Toyota Material Handling, U.S.A., Inc. 5559 Inwood Drive (47201) P.O. Box 3009 Columbus, IN 47202-3009 Date: September 4, 2015 To: From: Subject: General Manager/Service Manager/Warranty Administrator Gene Babinec III Warranty Administration Manager 2015FL-005 Attachment #2 1KD Diesel Turbo Replacement Campaign Repair Instructions Work Outline Toyota requests the replacement of the 1KD Diesel Turbo sub-assembly on select 2014/2015 Toyota forklift models 8FD35U-80U. Parts required: There is a kit available from TIEM service parts. Model 8FD35U-80U o Require kit: 90911-U9016-71 (contains all parts required to complete Turbo Sub-assembly replacement) Parts return: The removed parts are not required for warranty parts return. Please destroy parts and recycle accordingly. Page 1 of 8
1. Work outline Replacement procedure for Turbo Charger Sub-assembly Replace the Turbo Charger S/A with new one Fig. 1 Engine room Fig. 2 Turbo Charger S/A 2. Parts to use - All parts included in Turbo Campaign Kit Part number: 90911-U9016-71, do not order individually. No Fig. Qty/ Part name Part number No. unit Remark 1 A TURBO CHARGER SUB-ASSY 17201-UL010 1-2 B BOLT, STUD 80126-76009-71 2 For Inlet elbow pipe 3 C GASKET 17276-UL010 1 For Inlet elbow pipe 4 D GASKET 16347-76001-71 1 For Water pipe 5 E GASKET, OIL INLET 15471-76001-71 1 For Oil pipe 6 F BOLT, STUD 80116-76155-71 1 For Turbo Stay 7 G NUT 80179-76067-71 1 For Turbo Stay 8 H GASKET TURBO TO EXHAUST 17278-76001-71 1 For Turbo - Exhaust Manifold 9 I NUT 80179-76077-71 3 For Turbo - Exhaust Manifold 10 J GASKET, EXHAUST MANIFOLD, For Exhaust Manifold 17173-76019-71 NO.1 1 11 K NUT, LOCK 84184-76003-71 8 For Exhaust Manifold 12 L GASKET, OIL OUTLET 15472-76001-71 1 For Oil pipe 13 M GASKET 80904-76001-71 1 For Oil pipe 14 N GASKET 17279-UL010 1 For Converter 15 O NUT 80179-76081-71 3 For Converter 16 P GASKET, EXHAUST PIPE 90584-50001-71 1 For Converter - Exhaust pipe 17 Q NUT 84188-76002-71 3 For Converter - Exhaust pipe Please check whether the boxes include parts for 1KD by checking label Please check that "1KD" is written in the label Fig. 3 Label for identification 3. Work procedure and points Work safely according to "OPERATIONAL TIPS" in the repair manual for 8FG35U-80U series (. * CE104). * Long Life Coolant and oil remaining in the engine can be flushed during procedure. Page 2 of 8
Removal procedure of related parts from truck: (Fig. 4) 1) Park the truck on a level ground. 2) Set the parking brake. 3) Remove the key and keep it aside. 4) Open the engine hood and disconnect the battery negative terminal, remove the batteries and tray. 5) Remove the floor mat and the rear toe board. 6) Remove the radiator cover 7) Remove the relay block and injector driver 8) Drain coolant Fig. 4 Relay block and Injector driver Removal procedure of Turbo charger S/A from engine 9) Remove "1: Converter separator insulator No.1" 10) Remove "2: Intercooler hose No.1" and "3: Pipe" (Fig. 5) 11) Remove LH engine harness from the clamp and disconnect the connectors from sensor motor. (Fig. 6) Fig. 5 "2: Inter cooler hose No.1" Fig. 6 LH engine harness 12) Loosen the clamp on "4. Air hose", "5: Air hose No.2" and "6: Ventilation hose". (Fig. 7) 13) Remove bolts between "7: Intake pipe Assy" and "8: Manifold stay No.2". 14) Remove "5: Air hose No.2", "6: Ventilation hose" and "7: Intake pipe Assy". (Fig. 8) - Clamp to be unfixed - Bolt to be removed 7: Intake pipe Assy Fig. 7 "4: Air hose" Fig. 8 After removal of "7: Intake pipe Assy" and related parts Page 3 of 8
15) Remove "8: Manifold stay No.2". (Fig. 8) 16) Remove "9: Exhaust manifold heat insulator No.2" and "10: Turbo insulator". 17) Remove "11: Monolithic converter ASSY". 18) Remove rear clamps of turbo water hose and plug/cap as shown to minimize coolant loss. "12: Turbo water hose No.1" (Quantity 2) (Fig. 9) 19) Remove front bolt for "13: Turbo oil inlet pipe S/A" (13-A: Bolt) (Fig. 10) 12: Turbo water hose No.1 Fig. 9 "12: Turbo water hose No.1" Fig. 10 "13: Turbo oil inlet pipe S/A" 20) From beneath the truck, remove lower bolts for "13: Turbo oil inlet pipe S/A" (13-B: Bolt) (Quantity 2) and "14: Turbo charger stay". (Quantity 2) (Fig. 11) 21) Remove nuts connecting "15: Exhaust manifold "with "16: Turbo charger S/A", (Quantity 8) and remove "15. Exhaust manifold" with "16: Turbo Charger S/A" as shown. You may have to remove rear 4 manifold studs to clear weldment on some frames. (Fig. 12, 13) Fig. 11 "13: Turbo oil inlet pipe S/A" and "14: Turbo charger stay" Fig. 12 "15: Exhaust manifold" and "16: Turbo charger S/A" Fig. 13 "16: Turbo charger S/A" with manifold as shown Page 4 of 8
22) Remove "15.Exhaust manifold", "17: Compressor inlet elbow", "13: Turbo oil inlet pipe S/A", "18: Turbo water pipe S/A", and "14: Turbo charger stay" from "16: Turbo charger S/A " Installation procedure of turbo charger S/A components from Kit Part Number: 90911-U9016-71 23) Install new Stud bolts (B: 80126-76009-71) at (T=5-8ft. lbs) and new Gasket (C: 17276-UL010). 24) Install "17: Compressor inlet elbow" on new "16: Turbo charger S/A (A: 17201-UL010)" (T=10-18ft. lbs). 25) Install new Gasket (D: 16347-76001-71) and "18: Turbo water pipe S/A" (T=6-11 ft. lbs) on new "16: Turbo charger S/A (A: 17201-UL010)". 26) Install new Oil inlet gasket (E: 15471-76001-71) in accordance with Fig. 15. 27) Install "13: Turbo oil inlet pipe" on new "16: Turbo charger S/A (A: 17201-UL010)" by hand starting "13-B: Bolt" (Quantity 2). Install this side into "16: Turbo charger S/A" Fig. 14 Stud bolt (B: 80126-76009-71) installing direction Fig. 15 Oil inlet gasket (E: 15471-76001-71) installing direction 28) Install new Stud bolt (F: 80116-76155-71) (T=10-18ft. lbs) on the new "16: Turbo charger S/A (A: 17201-UL010)". (Fig. 16) 29) Add new nut (G: 80179-76067-71) to (F: Stud bolt) that will attach "14: Turbo charger stay" to the "16: Turbo charger S/A (A: 17201-UL010)" hand starting. 30) Install new "Gasket Turbo to Exhaust (H: 17278-76001-71)" on "16: Turbo charger S/A" 31) Install "16: Turbo charger S/A" on "15: Exhaust manifold" by hand starting new Nuts (I: 80179-76077-71). Install water pipe to turbo housing. 32) Install "16: Turbo charger S/A" on Engine Assy with "EXHAUST MANIFOLD, NO.1 Gasket (J: 17173-76019-71) by hand starting Lock Nut (K: 84184-76003-71). Note: Be careful not to damage the assembly during installation. 33) Tighten "15. Exhaust manifold" fully in accordance with the order in Fig. 17. (T=23-35ft. lbs) Fig. 16 Stud bolt (F: 80126-76009-71) installing direction Fig. 17 "15. Manifold Exhaust" tightening order Page 5 of 8
34) From the beneath of the truck, install "14: Turbo charger stay" by hand starting lower bolts. (Fig. 18) 35) From the beneath of the truck, install new Oil outlet gasket (L: 15472-76001-71), (Fig.18, 19) and "13: Turbo oil inlet pipe S/A" by tightening the lower bolts (13-B: Bolt) by hand starting. Fig. 18 "13: Turbo oil inlet pipe S/A" and "14: Turbo charger stay" Fig. 19 Oil outlet gasket (L: 15472-76001-71) installing direction 36) Install new Gasket (M: 80904-76001-71), and hand start the front bolt for 13: Turbo oil inlet pipe S/A (13-A: Bolt). (Fig. 20) 37) Tighten the bolts which connect "15: Exhaust manifold"&"16: Turbo charger S/A" fully. (T=30-46 ft. lbs.) 38) Tighten the front bolt for "13: Turbo oil inlet pipe S/A" (13-A: Bolt) fully. (T=21-31 ft. lbs.) 39) From the beneath of truck, tighten the nut connecting "13: Turbo oil inlet pipe S/A with "16: Turbo charger S/A" fully. (T=8-11 ft. lbs.) (Fig. 21) 40) From the beneath of the truck, tighten the lower bolts for 13: Turbo oil inlet pipe S/A (13-B: Bolt) fully. (T=7-10 ft. lbs.) (Fig. 22) Fig. 20 Front bolt for "13: Turbo oil inlet pipe S/A" (13-A) Fig. 21 "13: Turbo oil inlet pipe S/A" Fig. 22 "13: Turbo oil inlet pipe S/A" Page 6 of 8
41) From the beneath of the truck, tighten bolts for "14: Turbo charger stay" fully.(t=23-33ft. lbs)(fig. 23) 42) Install "12: Turbo water hose No.1" and the clamp in accordance with Fig. 24. (Quantity 2) (Fig. 24) Fig. 23 "14: Turbo charger stay" Fig. 24 "12: Turbo water hose No.1" 43) Install the new Gasket (N: 17279-UL010) on the new "16: Turbo charger S/A". 44) Install "11: Monolithic converter ASSY" by hand starting upper bolts. (Fig. 25) 45) Install "11: Monolithic converter Assy" on "16: Turbo charger S/A" by the new Nuts (O: 80179-76081-71). (T=23-34 ft. lbs.) 46) Tighten upper bolts for "11: Monolithic converter Assy" fully. (T=11-20 ft. lbs.) Install cat heat shield. 47) Install the new Exhaust pipe gasket (P: 90584-50001-71) and connect "11: Monolithic converter Assy" with "Exhaust pipe" by new nuts (Q: 84188-76002-71) (T=23-34 ft. lbs.) 48) Install "10: Turbo insulator" (T=11-20 ft. lbs.) 49) Install LH engine harness into the clamp, and connect connector. (Fig.26) 50) Install "9: Exhaust manifold heat insulator No.2". (T=19-28 ft. lbs.) 51) Install "8: Manifold stay No.2". (T=19-28 ft. lbs.) 52) Install "5: Air hose NO.2", "6: Ventilation hose", and "7: Intake pipe Assy". (Fig.27) Fig. 25 11: Monolithic converter ASSY Fig. 26 LH engine harness Fig. 27 "7: Intake pipe ASSY" and related parts Page 7 of 8
53) Install clamp for "6: Ventilation hose (Fig. 28) 54) Tighten the clamp for "8: Air hose No.2" (T= 1-4 ft. lbs.) (Fig. 29) Fig. 28 "6: Ventilation hose" Fig. 29 "5: Air hose No.2" 55) Tighten the clamp between "7: Intake pipe Assy" and "4: Air hose". (Fig.30) 56) Install "2: Intercooler hose No.1" and "3: Pipe". (Fig.31) 57) Install "1: Converter separator insulator No.1". 58) Fill coolant, and check engine oil level. 59) Install the relay block and the injector driver. 60) Install the floor mat and the rear toe board. 61) Install the battery and the battery tray. 62) Install the radiator cover 63) After completing all the repair work, make sure that the truck functions normally, check engine oil and coolant levels. Page 8 of 8