Hilux 2015 2018 manual 1gd ftv intake exhaust he thong nap xa khi

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER COMPONENTS

ILLUSTRATION

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*3 AIR CLEANER FILTER ELEMENT

*7 NO 1 OIL RESERVOIR BRACKET *8 NO 1 RADIATOR HOSE

*9 NO 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY *10 NO 2 AIR TUBE

*13 VANE PUMP OIL RESERVOIR ASSEMBLY *14 VISCOUS HEATER WITH MAGNET CLUTCHASSEMBLY

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-*A for Cold Specification Vehicles *B w/o DPF

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Tightening torque for "Major areas involvingbasic vehicle performance such as

moving/turning/stopping" : N*m (kgf*cm,ft.*lbf)

N*m (kgf*cm, ft.*lbf): Specified torque

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*A except Cold Specification Vehicles *B w/ DPF

moving/turning/stopping": N*m (kgf*cm,ft.*lbf)

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*A for Cold Specification Vehicles *B w/o DPF

*3 NO 1 TURBO WATER PIPE SUB-ASSEMBLY *4 TURBO OIL INLET PIPE SUB-ASSEMBLY

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-*A except Cold Specification Vehicles *B w/ DPF

*3 NO 1 TURBO WATER PIPE SUB-ASSEMBLY *4 TURBO OIL INLET PIPE SUB-ASSEMBLY

-Tightening torque for "Major areas involvingbasic vehicle performance such as

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*1 TURBOCHARGER NOZZLE VANE CONTROLACTUATOR *2 TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY

*3 COMPRESSOR WITH BEARING HOUSING SUB-ASSEMBLY *4 E-WASHER

N*m (kgf*cm, ft.*lbf): Specified torque ● Non-reusable part

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER DISASSEMBLY

PROCEDURE

1.REMOVE TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY

Secure the flange of the turbine housing sub-assembly of the turbocharger sub-assembly in a vise betweenaluminum plates

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Remove the 3 bolts and turbocharger nozzle vane control actuator

a.

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER INSPECTION

PROCEDURE

Check for deformation and cracks in the compressor impeller on the intake side

If the compressor impeller is cracked or deformed, replace the turbocharger sub-assembly

a.

*1 Compressor Impeller

b.

*1 Turbine Wheel

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2.INSPECT AXIAL PLAY OF TURBINE SHAFT 17201

Using a dial indicator, insert the needle of the dial indicator into the exhaust side of the turbine shaft

NOTICE:

Turbocharger sub-assembly and dial indicators are surely fixed when performing measurement

a.

Move the turbine shaft in an axial direction and measure the axial play of the turbine shaft

Maximum axial play:

0.11 mm (0.00433 in.)

If the axial play is more than the maximum, replace the turbocharger sub-assembly

b.

Rotate the turbine wheel on the exhaust side with your finger and check that it rotates smoothly

HINT:

Even if it takes a little effort to rotate the turbine wheel, this is not a problem

If the turbine wheel does not rotate smoothly, replace the turbocharger sub-assembly

a.

4.INSPECT TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR

Measure the resistance according to the value(s) in the table below

Standard Resistance:

a.

Tester Connection Condition Condition Specified

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER INSTALLATION

PROCEDURE

NOTICE:

If a stud bolt is deformed or its threads are damaged, replace it

1.INSTALL STUD BOLT

Using an E10 "TORX" socket wrench, install the 3 stud bolts at the positions shown in the illustration

Torque:

14.7 N*m (150 kgf*cm, 11 ft.*lbf) a.

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) b.

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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) c.

except Cold Specification Vehicles:

Install the hose clamp with the bolt

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) a.

Install a new gasket

b.

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

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf) c.

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) a.

Install the compressor inlet elbow to the turbocharger sub-assembly with the 2 nuts

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf) b.

Install the compressor inlet elbow stay with the 2 bolts

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf) c.

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4.INSTALL NO 1 TURBO WATER PIPE SUB-ASSEMBLY 16027

Install a new gasket

Connect the No 1 turbo water hose and No 2 turbo water hose to the No 1 turbo water pipe sub-assemblyand slide the 2 hose clips to secure the hoses

d.

5.TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY 15407

Install a new gasket as shown in the illustration

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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

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

d.

Temporarily install the union bolt

e.

Install a new gasket to the turbo oil outlet pipe

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8.TEMPORARILY INSTALL TURBOCHARGER STAY 17293

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

a.

9.TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY 17141

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 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

c.

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10.TIGHTEN TURBOCHARGER STAY 17293

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) a.

11.INSTALL NO 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV COOLING>WATER PUMP>INSTALLATION

12.INSTALL WIRE HARNESS CLAMP BRACKET (for Manual Transmission)

w/o DPF:

Connect the wire harness with the bolt

Torque:

18.6 N*m (190 kgf*cm, 14 ft.*lbf) a.

w/ DPF:

Connect the wire harness clamp and install the bolt

Torque:

18.6 N*m (190 kgf*cm, 14 ft.*lbf) b.

w/ DPF:

for Automatic Transmission:

Connect the oil cooler tube bracket with the bolt

Torque:

13.5 N*m (138 kgf*cm, 10 ft.*lbf) c.

13.INSTALL OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET (for Automatic Transmission)

w/o DPF:

Connect the wire harness with the bolt

Torque:

18.6 N*m (190 kgf*cm, 14 ft.*lbf) a.

w/ DPF:

Attach the 2 wire harness clamps and connect the wire harness

b.

for Automatic Transmission:

Connect the oil cooler tube bracket with the bolt

Torque:

13.5 N*m (138 kgf*cm, 10 ft.*lbf) c.

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

a.

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Click hereVehicle Interior>HEATING / AIR CONDITIONING>VISCOUS HEATER>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>INSTALLATION

17.INSTALL PCV HOSE (except Cold Area Specification Vehicles) 12261

Attach the clamp and install the PCV hose

a.

Slide the 2 hose clips to secure the hoses

b.

18.INSTALL PCV PIPE (for Cold Area Specification Vehicles) 12229

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

a.

Install the PCV pipe with the bolt to the compressor outlet elbow

Torque:

10 N*m (102 kgf*cm, 7 ft.*lbf) b.

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

c.

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

d.

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

a.

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

Torque:

21 N*m (214 kgf*cm, 15 ft.*lbf) b.

for Cold Specification Vehicles:

Install the water hose to the compressor inlet elbow and No 3 water by-pass pipe, and slide the 2 hose

c.

20.INSTALL VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous

21.INSTALL WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)

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

Torque:

6.0 N*m (61 kgf*cm, 53 in.*lbf) a.

Connect the 3 wire harness clamps

b.

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Click hereEngine / Hybrid System>1GD-FTV COOLING>RADIATOR>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>OIL AND OIL FILTER>REPLACEMENT

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

a.

24.INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE 17705

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

a.

Tighten the hose clamp

Torque:

4.0 N*m (41 kgf*cm, 35 in.*lbf) b.

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

c.

33.INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 25051

w/ DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/

34.ADD ENGINE OIL

35.ADD ENGINE COOLANT

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Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT

Click hereEngine / Hybrid System>1GD-FTV LUBRICATION>LUBRICATION SYSTEM>ON-VEHICLE INSPECTION

Click hereEngine / Hybrid System>1GD-FTV INTAKE / EXHAUST>EXHAUST PIPE>INSTALLATION

Click hereEngine / Hybrid System>1GD-FTV ENGINE CONTROL>ECD SYSTEM>INITIALIZATION

36.INSPECT FOR COOLANT LEAK

37.INSPECT FOR OIL LEAK

38.INSPECT ENGINE OIL LEVEL

39.INSPECT FOR EXHAUST GAS LEAK

41.PERFORM INITIALIZATION

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Pay due attention when removing and reinstalling the turbocharger sub-assembly Do not drop, strike, or

grasp easily-deformed assembly parts

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If replacing the turbocharger sub-assembly, check for deposits in the turbo oil inlet pipe sub-assembly

If necessary, replace the turbo oil inlet pipe sub-assembly

e.

*1 Oil Inlet Pipe Sub-assembly

*a Sludge

Thoroughly remove any old gasket material sticking to the lubrication oil pipe flange or turbocharger

sub-assembly oil flange

f.

If replacing the bolts or nuts, use TOYOTA genuine parts to prevent breakage or deformation

g.

If replacing the turbocharger assembly, add 20 cc (1.2 cu in.) of fresh oil into the turbocharger

sub-assembly oil inlet hole and turn the turbine wheel by hand to spread oil over the bearing

h.

*1 Turbocharger Sub-assembly Oil Inlet Hole

If overhauling or replacing the engine, cut the fuel supply after reassembly and crank the engine for 30

seconds to distribute oil throughout the engine

Then reconnect the fuel supply and allow the engine to idle for 60 seconds

i.

Since the turbine wheel runs at an extremely high speed, if the engine is running without the air cleaner,

air cleaner cap and hose, the turbine wheel will be damaged due to the entry of foreign particles

j.

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER REASSEMBLY

PROCEDURE

1.INSTALL TURBOCHARGER NOZZLE VANE CONTROL ACTUATOR

Install the turbocharger nozzle vane control actuator with the 3 bolts

Torque:

12.3 N*m (125 kgf*cm, 9 ft.*lbf) a.

2.INSTALL TURBOCHARGER VANE CONTROL ROD SUB-ASSEMBLY

Install the turbocharger vane control rod sub-assembly

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1GD-FTV INTAKE / EXHAUST EXHAUST MANIFOLD W/ TURBOCHARGER REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after

parts are removed, installed, or replaced during the turbocharger sub-assembly removal/installation are shown

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components

while the engine is hot

·

To prevent burns, do not touch the engine, exhaust pipe or other high temperature components while

the engine is hot

·

w/ DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC CONVERTER(w/

DPF)>REMOVAL

·

w/o DPF: Click hereEngine / Hybrid System>1GD-FTV EMISSION CONTROL>MONOLITHIC

·

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Click hereEngine / Hybrid System>1GD-FTV COOLING>COOLANT>REPLACEMENT

Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

Click hereEngine / Hybrid System>1GD-FTV COOLING>RADIATOR>REMOVAL

3.DRAIN ENGINE COOLANT

4.DRAIN ENGINE OIL

13.REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE 17705

Disconnect the mass air flow meter sub-assembly connector and detach the 2 harness clamps

a.

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Detach the 4 clips.

b.

Loosen the hose clamp and remove the air cleaner cap sub-assembly with air cleaner hose

c.

Remove the air cleaner element sub-assembly from the air cleaner case

a.

Disconnect the 3 wire harness clamps

a.

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE ASSEMBLY>REMOVAL

Click hereVehicle Interior>HEATING / AIR CONDITIONING>VISCOUS HEATER>REMOVAL

Remove the 3 bolts and air cleaner case sub-assembly

b.

16.REMOVE WATER HOSE SUB-ASSEMBLY (w/ Viscous Heater)

17.REMOVE VISCOUS HEATER WITH MAGNET CLUTCH ASSEMBLY (w/ Viscous

Heater)

87120G

for Cold Specification Vehicles:

Slide the 2 clips and remove the water hose from the compressor inlet elbow and No 3 water by-pass pipe

a.

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Slide the 2 clips and disconnect the 2 water hoses from the oil cooler assembly and No 2 water by-pass

pipe

b.

*A for Cold Specification Vehicles

*B except Cold Specification Vehicles

Remove the bolt and No 3 water by-pass pipe

c.

19.REMOVE PCV PIPE (for Cold Area Specification Vehicles) 12229

Slide the 2 clips and disconnect the No 20 water by-pass hose from the compressor inlet elbow and No 3water by-pass pipe

a.

Slide the clip and disconnect the No 19 water by-pass hose from the compressor inlet elbow

b.

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Click hereEngine / Hybrid System>1GD-FTV COOLING>WATER PUMP>REMOVAL

Remove the bolt and disconnect the PCV pipe from the compression outlet elbow

c.

Slide the 2 clips and remove the PCV pipe

d.

20.REMOVE PCV HOSE (except Cold Area Specification Vehicles) 12261

Slide the 2 clips

a.

Slide the 2 clips, detach the clamp and remove the PCV hose

b.

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Slide the 2 clips and disconnect the No 1 turbo water hose and No 2 turbo water hose from the water

outlet sub-assembly and water pump assembly

a.

*A for Cold Specification Vehicles

*B except Cold Specification Vehicles

23.DISCONNECT BRACKET OIL COOLER TUBE BRACKET AND WIRE HARNESS CLAMP BRACKET

(for Automatic Transmission)

Remove the bolt and disconnect the oil cooler tube bracket

a.

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Remove the 3 bolts, nut and the turbocharger stay.

a.

Slide the 2 clips and disconnect the turbo oil outlet hose from the turbo oil outlet pipe

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Remove the union bolt and gasket.

Remove the 2 nuts and the turbo oil inlet pipe sub-assembly

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Click hereEngine / Hybrid System>1GD-FTV ENGINE MECHANICAL>ENGINE UNIT>REMOVAL

Remove the 3 nuts and turbocharger sub-assembly

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Remove the 8 nuts, 8 plate washers, 8 collars and exhaust manifold.

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Slide the 2 hose clips and disconnect the No 1 turbo water hose and No 2 turbo water hose from the turbowater pipe sub-assembly.

Tiêu đề	Hilux 2015 2018 Manual 1gd Ftv Intake Exhaust He Thong Nap Xa Khi
Thể loại	manual
Năm xuất bản	2017

Định dạng
Số trang	114
Dung lượng	4,61 MB
File đính kèm	Hilux 2015-2018 Manual_He thong nap xa khi.zip (4 MB)