CYLINDER HEAD (w/o DPF) INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET

    A01KHD0E03
    Text in Illustration
    *a Measuring Tip
    *b Protrusion

    1. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.

    2. A01KH52E03
      Text in Illustration
      *a Measuring Point

      Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

    3. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

      Standard piston protrusion
      0.005 to 0.254 mm (0.0002 to 0.0100 in.)

      Tech Tips

      If the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.

    4. A01KGPSE04
      Text in Illustration
      *a Cutout Mark
      *b Front

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New installed cylinder head gasket thickness
      Mark Thickness
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

      1. Select the largest piston protrusion value from the measurements made. Then select a new appropriate gasket according to the table below.

        Use gasket size
        Gasket Size Piston Protrusion
        Use A 0.005 to 0.054 mm (0.0002 to 0.0021 in.)
        Use B 0.055 to 0.104 mm (0.0022 to 0.0041 in.)
        Use C 0.105 to 0.154 mm (0.0041 to 0.0061 in.)
        Use D 0.155 to 0.204 mm (0.0061 to 0.0080 in.)
        Use E 0.205 to 0.255 mm (0.0081 to 0.0100 in.)
    5. A01KIMVE03
      Text in Illustration
      *a Front

      Place the cylinder head on the cylinder block.


      1. Place the cylinder head gasket on the cylinder block.

        Note

        Be careful of the installation direction.

      2. Place the cylinder head on the cylinder head gasket.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01KEWBE01

    Tech Tips


    • The cylinder head bolts are tightened in 3 progressive steps.

    • If any bolt is broken or deformed, replace it.


    1. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.

    2. Install and uniformly tighten the 18 cylinder head bolts and 18 washers, in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt Length
      A 110 mm (4.33 in.)
      B 167 mm (6.57 in.)

      If any of the cylinder head bolts does not meet the torque specification, replace it.

    3. A01KFEKE04
      Text in Illustration
      *a Painted Mark
      *b Front

      Mark the front of the cylinder head bolts with paint.

    4. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

    5. Finally, tighten the cylinder head bolts by an additional 90°.

    6. Check that the painted mark is now facing rearward.

  3. INSTALL CAMSHAFTS

    A01KGB9E02

    1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

      Tech Tips

      Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    2. A01KFGIE07

      Install the camshaft.


      1. Apply MP grease to the thrust portion of the camshaft.

      2. Place the camshaft on the cylinder head, facing the key groove upward.

        Text in Illustration
        *1 Key Groove
        *a Upward
      3. A01KGP2E01

        Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.

    3. A01KEFRE09

      Remove any old packing (FIPG) material from the camshaft bearing cap.

    4. Apply seal packing to the specified areas shown in the illustration.

      Text in Illustration
      *1 Oil Passage
      *2 Seal Packing
      *a Seal Diameter: 4 mm
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal diameter
      4 mm (0.16 in.)

      Note


      • Do not allow FIPG to come into contact with the oil passage of the bearing cap.

      • After applying FIPG, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.

      • Do not start the engine for at least 2 hours after the installation.


      1. A01KEE1E01

        Install the 5 bearing caps in the proper locations.

      2. A01KGI2E02

        Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

      3. Install and uniformly tighten the 15 bearing cap bolts in several passes in the sequence shown in the illustration.

        Torque:
        19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  4. INSTALL CAMSHAFT SETTING OIL SEAL


    1. Apply MP grease to the lip of a new oil seal.

    2. A01KFLPE01

      Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge.

      SST
      09608-06041

  5. INSPECT VALVE CLEARANCE

    A01KG3PE05
    Text in Illustration
    *1 Exhaust
    *2 Intake
    *a Front

    1. Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance (Cold)
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down the valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

    2. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.

    3. A01KEKNE04
      Text in Illustration
      *1 Exhaust
      *2 Intake
      *a Front

      Check only the valves indicated.


      1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

        Standard valve clearance
        Intake Exhaust
        0.20 to 0.30 mm (0.008 to 0.012 in.) 0.35 to 0.45 mm (0.014 to 0.018 in.)

        Write down the valve clearance measurements that are not within the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  6. ADJUST VALVE CLEARANCE


    1. Remove the camshafts Click here.

    2. Remove the 8 valve lifters.

    3. A01KF1SE01

      Using a micrometer, measure the thickness of the removed lifter.

    4. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

      A B C
      New lifter thickness Used lifter thickness Measured valve clearance
      New lifter thickness
      Intake A = B + (C - 0.25 mm (0.0098 in.))
      Exhaust A = B + (C - 0.40 mm (0.00158 in.))

    5. Select a new lifter with a thickness as close as possible to the calculated values.

      Tech Tips

      Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

    6. Install the selected valve lifter.

      A01KI2YE01
      Text in Illustration
      *1 Intake Valve Lifter Chart (1/2) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KFC5E01
      Text in Illustration
      *1 Intake Valve Lifter Chart (2/2) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      Standard intake valve clearance (Cold)
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      EXAMPLE
      The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 40 lifter.
      New lifter thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -
      A01KEHUE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (1/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KF7IE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (2/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      A01KH8WE01
      Text in Illustration
      *1 Exhaust Valve Lifter Chart (3/3) *2 Measured Clearance mm (in.)
      *3 Installed Lifter Thickness mm (in.) - -
      Standard exhaust valve clearance (Cold)
      0.35 to 0.45 mm (0.014 to 0.018 in.)
      EXAMPLE
      The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a No. 42 lifter.
      New lifter thickness (mm (in.))
      Shim No. Thickness Shim No. Thickness Shim No. Thickness
      06 5.060 (0.1992) 30 5.300 (0.2087) 54 5.540 (0.2181)
      08 5.080 (0.2000) 32 5.320 (0.2094) 56 5.560 (0.2189)
      10 5.100 (0.2008) 34 5.340 (0.2102) 58 5.580 (0.2197)
      12 5.120 (0.2016) 36 5.360 (0.2110) 60 5.600 (0.2205)
      14 5.140 (0.2024) 38 5.380 (0.2118) 62 5.620 (0.2213)
      16 5.160 (0.2031) 40 5.400 (0.2126) 64 5.640 (0.2220)
      18 5.180 (0.2039) 42 5.420 (0.2134) 66 5.660 (0.2228)
      20 5.200 (0.2047) 44 5.440 (0.2142) 68 5.680 (0.2236)
      22 5.220 (0.2055) 46 5.460 (0.2150) 70 5.700 (0.2244)
      24 5.240 (0.2063) 48 5.480 (0.2157) 72 5.720 (0.2252)
      26 5.260 (0.2071) 50 5.500 (0.2165) 74 5.740 (0.2260)
      28 5.280 (0.2079) 52 5.520 (0.2173) - -

    7. Install the camshaft Click here.

  7. INSTALL CYLINDER BLOCK INSULATOR

  8. INSTALL NO. 2 TIMING BELT COVER

    A01KG80E04
    Text in Illustration
    *1 Seal Packing

    1. Apply seal packing (FIPG) to the specified areas shown in the illustration.

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

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten the bolts and nut within 15 minutes.

    2. Install the No. 2 timing belt cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  9. INSTALL CAMSHAFT TIMING PULLEY

    A01KG6WE01

    1. Install the camshaft timing pulley.

    2. Fasten the bolt of the camshaft timing pulley while holding the camshaft with a wrench.

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  10. INSTALL EXHAUST MANIFOLD

    A01KG97

    1. Install the new gasket onto the cylinder head.

    2. Install the exhaust manifold with the 8 nuts, spacers and collars.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.

  11. TEMPORARILY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KG5FE04
      Text in Illustration
      *1 Claw
      *a Wide
      *b Narrow
      *c Outside

      Install a new gasket to the turbo oil inlet pipe sub-assembly.

      Note

      Insert the gasket with its claws facing the turbo oil inlet pipe sub-assembly.

    2. Temporarily tighten the turbo oil inlet pipe sub-assembly with the 2 bolts, 2 nuts and union bolt.

  12. TEMPORARILY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Temporarily tighten the turbocharger stay with the 2 bolts and a new nut.

  13. FULLY TIGHTEN TURBOCHARGER STAY


    1. A01KFD3

      Tighten the 2 bolts and nut to the specified torque.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  14. FULLY TIGHTEN TURBO OIL INLET PIPE SUB-ASSEMBLY


    1. A01KHCKE04
      Text in Illustration
      *1 Union Bolt

      Tighten the 2 bolts, 2 nuts and union bolt to the specified torque and install the turbo oil inlet sub-assembly.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf, for bolt }
      13 N*m  { 133 kgf*cm, 10 ft.*lbf, for nut }
      26 N*m  { 265 kgf*cm, 19 ft.*lbf, for union bolt }

  15. INSTALL TURBINE OUTLET ELBOW


    1. A01KEND

      Install a new gasket and the turbine outlet elbow with the new 3 nuts.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

  16. CONNECT NO. 1 TURBO WATER HOSE


    1. A01KHWT

      Connect the No. 1 turbo water hose with the 2 clips.

  17. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01KG7W

      Temporarily install the No. 1 exhaust manifold heat insulator with the 2 bolts.

  18. INSTALL NO. 1 TURBO INSULATOR


    1. A01KGR2

      Temporarily install the No. 1 turbo insulator with the 2 bolts.

    2. Tighten the 4 bolts to the specified torque and install the No. 2 turbo insulator and No. 1 exhaust manifold heat insulator.

      Torque:
      12 N*m  { 122 kgf*cm, 9 in.*lbf }

  19. INSTALL VENTILATION PIPE SUB-ASSEMBLY


    1. A01KGB4

      Install a new O-ring to the ventilation pipe sub-assembly.

    2. Apply a small amount of engine oil to the O-ring and install it to the ventilation pipe sub-assembly with the bolt.

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

  20. INSTALL ENGINE WIRE HARNESS (for LHD)


    1. A01KG9Q

      Install the engine wire harness with bracket with the 2 bolts.

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

  21. INSTALL ENGINE WIRE HARNESS (for RHD)


    1. A01KIQT

      Install the engine wire harness with bracket with the 2 bolts.

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

  22. CONNECT TURBOCHARGER STROKE SENSOR CONNECTOR


    1. A01KEZH

      Connect the turbocharger stroke sensor connector to the turbocharger.

  23. INSTALL NO. 2 AIR CLEANER HOSE


    1. A01KF86

      Connect the No. 2 air hose and tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  24. CONNECT TURBOCHARGER MOTOR CONNECTOR


    1. A01KHOK

      Connect the turbocharger motor connector to the turbocharger.

  25. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01KEB4

      Install the compressor outlet elbow with No. 2 air hose with the hose clamp and bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf, for bolt }
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf, for hose clamp }

  26. CONNECT NO. 1 AIR HOSE


    1. A01KHAW

      Connect the No. 1 air hose and tighten the hose clamp.

  27. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    A01KEXT

    1. Inspect the compression spring.


      1. Using vernier calipers, measure the free length of the compression spring.

        Minimum length
        40.5 mm (1.594 in.)

        If the free length is less than the minimum, replace the compression spring.

    2. A01KH27E03
      Text in Illustration
      *1 New Gasket
      *2 Wooden Block

      Install a new gasket.


      1. Using a wooden block and plastic-faced hammer, tap in a new gasket until its flush with the front exhaust pipe end.

        Note


        • Install the gasket in the correct direction.

        • Do not damage the outer surface of the gasket.

        • Do not reuse the removed gasket.

        • Do not push in the gasket with the front exhaust pipe when connecting it.

    3. A01KHYR

      Install the 2 hooks and the front exhaust pipe.

    4. Install the front exhaust pipe with the 2 bolts and compression springs onto the exhaust manifold.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    5. Install the gasket onto the front exhaust pipe.

    6. Install the front exhaust pipe with the 2 bolts onto the center exhaust pipe.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  28. INSTALL OIL LEVEL GAUGE GUIDE (for LHD)


    1. Install the a O-ring onto the oil level gauge guide.

    2. Install the oil level gauge guide with the bolt.

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

    3. Install the oil level gauge.

  29. INSTALL INTAKE MANIFOLD

    A01KHW9E01

    1. Install a new gasket.

    2. Temporarily install the intake manifold with the 2 nuts and the 4 bolts.

    3. Uniformly tighten the 2 nuts and the 4 bolts as shown in the illustration.

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

  30. INSTALL FUEL COOLER


    1. Install the fuel cooler with the 2 bolts.

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

  31. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

  32. INSTALL GLOW PLUG ASSEMBLY

    Note


    • Measure the resistance of the glow plug when reinstalling it.

      If the result is not as specified, replace it with a new one.

    • Replace the glow plug with a new one when it has been dropped or subjected to a physical impact.

    • Remove any carbon deposits from the glow plug hole when reinstalling it.


    1. A01KHCSE02
      Text in Illustration
      *a Tape

      Wrap tape around a φ 4.4 drill, 118.5 mm (4.665 in.) from its tip.

    2. Insert the drill 118.5 mm (4.665 in.) into the glow plug hole and remove the carbon deposits by manually turning the drill.

    3. Insert the φ 4 drill into the glow plug hole and remove any carbon deposits from the tip end portion of the glow plug hole by manually turning the drill.

    4. A01KIIK

      Install the 4 glow plugs.

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

      Note

      Do not use any tools, such as air tools, which are liable to cause any impact to the glow plugs, when installing them.

  33. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    A01KILK

    1. Install the No. 2 Intake manifold Insulator.

  34. INSTALL NO. 1 GLOW PLUG CONNECTOR

    A01KIEP

    1. Temporarily install the No. 1 glow plug connector with the 4 nuts.

    2. Tighten the 4 nuts to the specified torque.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    3. Install the 4 screw grommets.

    4. Connect the wire harness to the No. 1 glow plug connector and install the nut.

      Torque:
      2.6 N*m  { 27 kgf*cm, 23 in.*lbf }

    5. Install the screw grommet.

  35. INSTALL MANIFOLD STAY

    A01KGL0E01

    1. Install the manifold stay with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf, for bolt A }
      19 N*m  { 194 kgf*cm, 14 ft.*lbf, for bolt B }

    2. Connect the 3 vacuum hoses and gas filter.

  36. INSTALL COMMON RAIL ASSEMBLY


    1. A01KI1X

      Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }
    2. A01KHC7

      Connect the fuel hose.

    3. Connect the 2 connectors to the common rail.

  37. INSTALL INJECTOR ASSEMBLY

    Refer to the procedures up to "INSTALL INJECTOR ASSEMBLY" Click here.

  38. INSTALL TIMING BELT

    Refer to the procedures up to "INSTALL TIMING BELT" Click here.

  39. ADD ENGINE OIL


    1. Add fresh oil and install the oil filler cap.

      Engine oil
      Oil Grade Oil Viscosity (SAE)

      • API CF-4 or CF, G-DLD-1, ACEA B1

      • 20W-50


      • 15W-40


      • 10W-30


      • 5W-30 Preferred
      Capacity
      Item Fill Amount
      Drain and refill with oil filter change 7.0 liters (7.4 US qts, 6.2 lmp. qts)
      Drain and refill without oil filter change 6.8 liters (7.2 US qts, 6.0 lmp. qts)
      Dry fill 7.7 liters (8.1 US qts, 6.8 lmp. qts)

  40. INSPECT FOR ENGINE OIL LEAK

  41. INSPECT FOR OIL LEVEL


    1. Warm up the engine and inspect for oil leak.