CYLINDER HEAD INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. Check each piston head protrusion.


      1. A01BG25

        Using a dial indicator, measure the amount of each piston head protrusion between the top surfaces of each cylinder head and piston head.

        Note

        Set the dial indicator in an upright position to the cylinder block.

      2. A01BEXDE02

        Perform the measurement at 2 places for each cylinder as shown in the illustration, making a total of 8 measurements.

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

        Protrusion
        0.005 to 0.255 mm(0.00020 to 0.01004 in.)

        Tech Tips

        Measurement should be done at 2 locations, right and left sides of each piston head.

    2. A01BB7KE01

      Select an appropriate cylinder head gasket.

      Tech Tips

      Each cylinder head gasket A to E has a unique notch position at its back-end, which helps identify an individual gasket.


      1. Find the maximum value among all the measured piston head protrusion length to select an appropriate cylinder head gasket from A to E.

        Piston protrusion
        Gasket size Piston protrusion mm (in.)
        A 0.005 to 0.054 (0.0002 to 0.00213)
        B 0.055 to 0.104 (0.00217 to 0.00409)
        C 0.105 to 0.154 (0.00413 to 0.00606)
        D 0.155 to 0.204 (0.00610 to 0.00803)
        E 0.205 to 0.255 (0.00807 to 0.01004)
        Cylinder head gasket thickness
        Gasket size Gasket thickness mm (in.)
        A 0.80 to 0.90 (0.0315 to 0.0354)
        B 0.85 to 0.95 (0.0335 to 0.0374)
        C 0.90 to 1.00 (0.0354 to 0.0394)
        D 0.95 to 1.05 (0.0374 to 0.0413)
        E 1.00 to 1.10 (0.0394 to 0.0433)

      2. Install the selected gasket to the cylinder block.

        Note

        Clean the top surface of the cylinder block and the underside of the cylinder head.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. A01BFILE01

      Set the crankshaft at 90° position in a counterclockwise direction from the TDC.

    2. Set a new cylinder head gasket and install the cylinder head.

      Tech Tips

      Temporarily set a new gasket to the turbocharger before installing the cylinder head.

    3. Apply a small amount of engine oil to each cylinder head bolt, screw, and washer.

    4. Set the washers to the cylinder head bolts, and insert the bolts to the cylinder head.

    5. A01BH02

      Tighten the cylinder head bolts equally in the specific order shown in the illustration in several steps, and then tighten them with the specified torque completely.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
    6. A01BDGEE01

      Put a paint mark on the top surface of the cylinder bolt head in the engine front direction.

    7. Tighten each cylinder head bolt by 90°.

      Tech Tips

      The cylinder head bolts must be tightened in the specified order.

    8. Tighten the bolts by additional 90°.

    9. Make sure that all the paint marks come toward the opposite side to the engine front.

  3. INSTALL CAMSHAFT


    1. A01BFIL

      Set the crankshaft to 90° position from the TDC/compression.

    2. A01BF4GE01

      Place the camshaft to the cylinder head as shown in the illustration.

      Note

      Apply engine oil to the cams, thrusts and gears of the camshaft as well as on the journal of the cylinder head.

    3. A01BD73E01

      Align the dot marks of the camshaft and No.2 camshaft by meshing the both gears before placing the No.2 camshaft.

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

    5. A01BEXNE01

      Apply seal packing to the specific places shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Thickness
      1 mm (0.04 in.)

      Note


      • Be careful not to adhere FIPG to the oil passage of the bearing cap.

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

      • Do not start the engine 2 hours after the installation.

    6. A01BAZF

      Install the camshaft bearing cap as shown in the illustration.

    7. Tighten the 15 bolts for the camshaft bearing cap in the specified order shown in the illustration.

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

    8. Adjust and inspect valve clearance.


      1. Fix the timing belt cover No.2 with the 4 bolts and nuts.

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

      2. Tighten the bolt for the camshaft timing pulley while holding the camshaft with a monkey wrench.

        Torque:
        98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      3. Adjust and inspect the valve clearance. Click here

      4. Remove the camshaft timing pulley and timing belt cover No.2.

  4. INSTALL CAMSHAFT SETTING OIL SEAL


    1. Apply a bit of MP grease to a new oil seal's lip.

      Note

      Keep the lip clean. Do not to bring dirt and dust on that area.

    2. A01BHAYE01

      Using SST and a hammer, fit the oil seal.

      SST
      09608-06041
      Oil seal depth from flat end face
      0.5 to 1.5 mm (0.020 to 0.060 in.)

      Note

      Install the oil seal straight.

  5. INSTALL INJECTOR ASSEMBLY

    Click here

  6. CHECK NOZZLE LEAKAGE PIPE LEAK

    Click here

  7. INSTALL TIMING BELT COVER NO.2


    1. A01BD2NE02

      Remove old seal packing (FIPG) from the timing gear case.

    2. Apply seal packing to the specific places shown in the illustration.

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

      Note


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

      • Do not start the engine 2 hours after the installation.

    3. Fix the timing belt cover No.2 with the 4 bolts and nuts.

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

  8. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1


    1. A01BH1Y

      Using a 10 mm socket hexagon wrench, install the new plate washer and timing belt idler No.1.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  9. INSTALL CAMSHAFT TIMING PULLEY


    1. A01BHHN

      Install the camshaft timing pulley.

    2. Tighten the bolt for the camshaft timing pulley while holding the camshaft with a monkey wrench.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

  10. PISTON AND VALVE BREAKE PREVENT WORK


    1. A01BFIL

      When turning the camshaft with the timing belt removed, turn the crankshaft 90° counterclockwise.

      Note

      When installing the timing belt, it is necessary to return the camshaft to the timing marks and then turn the crankshaft clockwise so that it aligns with the timing marks as shown in the illustration.

  11. INSTALL TIMING BELT


    1. A01BC61E01

      Check that the timing marks are aligned as shown in the illustration.

    2. Install the timing belt to pump drive shaft pulley, camshaft timing pulley and timing belt idler No.1 in sequence.

    3. A01BAP9

      Set the tensioner to the press upright.

      Note


      • Do not allow the rod end to scratch and deform.

      • Press the tensioner rod in upward.

      • Protect a tip of the push rod with a rag in order to prevent damage.

    4. Using a press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.

      Note

      Do not apply loads 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) or more on the push rod.

    5. Align the holes of push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    7. Tighten the 2 bolts.

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

      Note

      Uniformly tighten the 2 bolts and install the tensioner

    8. Remove the 1.5 mm hexagon wrench from the tensioner.

    9. A01BB9ZE01

      Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as shown in the illustration.

  12. INSTALL TIMING BELT COVER NO.1


    1. A01BHT6

      Install the timing belt No.1 cover with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the wire harness clamp.

  13. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BE87E02

      Install 4 new No. 3 cylinder head cover gaskets to the cylinder head cover as shown in the illustration.

      Note


      • Do not install the gaskets at an angle.

      • Keep the lip of the gasket free from foreign materials.

    2. Install a new cylinder head cover gasket to the cylinder head cover.

    3. Remove old seal packing (FIPG) from the cylinder head.

    4. A01BHVSE01

      Apply a seal packing to the specific places described in the illustration.

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

      Note


      • After applying the seal packing, parts must be assembled within 3 minutes, and then tighten within 15 minutes.

      • Otherwise the material must be removed and reapplied.

      • Do not start the engine 2 hour after the installation.

    5. Install the cylinder head cover with 10 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    6. Connect the ventilation hose.

    7. Install a new nozzle holder seal.

  14. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. Temporarily install the nozzle leakage pipe with the 2 bolts.

    2. A01BEHR

      Install the new gasket and union bolt to the nozzle leakage pipe.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A01BCQO

      Tighten the 2 bolts.

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

  15. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. Using SST, tighten the injection pipe on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

    3. Using SST, tighten the injection pipe on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

  16. INSTALL INJECTION PIPE

    SST
    09023-12701

    Note


    • When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.

    • Keep clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. A01BFG2

        Temporarily install the 4 injection pipes.

      2. A01BC89

        Install the injection pipe clamp No.3 in 2 nuts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A01BFG2E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        SST
        09023-12701
        Torque:
        Use union nut wrench and torque wrench
        32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  17. INSTALL OIL LEVEL GAUGE GUIDE


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

    2. Apply a light coat of engine oil to the O-ring.

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

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

    4. Install the oil level gauge.

  18. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. A01BACYE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with EGR valve assembly to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose to the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

      5. A01BAPE

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. A01BHSL

        Install the vacuum regulating valve with the 2 bolts.

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

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  19. REMOVE INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BEP8E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. A01BDK1

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  20. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  21. INSTALL ENGINE SERVICE HOLE COVER NO.2


    1. Install the engine service hole cover No.2 with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A01BFN9

      Return the carpet.

  22. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Install the vane pump oil reservoir assembly with the 2 bolts.

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

  23. CONNECT WATER BY-PASS HOSE NO.3


    1. Connect the water by-pass hose No.3 with the clamp to the water by-pass pipe No.2.

  24. CONNECT RADIATOR HOSE NO.4


    1. Connect the radiator hose No.4 with the clamp to the water outlet.

  25. CONNECT AIR HOSE NO.4


    1. Connect the air hose No.4 with the clamp to the diesel throttle body.

  26. CONNECT OIL RETURN HOSE (w/ Intercooler)

  27. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  28. INSTALL VENTILATION HOSE HEAT INSULATOR


    1. Install the ventilation hose insulator heat with the 2 bolts.

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

  29. INSTALL VENTILATION PIPE


    1. Install the ventilation pipe with the bolt.

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

  30. INSTALL COMPRESSOR BRACKET (w/ Air Conditioning System)


    1. A01BFLCE02

      Temporarily install the compressor bracket with the 4 bolts.

      Tech Tips

      Make sure that the compressor bracket is in contact with the engine block.

    2. Install the compressor bracket by tightening the 4 bolts as shown in the illustration.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  31. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A01BFJ0E01

    1. Provisionally tighten the compressor and magnetic clutch with the 4 bolts.

    2. Tighten the compressor and magnetic clutch with the 4 bolts.

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

      Note

      Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

  32. INSTALL COMPRESSOR OUTLET ELBOW


    1. A01BCJBE01

      Install the compressor outlet elbow with the 2 bolts and 2 clamps.

      Torque:
      Bolt (A)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  33. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Install the air cleaner hose assembly with the clamp.

  34. INSTALL AIR TUBE ASSEMBLY


    1. Install the air tube assembly with the 2 clamps and 2 bolts.

  35. INSTALL FENDER APRON MUDGUARD SEAL RH

  36. INSTALL EXHAUST PIPE ASSEMBLY FRONT


    1. Inspect the compression spring.


      1. A01BCDO

        Using vernier calipers, measure the free length of the compression springs.

        Minimum length
        40.5mm(1.594 in.)

        Tech Tips

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

    2. A01BD65E03

      Install the gasket.


      1. Fully insert a new gasket to the exhaust manifold by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust manifold are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not reuse the gasket.

        • Do not damage the gasket.

        • To ensure a proper seal, do not use the exhaust pipe assembly front to force the gasket onto the front exhaust manifold.

    3. Connect the exhaust pipe support, and install the exhaust pipe assembly front and a new gasket with the 4 bolts, 2 compression springs and 2nuts.

      Torque:
      Exhaust manifold side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly center side
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }

      Note

      After installation, check that the clearance is almost same at any point between the flanges of the exhaust manifold and exhaust pipe assembly front .

  37. INSTALL FAN & GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  38. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

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

  39. INSTALL FRONT DOOR SCUFF PLATE RH

  40. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  41. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  42. INSTALL FRONT WHEEL

  43. CONNECT BATTERY NEGATIVE TERMINAL

  44. ADD ENGINE COOLANT


    1. Firmly tighten the drain plugs.

    2. Fill the radiator reservoir with coolant to the top of the inlet.

      Standard Capacity
      Item Specified Condition
      w/o Heater 13.6 liters (14.4 US qts, 12.0 Imp. qts)
      w/ Front Heater 14.6 liters (15.4 US qts, 12.8 Imp. qts)
      w/ Front and Rear Heaters 16.6 liters (17.5 US qts, 14.6 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • Use of improper coolants may damage the engine cooling system.

      • Use only Toyota Super Long Life Coolant or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and 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).

    3. Loosen the bleeder plug of the outlet housing.

    4. When air is bled and the coolant drains out, firmly tighten the bleeder plug.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A01BGFB

      Add coolant up to the B line mark in the radiator reservoir and install the reservoir cap.

    6. Warm up the engine until the thermostat opens.


      1. While the thermostat is open, circulate the coolant for several minutes.

        Tech Tips

        The thermostat open timing can be confirmed by pressing the inlet radiator hose by hand, and checking when the engine coolant starts to flow inside the hose.

    7. A01BBOM

      After the engine cools down, check that the coolant level is between the LOW and FULL level marks.

  45. BLEED FUEL LINE


    1. Move the priming pump in the upper part of the fuel filter assembly up and down, and fill the injection pump assembly and fuel system with fuel.

  46. CHECK FUEL LEAK


    1. PERFORM ACTIVE TEST


      1. Connect the intelligent tester to the DLC3.

      2. Turn the ignition switch on.

      3. Turn the intelligent tester on.

      4. Enter the following menus: Powertrain / ECD / 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/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON

  47. CHECK FOR ENGINE OIL LEAKS

  48. CHECK FOR ENGINE COOLANT LEAKS

    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.


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

    2. Warm up the engine.

    3. 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.

      Tech Tips

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

  49. CHECK EXHAUST LEAKAGE

  50. INSTALL ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

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

  51. CHECK IDLE SPEED

    Note

    This checking procedure should be done under the following condition.

    Tech Tips


    • Regarding the details about the intelligent tester, refer to its operator's manual.

    • If the intelligent tester is not available, a tachometer's tester probe can substitute for it.


    1. Connect the intelligent tester to the DLC3.

    2. A01BFMPE01

      If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18030

    3. Start the engine and check the idle speed.

      Idle speed
      700 to 800 rpm

      Tech Tips

      If the idle speed is not as specified, check by troubleshooting in the diagnostics section.

    4. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.

    5. Disconnect the intelligent tester from the DLC3.

  52. INSPECT MAXIMUM ENGINE SPEED

    Note

    This checking procedure should be done under the following condition.

    Tech Tips


    • Regarding the details about the intelligent tester, refer to its operator's manual.

    • If the intelligent tester is not available, a tachometer's tester probe can substitute for it.


    1. Connect the intelligent tester to the DLC3.

    2. A01BFMPE01

      If the tester is not available, connect a tester probe of a tachometer to terminal 9 (TAC) of the DLC3 with SST.

      SST
      09843-18030

    3. Start the engine.

    4. Depress the accelerator pedal all the way to the limit.

    5. Check the maximum speed.

      Maximum speed
      4500 to 4700 rpm

      Tech Tips

      If the maximum speed is not as specified, check by troubleshooting in the diagnostics section.

    6. In case of the tester probe of the tachometer is connected to the DLC3, disconnect the tester probe from terminal 9 of the DLC3 with SST.

    7. Disconnect the intelligent tester from the DLC3.

  53. CHECK FUNCTION OF THROTTLE BODY


    1. Inspect the throttle control motor.


      1. A01BB4C

        Using an ohmmeter, measure the resistance between the terminals.

        Standard resistance
        Tester Connection Specified Condition
        1 (DUTY) - Body ground Infinity

  54. PERFORM INITIALIZATION

    Click here