CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. Install a new cylinder head gasket.

      Note

      Always use a new cylinder head gasket. Clean the surfaces of the cylinder head and cylinder block and keep them free of dirt, water and grease.

  2. INSPECT CYLINDER HEAD SET BOLT


    1. A01CGS1E02
      Text in Illustration
      *a Measurement Length

      Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Maximum length
      129 mm (5.07 in.)

      If the length is more than the maximum, replace the cylinder head set bolts.

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. Install the cylinder head over the straight pins on the cylinder block.

      Tech Tips

      Since the cylinder head bolts are unique to this engine, do not substitute them with ordinary bolts.

    2. A01CHONE01

      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. A01CJC1E02
      Text in Illustration
      *a Paint Mark
      A01CHIJ Front

      Mark the front side of each cylinder head bolt with paint as shown in the illustration.

    4. Retighten the cylinder head bolts 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. A01CIJ8E01

      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 }

  4. INSTALL VALVE BRIDGE

    Note

    Be sure to install the removed valve bridge to its original position.

  5. INSTALL VALVE PUSH ROD

    Note

    Be sure to install the removed push rods to their original positions.

  6. INSTALL NO. 1 VALVE ROCKER SHAFT SUB-ASSEMBLY


    1. A01CH84

      Apply engine oil to the rocker arm and push rod.

    2. Install the No. 1 valve rocker shaft sub-assembly to the cylinder head.

    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.

  7. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CI1KE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.

      • 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 and 2 new O-rings with the 6 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  8. INSTALL WATER PIPE SUB-ASSEMBLY


    1. Install the water pipe sub-assembly and a new O-ring with the 3 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  9. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Tech Tips

    Click here.

  10. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 12 mm deep socket wrench, install the 4 glow plugs.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  11. INSTALL GLOW PLUG GROUND WIRE


    1. A01CHM1E03
      Text in Illustration
      *1 Glow Plug Ground Wire
      *2 Wire Harness
      *3 Engine Front Side

      Install the 3 ground wires so that they overlap as shown in the illustration. Make sure that the ground wire on the front side of the engine is installed first.

      Note

      If the ground wires are not installed in the correct order, they may deform when the nuts are tightened.

    2. Install the wire harness onto the No. 4 glow plug.

    3. Install the 4 nuts.

      Torque:
      1.5 N*m  { 15 kgf*cm, 13 in.*lbf }

      Note

      Check that the ground wires do not interfere with the cylinder head or intake manifold.

    4. Install the 4 screw grommets.

  12. INSTALL RADIATOR PIPE


    1. Install the radiator pipe and a new O-ring with the 2 bolts.

      Torque:
      18 N*m  { 180 kgf*cm, 13 ft.*lbf }

  13. INSTALL GENERATOR BRACKET SUB-ASSEMBLY


    1. Install the generator bracket with the 3 bolts.

      Torque:
      55 N*m  { 560 kgf*cm, 41 ft.*lbf }

  14. 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 }

  15. INSTALL INJECTOR ASSEMBLY

    Note

    A01CJFWE04
    Text in Illustration
    *1 Injector Compensation Code

    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. Apply a small amount of clean engine oil to 4 new O-rings.

    2. A01CI6EE02
      Text in Illustration
      *1 O-ring

      Install the O-ring to each injector as shown in the illustration.

    3. Install a new gasket to each injector.

    4. 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.

    5. A01CGOO

      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.

    6. A01CIVM

      Install 4 new holder seals.

      Note

      Securely insert the tip of each holder seal into each fuel injector.

    7. A01CIAR

      Temporarily install the nozzle leakage pipe assembly and 5 new gaskets with the 5 hollow screws.

      Note

      Make sure that the hollow screws and nozzle leakage pipe assembly are not deformed or damaged.

    8. A01CHN3

      Temporarily tighten the union nuts of the 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.

    9. 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.

    10. Tighten the 5 hollow screws.

      Torque:
      13 N*m  { 130 kgf*cm, 10 ft.*lbf }

      Note

      If the nozzle leakage pipe assembly has been tightened to more than the specified torque, replace it with a new one.

    11. A01CHN3

      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 the union nut wrench. When using the union nut wrench, calculate the torque in accordance with the lengths of the union nut wrench and torque wrench Click here.

  16. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install the engine oil level dipstick guide and a new O-ring.

  17. 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. A01CGTY

      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.

    4. Install the oil level gauge.

  18. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. A01CI1KE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.

      • 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 and 2 new O-rings with the 6 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  19. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  20. CONNECT WIRE HARNESS AND CONNECTORS


    1. Connect the 3 connectors and 4 wire harness clamps and then install the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  21. INSTALL VENTURI ASSEMBLY


    1. A01CI8SE02
      Text in Illustration
      *1 Seal Packing

      Apply seal packing in a continuous line (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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 surfaces.

      • Install the venturi within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

    2. Install the venturi assembly with the 4 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Install the bracket with the bolt.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  22. INSTALL DIESEL THROTTLE BODY


    1. Remove any seal packing material from the contact surface.

    2. A01CJAVE02
      Text in Illustration
      *1 70 mm (2.75 in.)
      *2 Seal Packing

      Apply a continuous bead of seal packing (width: 1.5 to 2.5 mm (0.0591 to 0.0984 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. A01CH93

      Install the diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }
    4. A01CHFJ

      Connect the 2 diesel throttle body connectors.

  23. 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, cushions and spacers with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

    3. Install the cylinder head cover cushion rubber.

    4. Install the wire harness.

  24. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Install the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      29 N*m  { 290 kgf*cm, 21 ft.*lbf }

  25. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly.

  26. INSTALL EGR COOLER SUB-ASSEMBLY


    1. Install the EGR cooler, bracket and 2 new gaskets with the 6 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.

  27. INSTALL WIRE HARNESS


    1. Install the wire harness.

  28. CONNECT FUEL HOSE


    1. Connect the 2 fuel hoses.

  29. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install a new gasket and the front exhaust pipe assembly, and temporarily tighten 3 new nuts.

    2. Temporarily tighten a new 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 }

  30. INSTALL EXHAUST RETARDER ASSEMBLY


    1. Install 2 new gaskets and exhaust retarder assembly with 4 new bolts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

    2. Connect the vacuum hose.

  31. INSTALL GENERATOR ASSEMBLY


    1. A01CJ2NE01

      Temporarily install the generator assembly with the bolt (A).

    2. Temporarily install the generator belt adjusting bar to the generator assembly with the bolt (B).

    3. Install the generator belt adjusting bar with the 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 }

  32. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly with the fan shroud.

  33. INSTALL NO. 3 RADIATOR BRACKET


    1. A01CJBO

      Install the No. 3 radiator bracket with the 3 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  34. INSTALL NO. 4 RADIATOR BRACKET


    1. A01CIT5

      Install the No. 4 radiator bracket with the 3 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  35. INSTALL HEATER HOSE


    1. A01CJFI

      Install the heater hose with the 5 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  36. CONNECT OUTLET RADIATOR HOSE


    1. Install the outlet radiator hose.

  37. CONNECT INLET RADIATOR HOSE


    1. Install the inlet radiator hose.

  38. INSTALL FAN PULLEY


    1. Install the fan pulley.

  39. 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 }

  40. INSPECT DRIVE BELT


    1. A01CHS3E02
      Text in Illustration
      *1 Fan Pulley
      *2 Generator
      *3 Crankshaft Pulley

      Check the fan and generator V belt deflection.

      Tech Tips


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

      • When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

      Deflection
      Item Specified Condition
      New belt 10.5 to 12.5 mm (0.413 to 0.492 in.)
      Used belt 12.5 to 16.0 mm (0.492 to 0.630 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.

    2. A01CGPIE02
      Text in Illustration
      *1 Idler Pulley
      *2 A/C Compressor
      *3 Crankshaft Pulley

      Check the No. 1 V (cooler compressor to crankshaft pulley) belt deflection (w/ Air Conditioning System).

      Tech Tips


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

      • When inspecting the V belt deflection, apply 98 N (10 kgf, 22 lbf) tensile force to it.

      Deflection
      Item Specified Condition
      New belt 8.5 to 10.0 mm (0.335 to 0.394 in.)
      Used belt 10.0 to 12.0 mm (0.394 to 0.472 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.

  41. INSTALL INTERCOOLER ASSEMBLY


    1. Install the intercooler assembly with the 4 bolts.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

  42. INSTALL NO. 2 AIR HOSE

  43. 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. Install the bolt, and connect the turbo pressure sensor connector and wire harness clamp.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    3. Install the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Install the No. 1 intake air pipe with No. 4 air hose with a new hose band.

  44. 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).

  45. INSTALL NO. 2 INTAKE PIPE


    1. Install the No. 2 intake pipe and No. 1 air hose with the 3 bolts and 2 new hose bands.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  46. INSTALL INJECTOR DRIVER ASSEMBLY


    1. A01CHLQ

      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.

  47. INSTALL VACUUM RESERVOIR SUB-ASSEMBLY

  48. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH

  49. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH

  50. 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, 9 ft.*lbf }

  51. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY LH

  52. INSTALL ENGINE SIDE COVER SUB-ASSEMBLY RH

  53. INSPECT FOR EXHAUST GAS LEAK

  54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  55. ADD ENGINE OIL


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

      Engine oil
      Oil Grade Oil Viscosity (SAE)

      • API (CF, CF-4, CH-4, CI-4, CG-4, CJ-4)

      • JASO (DH-1, DH-2)

      • ACEA (E-3, E-4, E-5, E-6)

      • 10W-30

      • 20W-20

      • 15W-40

      • 30

      • 40
      Capacity
      Item Fill amount
      Drain and refill with oil filter change 6.5 liters (6.9 US qts, 5.7 Imp. qts)
      Drain and refill without oil filter change 5.2 liters (5.5 US qts, 4.6 Imp. qts)
      Dry fill 7.8 liters ( 8.3 US qts, 6.9 Imp. qts)

  56. 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 is 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 sub-assembly.

    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 sub-assembly 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.

  57. BLEED AIR FROM FUEL SYSTEM

    Tech Tips

    Click here.

  58. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Connect the intelligent tester to the DLC3.

      2. Start the engine.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Intelligent Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop or Start

        • Fuel pressure inside common rail is pressurized to specified value and engine speed is increased to 2000 rpm when Start is selected.

        • Above conditions preserved while Start is selected.

  59. INSPECT FOR ENGINE OIL LEAK

  60. INSPECT FOR ENGINE COOLANT LEAK


    1. Remove the radiator cap sub-assembly.

      CAUTION:

      Do not remove the radiator cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    2. A01CIGLE02
      Text in Illustration
      *1 Radiator Cap Tester

      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 sub-assembly.

  61. INSTALL ENGINE UNDER COVER