CYLINDER HEAD GASKET INSTALLATION

INSTALL CYLINDER HEAD GASKET
1. Install a new cylinder head gasket.
  
  Note
  
  Always use a new cylinder head gasket after cleaning the surface of the cylinder head, cylinder block and head gasket and keeping them free of dirt, water and grease.
INSPECT CYLINDER HEAD SET BOLT
1. Measure the length of the M12 head bolts (No. 1 to No. 18).
  
  Maximum length
  
  129 mm (5.07 in.)
  
  If the length is greater than the maximum, replace the bolts.
INSTALL CYLINDER HEAD SUB-ASSEMBLY
1. Install the cylinder head over the dowels on the cylinder block.
  
  Tech Tips
  
  Since the cylinder head bolts are unique to this engine, do not substitute them with ordinary bolts.
2. Uniformly install and tighten the cylinder head bolts (1 to 18) in the order shown in the illustration.
  
  Torque:
  
  60 N*m { 610 kgf*cm, 44 ft.*lbf }
3. Mark the front side of each cylinder head bolt with paint as shown in the illustration.
4. Retighten the cylinder head bolts by 90° in the same order as step (b).
5. Perform step (d) again.
6. Check that each painted mark is now at a 180° angle to the front.
7. Uniformly install and tighten the cylinder head bolts (1 to 4) in the order shown in the illustration.
  
  Torque:
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
INSTALL VALVE BRIDGE

Note

Be sure to install the removed valve bridge to its original position.
INSTALL VALVE PUSH ROD

Note

Be sure to install the removed push rods to their original positions.
INSTALL NO. 1 VALVE ROCKER SHAFT SUB-ASSEMBLY
1. Install the rocker shaft to the cylinder head.
2. Apply engine oil to the rocker arm and push rod.
3. Install the bolts in the order shown in the illustration.
  
  Torque:
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
  
  Note
  
  Make sure that the push rods do not interfere with the adjusting screws.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surface.
  
  Install the water by-pass pipe sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
2. Install the water by-pass pipe sub-assembly with the clamp and the 6 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL WATER PIPE SUB-ASSEMBLY
1. Install the water pipe sub-assembly with a new O-ring and the 3 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL TURBOCHARGER SUB-ASSEMBLY

Tech Tips

Click here
INSTALL RADIATOR PIPE
1. Install the radiator pipe with a new O-ring and the 2 bolts.
  
  Torque:
  
  18 N*m { 180 kgf*cm, 13 ft.*lbf }
INSTALL GENERATOR BRACKET SUB-ASSEMBLY
1. Install the generator bracket with the 3 bolts.
  
  Torque:
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
INSTALL GENERATOR BELT ADJUSTING BAR
1. Install the generator belt adjusting bar with the 2 bolts.
  
  Torque:
  
  125 N*m { 1275 kgf*cm, 92 ft.*lbf }
INSTALL INJECTOR ASSEMBLY
Note

Register the injector compensation code of a new fuel injector in the ECM when replacing the fuel injector. Register the injector compensation code in advance so that it can be installed in the correct position Click here.
1. Attach tags to identify the cylinder (#1 to #4) to the new injector assemblies so that each injector assembly can be inserted into the correct cylinder during installation.
2. Apply a small amount of clean engine oil to 4 new O-rings.
3. Install the O-ring to each injector as shown in the illustration.
4. Install a new No. 2 cylinder head cover gasket to each injector.
5. Referring to each cylinder number identification tag attached to the fuel injector assemblies, insert the fuel injector assembly, nozzle holder clamp, and nozzle holder clamp bolt for each cylinder.
  Note
  - Check that the tip of the fuel injector has no foreign matter attached.
  - When reusing the fuel injectors, reinstall them to the same cylinder they were removed from. Otherwise, it could cause the engine to malfunction.
  - Carefully insert the fuel injector so that the O-ring is not caught between the cylinder head and the injector.
6. Temporarily install the 4 nozzle holder clamps with the 4 clamp bolts.
  
  Note
  
  Be sure to install the holder clamps and bolts in their original positions.
7. Install 4 new holder seals.
  
  Note
  
  Securely insert the tip of each holder seal into each fuel injector.
8. Temporarily install the nozzle leakage pipe assembly through 5 new gaskets by hand with the union bolt and the 5 hollow screws.
  
  Note
  
  Make sure that the hollow screws and nozzle leakage pipe assembly are not deformed or damaged.
9. Temporarily tighten the union nuts of new injection pipes No. 1, No. 2, No. 3 and No. 4 by hand.
  
  Note
  
  If an injector has been replaced, the corresponding injection pipe must also be replaced.
10. Tighten the 4 nozzle holder clamp bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  After tightening the nozzle holder clamp bolts, check that the fuel injector and the nozzle holder clamp do not interfere with the valve spring.
11. Tighten the 5 hollow screws.
  
  Torque:
  
  12 N*m { 125 kgf*cm, 9 ft.*lbf }
  
  Note
  
  Do not reuse the nozzle leakage pipe assembly that has been tightened to more than the specified torque.
12. Using a union nut wrench (17 mm), tighten the 8 union nuts.
  
  Torque:
  
  35 N*m { 360 kgf*cm, 26 ft.*lbf }
  
  Note
  
  Refer to the torque above when not using SST. When using SST, calculate the torque in accordance with the lengths of SST and the torque wrench Click here.
INSTALL OIL LEVEL GAUGE GUIDE
1. Install the oil level gauge guide with a new O-ring.
INSTALL INJECTION PIPE CLAMP
1. Install a new O-ring to the oil level gauge guide.
  
  Note
  
  Apply a small amount of clean engine oil to the new O-ring.
2. Temporarily install the 2 pipe clamps and oil level gauge guide to the intake manifold.
3. Install the 2 injection pipe clamps with the 2 nuts. Tighten the 2 nuts until the clamp edges make contact with the engine side clamp edges.
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
1. Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surface.
  
  Install the water by-pass pipe sub-assembly within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
2. Install the water by-pass pipe sub-assembly with the clamp and the 6 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL EGR VALVE BRACKET
1. Install the EGR valve bracket with the 4 bolts.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
CONNECT WIRE HARNESS AND CONNECTORS
1. Connect the 3 connectors and 3 connector clamps and then install the bolt.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL VENTURI ASSEMBLY
1. Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.
  
  Seal packing
  
  Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
  Note
  
  Remove any oil from the contact surface.
  
  Install the intake pipe with the EGR valve within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.
2. Install the venturi assembly with the 4 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL DIESEL THROTTLE BODY
1. Remove any seal packing material from the contact surface.
2. Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.06 to 0.10 in. )) as shown in the illustration.
  Tech Tips
  
  Remove any oil from the contact surface.
  
  Install the diesel throttle body assembly within 3 minutes of applying the seal packing.
  
  Do not run the engine for at least 2 hours after installing.
3. Install the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
4. Connect the 2 diesel throttle body connectors.
INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install a new cylinder head cover gasket onto the No. 2 cylinder head cover.
2. Install the No. 2 cylinder head cover sub-assembly with the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
3. Install the cylinder head cover cushion rubber.
4. Connect the ventilation hose.
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
1. Install the cylinder head cover sub-assembly with a new gasket and the 2 bolts.
  
  Torque:
  
  29 N*m { 290 kgf*cm, 21 ft.*lbf }
INSTALL OIL FILLER CAP SUB-ASSEMBLY
1. Install the oil filler cap sub-assembly.
INSTALL EGR COOLER SUB-ASSEMBLY
1. Install the EGR cooler with a new gasket and the 2 bolts.
  
  Torque:
  
  Flange
  
  55 N*m { 560 kgf*cm, 41 ft.*lbf }
  
  Engine
  
  69 N*m { 700 kgf*cm, 51 ft.*lbf }
2. Connect the water by-pass hose.
INSTALL WIRE HARNESS
1. Install the wire harness.
CONNECT FUEL HOSE
1. Connect the 2 fuel hoses.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
1. Install a new gasket and front exhaust pipe assembly, and temporarily tighten 3 new nuts.
2. Temporarily tighten the bolt.
3. Tighten the 3 nuts.
  
  Torque:
  
  70 N*m { 714 kgf*cm, 52 ft.*lbf }
4. Tighten the bolt.
  
  Torque:
  
  25 N*m { 250 kgf*cm, 18 ft.*lbf }
INSTALL EXHAUST RETARDER ASSEMBLY
1. Install 2 new gaskets and exhaust retarder assembly with the 4 bolts.
  
  Torque:
  
  30 N*m { 306 kgf*cm, 22 ft.*lbf }
2. Connect the vacuum hose.
INSTALL GENERATOR ASSEMBLY
1. Temporarily install the generator assembly with bolt A.
2. Temporarily install the generator bracket to the generator assembly with bolt B.
3. Install the generator bracket with 2 bolts C.
  
  Torque:
  
  125 N*m { 1275 kgf*cm, 92 ft.*lbf }
4. Connect the 3 wire harness clamps.
5. Connect the connector to the generator.
6. Install the wire harness to terminal B with the nut, and install the terminal cap.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL RADIATOR ASSEMBLY
1. Install the radiator assembly with the fan shroud.
INSTALL NO. 3 RADIATOR BRACKET
1. Install the No. 3 radiator bracket with the 3 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL NO. 4 RADIATOR BRACKET
1. Install the No. 4 radiator bracket with the 3 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
INSTALL HEATER HOSE
1. Install the heater hose with the 5 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
CONNECT RADIATOR HOSE OUTLET
1. Install the radiator hose outlet.
CONNECT RADIATOR HOSE INLET
1. Install the radiator hose inlet.
INSTALL FAN PULLEY
1. Install the fan pulley.
INSTALL FAN
1. Temporarily install the fan with the 4 nuts.
2. Install the fan and generator V belt Click here.
3. Holding the V belt, tighten the 4 nuts completely to install the fan pulley and fan properly.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }

Maximum length
129 mm (5.07 in.)

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

Seal packing
Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

INSPECT DRIVE BELT

Check the fan and generator V belt deflection.

Tech Tips

The specified deflection values per belt are shown in the following table.

Deflection

Item	Specified Condition
New belt	10.5 to 12.5 mm (0.41 to 0.49 in.)
Used belt	12.5 to 16.0 mm (0.49 to 0.63 in.)

Note

Check the V belt deflection at the specified point.
When inspecting a belt which has been used for over 5 minutes, apply the used belt specifications.

INSTALL INTERCOOLER ASSEMBLY
1. Install the intercooler assembly with the 4 bolts.
  
  Torque:
  
  7.5 N*m { 77 kgf*cm, 66 in.*lbf }
INSTALL NO. 2 AIR HOSE
INSTALL NO. 1 INTAKE AIR PIPE WITH NO. 4 AIR HOSE
1. Connect the No. 1 intake air pipe with No. 4 air hose with a new hose band.
2. Connect the intake air temperature sensor connector.
3. Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
4. Install the bolt.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
5. Install the No. 1 intake air pipe with No. 4 air hose with a new hose band.
INSTALL NO. 3 CAB MOUNTING BRACKET SUB-ASSEMBLY
1. Install the No. 3 cab mounting bracket with the 8 bolts.
  
  Torque:
  
  120 N*m { 1224 kgf*cm, 89 ft.*lbf }
2. Install the No. 1 air hose assembly with the 2 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
3. Install the air cleaner case with the 4 bolts.
  
  Torque:
  
  18 N*m { 184 kgf*cm, 13 ft.*lbf }
4. Connect the connector. (w/ Cab tilt warning)
INSTALL NO. 2 INTAKE PIPE
1. Install the No. 2 intake pipe with the 3 bolts and 2 bands.
  
  Torque:
  
  29 N*m { 291 kgf*cm, 21 ft.*lbf }
INSTALL INJECTOR DRIVER ASSEMBLY
1. Install the injector driver assembly with the 2 bolts.
  
  Torque:
  
  20 N*m { 200 kgf*cm, 14 ft.*lbf }
2. Connect the wire harness clamp and connector to the injector driver assembly.
3. Connect the 2 injector driver connectors.
INSTALL VACUUM RESERVOIR SUB-ASSEMBLY
INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH
INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH
INSTALL RADIATOR RESERVE TANK ASSEMBLY
1. Install the radiator reserve tank assembly with the bolt and 3 nuts.
  
  Torque:
  
  12 N*m { 120 kgf*cm, 10 ft.*lbf }
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH
INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH
INSPECT FOR EXHAUST GAS LEAK
INSTALL NEGATIVE BATTERY TERMINAL

ADD ENGINE OIL

Add fresh oil and install the oil filler cap sub-assembly.

Engine oil

Oil Grade	Oil Viscosity (SAE)
API CD, CE, CF, CH-4, or CI-4 (May also use API CE, or CD.)	10W-30 20W-20 15W-40 30 40

Capacity

Item	Fill amount
Drain and refill with oil filter change	7.1 liters (7.5 US qts, 6.2 Imp. qts)
Drain and refill without oil filter change	5.9 liters (6.2 US qts, 5.2 Imp. qts)
Dry fill	7.8 liters ( 8.3 US qts, 6.9 Imp. qts)

ADD ENGINE COOLANT
1. Add engine coolant.
  
  Specified capacity
  
  14.7 liters (15.5 US qts, 12.9 Imp. qts)
  
  Note
  
  Never use water as a substitute for engine coolant.
  Tech Tips
  - TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, non-borate coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).
  - Contact your TOYOTA dealer for further details.
2. Check the coolant level inside the radiator by squeezing the inlet and outlet radiator hoses several times by hand. If the coolant level goes down, add coolant.
3. Install the radiator cap.
4. Slowly pour coolant into the radiator reservoir until it reaches the FULL line.
5. Bleed air from the cooling system.
  1. Warm up the engine until the thermostat opens.
    
    While the thermostat is open, circulate the coolant for several minutes.
  2. Press the inlet and outlet radiator hoses several times by hand to bleed air.
    Note
    - Be careful as the radiator hoses are hot.
    - Keep your hands away from the radiator fan.
6. Stop the engine and wait until the coolant cools down.
7. Remove the radiator cap and check the coolant level.
8. If the coolant level has dropped, add coolant.
9. Check the coolant level inside the radiator reservoir tank again. If it is below the full level, add coolant.
BLEED AIR FROM FUEL SYSTEM

Tech Tips

Click here.

Specified capacity
14.7 liters (15.5 US qts, 12.9 Imp. qts)

INSPECT FOR FUEL LEAK

Perform the Active Test.

Connect the intelligent tester to the DLC3.
Start the engine.
Turn the intelligent tester on.
Select the following menu items: Powertrain / Engine / Active Test.

Perform the Active Test.

Intelligent Tester Display	Test Details	Control Range	Diagnostic Notes
Test the Fuel Leak	Fuel leaks (common rail internal fuel pressure is raised)	Stop/Start	Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2000 rpm when Start is selected. Above conditions preserved while Start is selected.

INSPECT FOR ENGINE OIL LEAK
INSPECT FOR ENGINE COOLANT LEAK
1. Remove the radiator cap.
  
  CAUTION:
  
  Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.
2. Fill the radiator with coolant and attach a radiator cap tester.
3. Warm up the engine.
4. Using a radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm², 19.9 psi), and check that the pressure does not drop.
  
  If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.
5. Install the radiator cap.
INSTALL ENGINE UNDER COVER