightening torque

1: 52 N・m { 5.3 kgf・m / 38 lb・ft }

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2: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 25 N・m { 2.5 kgf・m / 18 lb・ft }

6: 25 N・m { 2.5 kgf・m / 18 lb・ft }

7: 51 N・m { 5.2 kgf・m / 38 lb・ft }

High pressure turbocharger

Part name

1. High pressure turbocharger water feed and return pipe

2. High pressure turbocharger
3. High pressure turbocharger heat protector
4. Low pressure turbocharger
5. High pressure turbocharger oil return pipe

Tightening torque

1: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

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2: 52 N・m { 5.3 kgf・m / 38 lb・ft }

3: 25 N・m { 2.5 kgf・m / 18 lb・ft }

4: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

5: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2. Turbocharger installation

1. 2WD models

1) Temporarily tighten the oil drain pipe to the crankcase.

Caution
• Do not reuse the gasket.

2) Install the low pressure turbocharger and gasket to the exhaust manifold.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

Caution
• Do not reuse the gasket.

3) Pour approx. 1.0 cc of engine oil into the low pressure turbocharger oil feed port.

4) Temporarily tighten the oil drain pipe to the low pressure turbocharger.

Caution
• Do not reuse the gasket.

5) Final tighten the oil drain pipe to the low pressure turbocharger and crankcase.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Nut

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt

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6) Install the low pressure turbocharger bracket to the bracket and low pressure turbocharger.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

7) Install the high pressure turbocharger water feed and return pipe to the high pressure turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Caution
• Do not reuse the gasket.

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8) Install the oil drain pipe to the high pressure turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Caution
• Do not reuse the gasket.

9) Install the high pressure turbocharger and gasket to the low pressure turbocharger.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

Caution
• Do not reuse the gasket.

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10) Pour approx. 1.0 cc of engine oil into the high pressure turbocharger oil feed port.

2. 4WD models

1) Temporarily tighten the oil drain pipe to the crankcase.

Caution
• Do not reuse the gasket.

2) Install the catalytic converter in the engine room in advance.

3) Install the low pressure turbocharger and gasket to the exhaust manifold.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

Caution
• Do not reuse the gasket.

4) Pour approx. 1.0 cc of engine oil into the low pressure turbocharger oil feed port.

5) Temporarily tighten the oil drain pipe to the low pressure turbocharger.

Caution
• Do not reuse the gasket.

6) Final tighten the oil drain pipe to the low pressure turbocharger and crankcase.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Nut

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Bolt

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7) Install the low pressure turbocharger bracket to the bracket and low pressure turbocharger.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

8) Install the high pressure turbocharger water feed and return pipe to the high pressure turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Caution
• Do not reuse the gasket.

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9) Install the oil drain pipe to the high pressure turbocharger.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

Caution
• Do not reuse the gasket.

10) Install the high pressure turbocharger and gasket to the low pressure turbocharger.

Tightening torque: 52 N・m { 5.3 kgf・m / 38 lb・ft }

Caution
• Do not reuse the gasket.

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11) Pour approx. 1.0 cc of engine oil into the high pressure turbocharger oil feed port.

3. Catalytic converter installation

1. 2WD models

1) Temporarily tighten the catalytic converter and gasket to the turbocharger in the order shown in the diagram.

Caution
• Do not reuse the gasket.

2) Temporarily tighten the exhaust pipe bracket to the catalytic converter and crankcase in the order shown in the
diagram.

Caution
• Install so that there is no clearance between brackets.

3) Final tighten the catalytic converter to the turbocharger in the order shown in the diagram.

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

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4) Final tighten the exhaust pipe bracket to the catalytic converter and crankcase in the order shown in the
diagram.

Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }

5) Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion of
the exhaust gas temperature sensor sleeve nut.

Note
• If Exhaust gas temperature sensor 2 is replaced with a new one, it is not necessary to apply new anti-
seize lubricant.

Caution
• Apply Never-Seez High Temperature Stainless Grade 5-87411-039-0 by Bostik of USA as the anti-seize
lubricant.

6) Connect Exhaust gas temperature sensor 2 to the catalytic converter.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

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1. Exhaust gas temperature sensor 2

7) Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion of
the exhaust gas temperature sensor sleeve nut.

Note
• If Exhaust gas temperature sensor 3 is replaced with a new one, it is not necessary to apply new anti-
seize lubricant.

Caution
• Apply Never-Seez High Temperature Stainless Grade 5-87411-039-0 by Bostik of USA as the anti-seize
lubricant.

8) Connect Exhaust gas temperature sensor 3 to the catalytic converter.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

1. Exhaust gas temperature sensor 3

2. 4WD models

1) Temporarily tighten the catalytic converter and gasket to the turbocharger in the order shown in the diagram.

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Caution
• Do not reuse the gasket.

2) Temporarily tighten the exhaust pipe bracket to the catalytic converter and crankcase in the order shown in the
diagram.

Caution
• Install so that there is no clearance between brackets.

3) Final tighten the catalytic converter to the turbocharger in the order shown in the diagram.

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

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4) Final tighten the exhaust pipe bracket to the catalytic converter and crankcase in the order shown in the
diagram.

Tightening torque: 94 N・m { 9.6 kgf・m / 69 lb・ft }

5) Install the mounting bracket to the frame.

Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft }

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1. Mounting bracket

6) Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion of
the exhaust gas temperature sensor sleeve nut.

Note
• If Exhaust gas temperature sensor 2 is replaced with a new one, it is not necessary to apply new anti-
seize lubricant.

Caution
• Apply Never-Seez High Temperature Stainless Grade 5-87411-039-0 by Bostik of USA as the anti-seize
lubricant.

7) Connect Exhaust gas temperature sensor 2 to the catalytic converter.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

1. Exhaust gas temperature sensor 2

8) Clean the old anti-seize lubricant on the sleeve nut, and apply new anti-seize lubricant to the threaded portion of
the exhaust gas temperature sensor sleeve nut.

Note

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• If Exhaust gas temperature sensor 3 is replaced with a new one, it is not necessary to apply new anti-
seize lubricant.

Caution
• Apply Never-Seez High Temperature Stainless Grade 5-87411-039-0 by Bostik of USA as the anti-seize
lubricant.

9) Connect Exhaust gas temperature sensor 3 to the catalytic converter.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

1. Exhaust gas temperature sensor 3

4. DPD installation

1) Install the DPD and gasket to the catalytic converter.

Caution
• Do not reuse the gasket.

Tightening torque: 67 N・m { 6.8 kgf・m / 49 lb・ft }

1. DPD hanger rubber

2. DPD

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3. Differential pressure hose

2) Install the DPD hanger rubber to the DPD.

3) Connect the connector to Exhaust gas temperature sensor 1.

4) Align the markings, and connect the differential pressure hoses to the differential pressure pipe.

Caution
• Do not reuse the differential pressure hose clip.
• Do not incorrectly assemble differential pressure hoses.

5. Exhaust pipe installation

Refer to "1.Engine 1G.Exhaust(4JK1-TCY) exhaust pipe installation".

6. Exhaust differential pressure sensor installation

Refer to "1.Engine 1Z.Engine Electrical Control(4JK1-TCY) exhaust differential pressure sensor installation".

7. Low pressure turbocharger heat protector installation

1) Install the low pressure turbocharger heat protector to the low pressure turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8. EGR cooler installation

1) Temporarily tighten the EGR cooler and gasket to the cylinder head and exhaust manifold in the order shown in
the diagram.

Caution
• Do not reuse the gasket.

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2) Final tighten the EGR cooler to the cylinder head and exhaust manifold in the order shown in the diagram.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

3) Connect the EGR cooler water return hose to the EGR cooler.

4) Connect the EGR cooler water feed hose to the EGR cooler.

5) Install the low pressure turbocharger vacuum pipe to the EGR cooler.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Bolt

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Nut

6) Connect the low pressure turbocharger vacuum pipe to the low pressure turbocharger.

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7) Install the EGR cooler heat protector to the EGR cooler.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

8) Install the low pressure turbocharger vacuum pipe to the EGR cooler heat protector.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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9) Connect the vacuum hose to the low pressure turbocharger vacuum pipe.

10) Connect the vacuum hose to the low pressure turbocharger.

11) Connect the high pressure turbocharger water return hose to the high pressure turbocharger.

9. Water feed and return pipe installation

1) Install the low pressure turbocharger water feed and return pipe to the low pressure turbocharger.

Caution
• Do not reuse the gasket.

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in }

2) Connect the low pressure turbocharger water return hose to the water intake pipe.

3) Connect the high pressure turbocharger water return hose to the high pressure turbocharger water feed and
return pipe.

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4) Connect the high pressure turbocharger water feed hose to the high pressure turbocharger water feed and
return pipe.

1. High pressure turbocharger water return hose

2. High pressure turbocharger water feed hose

10. Turbocharger feed oil pipe installation

1) Temporarily tighten the oil feed pipe to the high pressure turbocharger and low pressure turbocharger in the
order shown in the diagram.

Caution
• Do not reuse the gasket.

2) Final tighten the oil feed pipe to the high pressure turbocharger and low pressure turbocharger in the order
shown in the diagram.

Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft } Nipple

Tightening torque: 28 N・m { 2.9 kgf・m / 21 lb・ft } Eyebolt

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3) Install the high pressure turbocharger feed oil pipe to the high pressure turbocharger and oil cooler.

Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft } Nut

Tightening torque: 23 N・m { 2.3 kgf・m / 17 lb・ft } Eyebolt

11. High pressure turbocharger heat protector installation

1) Install the high pressure turbocharger heat protector to the high pressure turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

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12. Air cleaner installation

1) Install the air cleaner to the vehicle.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

1. Air cleaner
2. MAF and IAT sensor
3. Vacuum hose
4. Blow-by hose
5. Intake pipe
6. Barometric pressure sensor

2) Referring to the diagram, connect the intake pipe to the turbocharger by aligning the alignment marks.

Tightening torque: 4.0 N・m { 0.41 kgf・m / 35.4 lb・in }

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1. Alignment mark

3) Connect the vacuum hose to the air cleaner.

4) Connect the connector to the barometric pressure sensor.

5) Connect the connector to the MAF and IAT sensor.

13. Blow-by hose connect

1) Connect the blow-by hose to the cylinder head cover.

14. Intake air bypass valve installation

1) Temporarily tighten the bracket to the front engine hanger bracket.

2) Temporarily install the intake hose to the low pressure turbocharger.

Caution
• Do not final tighten the clamp.

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3) Temporarily tighten the intake pipe and O-ring to the intake air bypass valve.

Caution
• Do not reuse the O-ring.

4) Insert the intake air bypass valve to the intake hose and temporarily tighten it to the turbocharger.

Note
• Temporarily tighten the intake air bypass valve bolts after temporarily tightening the clamp.

Caution
• Do not reuse the gasket.

5) Final tighten the intake air bypass valve to the turbocharger.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Intake air bypass valve

Tightening torque: 10.0 N・m { 1.0 kgf・m / 89 lb・in } Intake pipe

6) Final tighten the intake hose clamp.

Tightening torque: 7.4 N・m { 0.8 kgf・m / 65 lb・in }

7) Temporarily tighten the intake air bypass valve to the bracket.

8) Securely tighten the bracket to the front engine hanger bracket.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

9) Final tighten the intake air bypass valve to the bracket.

10) Connect the vacuum pipe to the intake air bypass valve.

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }

11) Connect the vacuum hose to the intake air bypass valve.

15. Intake hose installation

1) Install the intake hose to the intake air bypass valve and intercooler.

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Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }

16. Engine cover installation

1) Install the engine cover to the engine.

1. Engine cover

17. Underguard installation

Refer to "9.Body, Cab, Accessories 9G.Hood, Fenders, Doors underguard installation".

18. Preliminary and post procedures

1. Post procedures

1) Lower the vehicle.

2) Connect the battery cable to the battery negative terminal.

3) Referring to the following, perform the settings for the steering angle sensor and for the front door power
window switch with AUTO UP/AUTO DOWN function.

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Refer to "6.Steering 6Z.Steering Electrical Control steering angle sensor setting".

Refer to "9.Body, Cab, Accessories 9T.Glass, Windows, Mirrors front door power window switch setting".

4) Close the engine hood.

19. Coolant filling

1) Fill with engine coolant up to the radiator filler neck.

Note
• Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

Caution
• Fill slowly to prevent air from entering the system.

2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator
with engine coolant.

Note
• Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant
lowers.

Caution
• Repeat the operation until the coolant level no longer drops.

3) Add engine coolant up to the MAX line of the radiator reserve tank.

1. Radiator reserve tank

2. MAX line
3. MIN line

4) Install the radiator cap to the radiator.

5) Start and idle the engine.

Caution
• Idle the engine for 5 minutes or more.

6) Stop the engine.

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7) Remove the radiator cap from the radiator.

Warning
• Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
• When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

8) Fill with engine coolant up to the radiator filler neck.

Note
• If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.

9) Install the radiator cap to the radiator.

10) Start the engine.

11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant
temperature gauge reaches the center.

12) With the engine running, check that the thermostat valve is open.

Note
• Touch the radiator upper hose, and confirm that it has become warm.
• If it has not become warm, go back to Step 11.

Caution
• Do not try determining it by using only an engine coolant temperature gauge.

13) Idle the engine for 5 minutes.

14) Stop the engine.

15) Remove the radiator cap from the radiator.

Warning
• Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in
burns caused by the release of steam or hot water.
• When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled
and slowly turn to release pressure.

16) Fill with engine coolant up to the radiator filler neck.

Note
• Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.

17) Add engine coolant up to the MAX line of the radiator reserve tank.

18) Install the radiator cap to the radiator.

19) Repeat steps 10 to 18 until the coolant level no longer lowers.

Caution
• If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.

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