CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. Install a new cylinder head gasket.

      Note


      • Always use a new cylinder head gasket.

      • Always clean the surfaces of the cylinder head and cylinder block before installing the cylinder head gasket. Also, be sure to keep the surfaces free of dirt, water and grease.

  2. 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. Apply a light coat of engine oil to the threads of the cylinder head bolts.

    3. A01CIDGE01

      Step 1:

      Uniformly install and tighten the cylinder head bolts in the order shown in the illustration.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

    4. Step 2:


      1. Mark the front side of each cylinder head bolt head with paint.

      2. Tighten the cylinder head bolts 90°.

    5. Step 3:


      1. Tighten the cylinder head bolts an additional 90°.

      2. Check that the paint marks are now at a 180° angle to the front.

    6. A01CHTKE01

      Uniformly install and tighten the cylinder head bolts in the order shown in the illustration.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  3. INSTALL VALVE BRIDGE

    Tech Tips

    Be sure to install the removed valve bridges to their original positions.

  4. INSTALL VALVE LIFTER

    Tech Tips

    Be sure to install the removed valve lifters to their original positions.

  5. INSTALL VALVE PUSH ROD

    Tech Tips

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

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


    1. Apply engine oil to the valve rocker arm and valve push rod.

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

    3. A01CJ24E02

      Install the 5 bolts in the order shown in the illustration.

      Torque:
      69 N*m  { 699 kgf*cm, 51 ft.*lbf }

      Note

      Make sure that the valve push rods do not interfere with the valve adjusting screws.

  7. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install 6 new O-rings and the water by-pass pipe sub-assembly with the 6 bolts.

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

  8. INSTALL RADIATOR PIPE SUB-ASSEMBLY


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

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

  9. CONNECT OIL PUMP TO GEAR BOX TUBE


    1. A01CIY9

      Connect the oil pump to gear box tube with the 4 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }
      Text in Illustration
      A01CHW8 Bolt
      A01CHIJ Union Bolt

    2. Install a new gasket with the union bolt.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

  10. INSTALL NO. 3 NOZZLE LEAKAGE PIPE SUB-ASSEMBLY


    1. A01CHAT

      Install 2 new gaskets and the No. 3 nozzle leakage pipe with the 2 union bolts.

      Torque:
      for union bolt A
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }
      for union bolt B
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }
      Text in Illustration
      A01CHW8 Union Bolt A
      A01CHIJ Union Bolt B
      A01CHLZ Nut

    2. Install the nozzle leakage clamp with the nut.

  11. INSTALL REAR CAB MOUNTING BRACKET SUB-ASSEMBLY


    1. Install the rear cab mounting bracket sub-assembly with the 4 bolts.

      Torque:
      86 N*m  { 877 kgf*cm, 63 ft.*lbf }

  12. INSTALL REAR ENGINE SIDE SHUTTER


    1. Install the rear engine side shutter to the rear cab mounting bracket sub-assembly with the 4 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  13. INSTALL RELAY BLOCK BRACKET ASSEMBLY


    1. Install the relay block bracket sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  14. CONNECT RELAY BLOCK


    1. Connect the relay block with the 2 bolts and nut.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  15. INSTALL INJECTOR DRIVER ASSEMBLY


    1. Install the injector driver assembly with the 2 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    2. Connect the 3 injector driver assembly connectors.

  16. INSTALL STARTER RELAY ASSEMBLY


    1. Install the starter relay assembly with the 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the connector and attach the wire harness clamp.

    3. Connect the 2 lead wires to the starter relay assembly with the 2 nuts.

      Torque:
      4.7 N*m  { 48 kgf*cm, 42 in.*lbf }

    4. Install the terminal cap.

  17. INSTALL EXHAUST BRAKE WITH BRACKET SOLENOID ASSEMBLY


    1. Install the exhaust brake solenoid with bracket assembly with the 2 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

    2. Connect the exhaust retarder hose and solenoid hose with the 2 clips.

    3. Connect the connector to the exhaust brake solenoid with bracket assembly.

  18. INSTALL AIR CLEANER ASSEMBLY


    1. Install the air cleaner assembly to the No. 1 air cleaner stay with the 4 nuts

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

  19. INSTALL AIR CLEANER STAY


    1. Install the No. 1 air cleaner stay and No. 2 air cleaner stay with the 3 nuts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  20. INSTALL AIR HOSE ASSEMBLY


    1. Install 2 new hose clamps to the air hose assembly.

    2. A01CH5LE01

      Install the air hose assembly with the bolt.

      Torque:
      20 N*m  { 199 kgf*cm, 14 ft.*lbf }

    3. Tighten the 2 hose clamps.

      Torque:
      for hose clamp A
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }
      for hose clamp B
      3.7 N*m  { 38 kgf*cm, 33 in.*lbf }

    4. Install the ventilation hose to the air hose assembly, and slide the clamp to secure the hose.

  21. INSTALL FENDER SIDE APRON SUB-ASSEMBLY LH


    1. Install the fender side apron sub-assembly LH with the 6 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  22. INSTALL FENDER SIDE APRON SUB-ASSEMBLY RH


    1. Install the fender side apron sub-assembly RH with the 6 bolts.

      Torque:
      12 N*m  { 117 kgf*cm, 8 ft.*lbf }

  23. INSTALL INJECTOR ASSEMBLY

    Click here

  24. INSTALL INTAKE MANIFOLD

    Click here

  25. INSTALL GLOW PLUG ASSEMBLY (for Cold Area Specification Vehicles)

    Click here

  26. INSTALL COMMON RAIL ASSEMBLY

    Click here

  27. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  28. INSTALL GENERATOR ASSEMBLY

    Click here

  29. INSTALL RADIATOR ASSEMBLY

    Click here

  30. INSPECT FOR EXHAUST GAS LEAK

    Click here

  31. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  32. ADD ENGINE OIL


    1. Add new engine oil.

      Standard Oil Grade
      Oil Grade Oil Viscosity (SAE)

      API (CJ-4)

      JASO (DH-2)

      ACEA (E-6, E-9)

      - 5W-30

      - 10W-30

      - 15W-40
      Standard Capacity
      Item Specified Condition
      Drain and refill without oil filter change 5.2 liters (5.5 US qts, 4.6 Imp. qts)
      Drain and refill with oil filter change 6.5 liters (6.9 US qts, 5.7 Imp. qts)
      Dry fill 8.7 liters (9.2 US qts, 7.7 Imp. qts)

    2. Install the oil filler cap.

  33. ADD ENGINE COOLANT

    CAUTION:

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

    Note

    Do not substitute plain water for engine coolant.


    1. Add engine coolant.

      Standard capacity
      14.2 liters (15.0 US qts, 12.5 Imp. qts)

      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).

    2. Check the coolant level inside the radiator by squeezing the inlet radiator hose and outlet radiator hose 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 F 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. Maintain the engine speed at a speed between 2500 and 3000 rpm.

      3. Press the inlet and outlet radiator hoses several times by hand to bleed air.

        Note


        • Wear protective gloves.

        • 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 to ambient temperature.

    7. Remove the radiator cap sub-assembly and check the coolant level.

      If the coolant level has dropped, add coolant.

    8. Check the coolant level inside the radiator reservoir assembly again.

      If the coolant level is below the F line, add coolant to F line.

  34. BLEED AIR FROM FUEL SYSTEM


    1. A01CHFE

      Loosen the bleeder plug.

      Text in Illustration
      A01CHW8 Bleeder Plug

      Note

      Make sure that the drain plug and bleeder plug of the filter on the fuel tank side are closed.

    2. A01CHX4

      Bleed air using the priming pump on the fuel tank side.

      Note


      • Place a container, etc. underneath the fuel filter to prevent fuel from spraying.

      • The hand pump must be pushed with a full stroke during pumping.

      • The maximum hand pump pumping speed is 2 strokes per second.

      • When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.

      • If pumping is interrupted during the air bleeding process, fuel in the fuel line may return to the fuel tank. Continue pumping until the hand pump resistance increases.

      • If the hand pump resistance does not increase despite consecutively pumping 200 times or more, there may be a fuel leak between the fuel tank and fuel filter, the hand pump may be malfunctioning, or the vehicle may have run out of fuel.

      • If air bleeding using the hand pump is incomplete, the common rail pressure does not rise to the pressure range necessary for normal use and the engine cannot be started.

    3. Tighten the bleeder plug.

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

    4. Check if the engine starts.

      Note


      • Even if air bleeding using the hand pump has been completed, the starter may need to be cranked for 10 seconds or more to start the engine.

      • Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.

      • Use a fully-charged battery.


      1. When the engine can be started, proceed to the next step.

        Tech Tips

        If the engine cannot be started, bleed air again using the hand pump until the hand pump resistance increases (refer to the procedures above). Then start the engine.

    5. Turn the ignition switch off.

    6. Connect the intelligent tester to the DLC3.

    7. Turn the ignition switch to ON and turn the intelligent tester on.

    8. Clear the DTCs Click here.

    9. Start the engine.*1

    10. A01CJCTE05
      Text in Illustration
      *a

      Reference

      (Active Test operation)

      Enter the following menus: Powertrain / Engine and ECT / Active Test / Test the Fuel Leak.*2

    11. Perform the following test 5 times with on/off intervals of 10 seconds: Active Test / Test the Fuel Leak.*3

      A01CHBIE15
      Text in Illustration
      *a Active Test operation *b Time
      *c ON *d OFF
      *e 1st time *f 2nd time
      *g 5th time *h 10 seconds
      *i 3 minutes or more - -

    12. Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

    13. Enter the following menus: Powertrain / Engine and ECT / DTC.

    14. Read Current DTCs.


      1. If no DTCs are output, air bleeding is completed.

      2. If DTCs are output, perform the following procedure.

    15. Clear the DTCs Click here.

    16. Repeat steps *1 to *3.

    17. Enter the following menus: Powertrain / Engine and ECT / DTC.

    18. Read Current DTCs.

      OK
      No DTCs are output

  35. INSPECT FOR FUEL LEAK


    1. Perform the Active Test.


      1. Replace the normal DLC3 cable (12 V specification) for the intelligent tester with the 24 V DLC3 cable.

        Note

        Be sure to use the 24 V DLC3 cable when connecting the intelligent tester to the DLC3. Using the normal DLC3 cable (12 V specification) will cause damage to the tester.

      2. Connect the intelligent tester to the DLC3.

      3. Start the engine.

      4. Turn the intelligent tester on.

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

      6. Perform the Active Test.

        Tester Display Test Part Control Range Diagnostic Note
        Test the Fuel Leak Pressurizes common rail interior and checks for fuel leaks Stop or Start

        • The fuel pressure inside the common rail is increased to a specified value and the engine speed is increased to 2000 rpm when Start is selected

        • The above conditions are preserved while the control parameter of the test is Start

    2. Check for leaks from the fuel system while performing the Active Test (with a fuel pressure applied).

  36. INSPECT FOR OIL LEAK


    1. Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

  37. INSPECT FOR COOLANT LEAK

    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.

    Note

    Before each inspection, turn the A/C switch off.


    1. Fill the radiator with coolant and attach a radiator cap tester.

    2. Warm up the engine.

    3. Using the radiator cap tester, increase the pressure inside the radiator to 137 kPa (1.4 kgf/cm2, 20 psi), and check that the pressure does not drop.

      If the pressure drops, check the hoses, radiator assembly and engine water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.