Current alarm: 600°C
Safe limits:
• Sustained: ≤ 550°C
• Short bursts: ≤ 650°C
If sensor is post-turbo, add ~150°C to estimate pre-turbo temp
Aluminum pistons melt at 650°C — monitor closely under load
Critical System Status
✓ EGT Gauge: Madman pyrometer
✓ Safe limits: ≤550°C sustained | ≤650°C bursts
⚠️ Boost monitoring: Need to verify if Madman gauge can measure boost
⚠️ Boost levels & wastegate function: Require verification
✓ Intercooler: Installed Jul 2012
✓ Radiator: Replaced Nov 2024 @ 264,347km (standard, not heavy duty)
✓ Radiator cap: Replaced Apr 2025 @ 273,023km
✓ Coolant: Jan 2026 (2,051km ago)
✓ Intercooler: Jul 2012 @ 50,637km
245,363km since install — monitor for leaks
❌ Water pump: NO RECORD
❌ Thermostat: NO RECORD
❌ Viscous fan: NO RECORD
✓ SAC turbo install: 2011
✓ Turbo recon: Aug 2023 @ 224,406km
✓ Km since recon: 71,594km
✓ Turbo drain hose: Mar 2025
✓ Turbo pipe: Nov 2024
⚠️ Intercooler boots: Check for oil
⚠️ Boost leaks: Listen for hissing
✓ Last change: Jan 2026 @ 293,949km
✓ Km since: 2,051km
✓ Turbo oil feed/return lines: Recent service
Turbo requirements:
• 5,000km MAX interval (strict)
• Diesel-rated oil (15W-40)
• NEVER exceed 10,000km
Turbo-Specific Systems
MONITORING SYSTEM
✓ EGT gauge installed (Madman)
✓ EGT monitored (≤550°C sustained)
⚠️ Boost gauge: VERIFY if installed
⚠️ Boost ≤10 psi: REQUIRES VERIFICATION
INJECTION SYSTEM
✓ Pump serviced: Mar 2025 @ 272,185km
✓ Dyno verified: 118kW, 373Nm
✓ Injectors: Mar 2025 (reman Toyota)
⚠️ Smoke check: Monitor exhaust
INTERCOOLER SYSTEM
✓ Intercooler installed: Jul 2012
⚠️ Boost leaks: Listen for hissing
⚠️ Intercooler clean: Check fins
⚠️ Boot condition: Check for oil
COOLING SYSTEM
✓ Radiator: Nov 2024 (standard)
✓ Coolant: Jan 2026 (fresh)
❌ Water pump: NO RECORD
❌ Viscous fan: NO RECORD
⚠️ No overheating events
ENGINE PROTECTION
✓ Oil changes: 5,000km (strict)
✓ Last oil: Jan 2026 @ 293,949km
✓ Turbo oil lines: Inspected
✓ Feed/drain hoses: Mar 2025
❌ Valve clearances: NO RECORD
CYLINDER HEAD & GASKET
❌ Head studs: NO RECORD
✓ No coolant pressurization
✓ No coolant loss reported
⚠️ Monitor for white smoke
TURBO UNIT HEALTH
✓ Last recon: Aug 2023 (71,594km ago)
⚠️ Shaft play: Inspect periodically
Movement of the shaft connecting the compressor wheel (intake) and turbine wheel (exhaust) within the bearing housing
✓ No oil leaks reported
✓ No abnormal noise
DRIVELINE
✓ Clutch installed: Jan 2026
✓ Clutch holding torque: Good
✓ Gearbox rebuilt: Feb 2025
✓ No driveline issues
DRIVING PRACTICE
⚠️ Warm-up before boost (oil temp >60°C)
⚠️ Idle 30-60 seconds before shutdown
⚠️ Cool-down after hard driving
⚠️ Never lug the engine at low RPM
Injection Pump Tuning History (Dyno Verified):
May 2010 @ 10,384km: 96kW, 285Nm (stock) → Mar 2023 @ 220,615km: 112kW, 363Nm → Feb 2024 @ 249,468km: 121kW, 371Nm → Mar 2025 @ 272,185km: 118kW, 373Nm (current calibration)
❌ Head studs: NO RECORD — Monitor closely for issues
✓ No known coolant loss | ✓ No pressurization issues reported
Watch for: White smoke • Coolant loss (no external leaks) • Oil in coolant • Combustion gas in cooling system
✓ Last recon: Aug 2023 (71,594km ago)
✓ No abnormal turbo noise reported
✓ No oil consumption increase
Inspect periodically:
• Shaft play (in/out & side-to-side)
• Oil leaks from turbo housing
• Whining or grinding noises
• Excessive blue smoke (oil burning)
Required habits:
⚠️ Warm-up before boost (oil temp >60°C)
⚠️ Idle 30-60 seconds before shutdown
⚠️ Allow turbo to cool after hard driving
Why critical:
• Cold oil → turbo bearing damage
• Immediate shutdown → oil coking
• Cooked oil → turbo failure
Lifecycle Tracking
❌ NO RECORD — Recommended every 40,000-50,000km
Current: 305,000km | Missed: 6-7 services | ACTION: Schedule immediately
Symptoms: Valve ticking • Hard starting • Power loss • Poor economy • Burnt valves
✓ Last: Apr 2025 @ 273,023km
✓ Km since: ~32,000km
✓ Tensioner & idlers replaced
❌ Water pump: Should replace WITH belt
Interval: 100,000km or 5 years (whichever first)
✓ Injectors: Mar 2025 reman Toyota (23,815km)
✓ Injection pump: Mar 2025 DupDiesel (23,815km)
Calibrated & timed — Dyno: 118kw / 373Nm
✓ Compression test: Mar 2025 — Passed
✓ Glow plugs: Tested Mar 2025 — Passed
✓ Filter kit: Jan 2026 (2,051km)
Includes all filters: fuel, air, oil
✓ Filter kit (air, fuel, oil): Jan 2026 @ 293,949km
2,051km ago (20,000km interval)
✓ Air filter: Part of filter kit (Jan 2026)
✓ Fuel filter: Part of filter kit (Jan 2026)
✓ Oil filter: Part of filter kit (every 5,000km)
Recommended intervals:
Air filter: 15,000–30,000km (shorten in dusty conditions)
Fuel filter: 20,000–30,000km
Oil filter: 5,000km (strict with turbo)
Set 1 (BFG KO2): 100,000-179,000km = 79,000km
Set 2: Single tyre @ 179,000km
Set 3 (BFG KO2): 215,000-263,000km = 48,000km
Set 4 (Maxxis AT811): Nov 2024, 33,000km on set
Expected replacement: ~311,000km
Clutch 1 (OEM): 0-212,330km = 212,330km ✓
❌ Clutch 2: 12,076km ONLY
⚠️ Clutch 3 (HD): 26,488km
✓ Clutch 4 (4WD HD): Feb 2026 — NEW
Heavy duty 4WD spec should handle turbo torque better
Feb 2025 Complete Rebuild @ 271,200km (24,800km ago):
✓ Gearbox: Fully rebuilt with upgraded 5th gear, mainshaft, input shaft
✓ Transfer case: Input gear & bearing seal kit
✓ Front diff: Rebuilt with solid spacer bearing kit, new CV joints
✓ Rear diff: Rebuilt with solid spacer bearing kit, rechromed driveshaft
✓ U-joints: All replaced (GUT 20 & GUT 21)
✓ Wheel bearings: Front & rear replaced
GEARBOX + TRANSFER CASE
Interval: Oil change 40,000–60,000km
✓ Gearbox oil: Feb 2025 (24,800km ago)
✓ Transfer case oil: Feb 2025 (24,800km ago)
⚠️ Check especially if towing/off-road
DIFFERENTIALS (FRONT + REAR)
Interval: Oil change 40,000km
✓ Front diff oil: Jan 2026 @ 293,949km (2,051km ago)
✓ Rear diff oil: Apr 2025 @ 273,023km (22,977km ago)
⚠️ After water crossings → immediate check
⚠️ Water contamination history?
PROPSHAFT & UNIVERSAL JOINTS
Critical: Grease every 5,000–10,000km
✓ Propshaft greasing: Jan 2026 (2,051km ago)
✓ U-joints replaced: Feb 2025 (24,800km ago)
Toyota note: Must be greased frequently, especially off-road
✓ Regular greasing recorded
Critical Inspections & Red Flags
Daily/Weekly:
□ Viscous fan (should NOT spin freely when hot)
□ Boost leaks (listen for hissing)
□ Oil leaks (turbo, rocker cover, rear main seal)
□ Coolant level
□ EGT readings under load
Every 10,000km:
□ Blow-by check (oil filler cap @ idle)
□ Turbo shaft play
□ Intercooler boots (oil sweating)
□ Air intake (smoke test)
STOP IMMEDIATELY if you observe:
❌ Rising EGT under same load • ❌ Sudden coolant loss • ❌ White smoke (head gasket) • ❌ Excessive black smoke • ❌ Loss of power + high temps • ❌ Metallic engine noises
SUSPENSION:
✓ Rear leaf springs: OME CS058R (Jan 2026 @ 294,500km)
✓ Rear shocks: OME Nitrocharger Plus 63111 (Jan 2026 @ 294,500km)
✓ Spring bushes: Greasable shackles (Jan 2026 @ 294,500km)
✓ Wheel alignment: Jan 2026 @ 294,500km
⚠️ Ball joints: Inspection needed
⚠️ Bushings: Inspection needed
STEERING:
Interval: Lubrication every 5,000km
✓ Steering linkage lube: Jan 2026 (2,051km ago)
⚠️ Check for play in steering?
⚠️ Uneven tyre wear?
BRAKING SYSTEM:
Maintenance:
• Brake pads/shoes: inspect frequently
• Brake fluid: replace every 2 years
✓ Brake fluid: Jan 2026 (Jan 2028 due)
✓ Rear brake shoes: Jan 2026
✓ Rear brake drums: Jan 2026
⚠️ Severe use: More frequent inspections required
WHEEL BEARINGS:
Interval: Repack every 20,000km
✓ Wheel bearings replaced: Feb 2025 @ 271,200km
⚠️ Last repack: Oct-Nov 2023 (~245,000km) — 51,000km overdue
Recommended intervals: Steering linkage lube 5,000km | Wheel bearings repack 20,000km | Shock inspection 20,000km
| System | Interval | Last Service | Status |
|---|---|---|---|
| Air Filter | 15,000-30,000km | Jan 2026 @ 293,949km (part of filter kit) | ✓ Recent (2,051km ago) |
| Ball Joints | Inspect regularly | Verify records | ⚠️ Inspection needed |
| Belts (Fan Belt Kit) | 40,000-80,000km preventative | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Brake Fluid | 24 months | Jan 2026 @ 293,949km | ✓ Recent (Jan 2028 due) |
| Brake Pads/Shoes | Inspect frequently (severe use) | Jan 2026 @ 293,949km (rear shoes) | ✓ Recent |
| Bushings (Suspension) | Inspect regularly | Verify records | ⚠️ Inspection needed |
| Coolant | 100,000km / 2 years | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Diesel Oil (Engine Oil) | ≤10,000km MAX (5,000km turbo) | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Differential Oils (Front & Rear) | 40,000km or after water crossings | Jan 2026 @ 293,949km (front) / Apr 2025 @ 273,023km (rear) | ✓ Recent |
| Engine Oil Filter | Every oil change (5,000km) | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Engine Seals | Monitor for leaks | Various seal replacements | ⚠️ Ongoing monitoring |
| Fuel Filter | 20,000-30,000km | Jan 2026 @ 293,949km (part of filter kit) | ✓ Recent (2,051km ago) |
| Gearbox Oil (GL-4) | 40,000-60,000km | Feb 2025 @ 271,200km (rebuilt) | ✓ Good (24,800km ago) |
| Glow Plugs | As needed (~150,000km) | Tested Mar 2025 | ✓ Tested OK |
| Head Studs (Turbo) | Recommended with turbo | NO RECORD | ❌ CRITICAL |
| Hoses (Radiator/Cooling) | Inspect or replace as needed | Radiator Nov 2024 (new) | ✓ Recent with radiator |
| Injection Pump | 300,000km or high km service | Mar 2025 @ 272,185km (serviced & calibrated) | ✓ Recent (23,815km ago) |
| Injectors | 120,000km or when checked | Mar 2025 @ 272,185km (reman Toyota) | ✓ Recent (23,815km ago) |
| Propshaft Greasing | 5,000-10,000km (critical off-road) | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Shock Absorbers | Inspect every 20,000km | Jan 2026 @ 294,500km (rear OME replaced) | ✓ New rear (1,500km ago) |
| Steering Linkage Lubrication | 5,000km | Jan 2026 @ 293,949km | ✓ Recent (2,051km ago) |
| Thermostat | As needed / 100,000km | NO RECORD | ❌ CRITICAL |
| Timing Belt (Cambelt) | 100,000km or 5 years | Apr 2025 @ 273,023km | ✓ Good (22,977km ago) |
| Transfer Case Oil | 40,000-60,000km | Feb 2025 @ 271,200km (rebuilt) | ✓ Good (24,800km ago) |
| Universal Joints (U-Joints) | Grease every 5,000-10,000km | Feb 2025 @ 271,200km (all replaced) + greased Jan 2026 | ✓ Rebuilt & greased |
| Valve Clearances (Tappets) | 40,000-50,000km | NO RECORD | ❌ CRITICAL |
| Viscous Fan Clutch | Daily inspection | NO RECORD | ❌ CRITICAL |
| Water Pump | With timing belt (100,000km) | NO RECORD | ❌ CRITICAL |
| Wheel Bearings | 20,000km (repack) | Feb 2025 @ 271,200km (replaced) but Oct-Nov 2023 last repack (~245,000km) | ⚠️ 51,000km since last repack |
| Date | Km | Service | Work | Dealer | Cost | Notes |
|---|