CYLINDER HEAD INSTALLATION


  1. INSPECT CYLINDER HEAD SET BOLT


    1. A01BGI1E02

      Using vernier calipers, measure the minimum outer diameter of the compressed thread at the measuring point.

      Standard outer diameter
      11.80 to 12.00 mm (0.4646 to 0.4724 in.)
      Minimum outer diameter
      11.60 mm (0.4567 in.)

      If the outer diameter is less than the minimum, replace the bolt.

  2. INSTALL CYLINDER HEAD GASKET


    1. A01BARDE02

      Check piston protrusion for each cylinder.


      1. Clean the cylinder block with solvent.

      2. Set the piston of the cylinder to be measured to slightly before TDC.

      3. Place a dial indicator on the cylinder block, and set the measuring tip as shown in the illustration.

      4. Set the dial indicator at 0 mm (0 in.).

        Tech Tips


        • Use a dial indicator measuring tip as shown in the illustration.

        • Make sure that the measuring tip is square to the cylinder block gasket surface and piston head when taking the measurements.

      5. A01BFQXE01

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

      6. A01BACVE02

        Measure the protrusion of each cylinder at 2 places as shown in the illustration, making a total of 8 measurements.

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

        Protrusion
        0.68 to 0.97 mm (0.00268 to 0.0382 in.)

        Tech Tips

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

    2. A01BBRUE02

      Select a new cylinder head gasket.

      Tech Tips

      There are 3 sizes of new cylinder head gaskets, marked "B", "D" or "F" accordingly.

      New installed cylinder head gasket thickness:
      Mark B 1.40 to1.50 mm (0.0551 to 0.0591 in.)
      Mark D 1.50 to 1.60 mm (0.0591 to 0.0630 in.)
      Mark F 1.60 to 1.70 mm (0.0630 to 0.0669 in.)

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

        Piston protrusion mm (in.) Gasket size
        0.68 to 0.77 (0.0268 to 0.0303) Use B
        0.78 to 0.87 (0.0307 to 0.0343) Use D
        0.88 to 0.97 (0.0346 to 0.0382) Use F
    3. A01BBF7E01

      Place a new cylinder head gasket in position on the cylinder block.

      Note

      Be careful of the installation direction.

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips

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


    1. A01BAG8E01

      Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and align the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

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

    3. A01BFISE01

      Install cylinder head bolts.

      Tech Tips


      • The cylinder head bolts are tightened in 3 progressive steps (steps (2), (4) and (5))

      • 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, in several steps, in the sequence shown.

        Torque:
        78 N*m  { 800 kgf*cm, 58 ft.*lbf }

        Tech Tips

        Each bolt length is indicated below.

        Bolt length:

        107 mm (4.21 in.) for A

        127 mm (5.00 in.) for B

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

      3. A01BGAYE02

        Mark the front of the cylinder head bolt with paint.

      4. Retighten the cylinder head bolts 90° in the numerical order shown.

      5. Retighten the cylinder head bolts by an additional 90°.

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

  4. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01BHSPE02

      Remove the any oil packing (FIPG) material.

    2. Apply seal packing to the cylinder head as shown in the illustration.

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

    3. Install the gasket to the cylinder head cover.

    4. Install the cylinder head cover with the 9 bolts and nut. Uniformly tighten the bolts and nuts in several steps.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

    5. Connect the ventilation hose.

  5. INSTALL GLOW PLUG NO.1 CONNECTOR

    Torque:
    1.0 N*m  { 10 kgf*cm, 9 in.*lbf }

  6. INSTALL INJECTION PIPE SET


    1. Connect the 2 lower clamps on the intake manifold.

    2. Install the 4 injection pipes.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Secure the injection pipes with the 2 upper pipe clamps and 2 nuts.

      Torque:
      5.0 N*m  { 50 kgf*cm, 44 in.*lbf }

  7. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRON NO.1 (for Long Wheelbase)


    1. Install a new gasket and exhaust pipe sub-assembly front No.1 with the 3 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Tighten the clamp bolt, and install the exhaust pipe support bracket No.1 to the exhaust pipe sub-assembly front No.1.

  8. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRON NO.1


    1. Install a new gasket and exhaust pipe sub-assembly front No.1 with the 3 bolts.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

    2. Tighten the clamp bolt, install the exhaust pipe support bracket No.1 to the exhaust pipe sub-assembly front No.1.

  9. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Long Wheelbase)


    1. A01BCDO

      Inspect the compression spring.


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

        Minimum length
        40.5 mm (1.594 in.)

        Tech Tips

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

    2. A01BD65E05

      Install the gasket.


      1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not damage the outer face.

        • Do not reuse the gasket.

        • To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.

    3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.

      Torque:
      Exhaust pipe sub-assembly front No.1 side
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Exhaust pipe assembly tail 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 pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1.

  10. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.2 (for Super Long Wheelbase)


    1. A01BCDO

      Inspect the compression spring.


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

        Minimum length
        40.5 mm (1.594 in.)

        Tech Tips

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

    2. A01BD65E05

      Install the gasket.


      1. Fully insert a new gasket to the exhaust pipe sub-assembly front No.1 by hand.

      2. Using a wooden block, uniformly strike the gasket so that the gasket and exhaust pipe sub-assembly front No.1 are properly fit.

        Note


        • Be careful with the installation direction of the gasket.

        • Do not damage the gasket.

        • Do not reuse the gasket.

        • To ensure a proper seal, do not use the exhaust pipe sub-assembly front No.2 to force the gasket onto the exhaust pipe sub-assembly front No.1.

    3. Connect the exhaust pipe support, and install a new gasket and the exhaust pipe sub-assembly front No.2 with the 4 bolts, 2 nuts, and 2 compression springs.

      Torque:
      Exhaust pipe sub-assembly front No.1 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 pipe sub-assembly front No.2 and exhaust pipe sub-assembly front No.1 .

  11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A01BDOWE01

      Install the heat insulator with the 3 bolts.

      Torque:
      Bolt (A)
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
      Bolt (B)
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  12. INSTALL VENTURI ASSEMBLY


    1. Install a new gasket and venturi.

    2. A01BFXZE01

      Connect the throttle control motor connector.

    3. A01BAY2E01

      Connect the throttle open switch connector.

  13. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. A01BCJN

      Install a new gasket and intake air connector with the bolt and 3 nuts.

      Torque:
      bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the turbo pressure sensor connector.

    3. Connect the ventilation hose.

  14. CONNECT AIR CLEANER HOSE NO.2


    1. Install the air cleaner hose No.2 with the clamp.

  15. INSTALL TIMING BELT

    Click here

  16. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

  17. BLEED AIR FROM FUEL SYSTEM


    1. A01BEO7E01

      Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

  18. 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 12.7 liters (13.4 US qts, 11.2 Imp. qts)
      w/ Front Heater 13.7 liters (14.5 US qts, 12.1 Imp. qts)
      w/ Front and Rear Heaters 15.7 liters (16.6 US qts, 13.8 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. A01BGFB

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

    4. 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.

    5. A01BBOM

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

  19. 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 118 kPa (1.2 kgf/cm2, 17.1 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.

  20. CHECK FOR FUEL LEAKS


    1. Check that there are no fuel leaks anywhere on the fuel system after doing maintenance.

      Tech Tips

      When checking for fuel leaks, make sure that there is pressure in the fuel line.

  21. CHECK FOR EXHAUST GAS LEAKS

  22. CHECK IDLE SPEED


    1. Warm up the engine.

    2. When using an intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Tech Tips

        Refer to the intelligent tester operator's manual for further details.

    3. A01BAF6E02

      When not using an intelligent tester:


      1. Using SST, connect the tachometer test probe to terminal 9 (TAC) of the DLC3.

        SST
        09843-18040

      2. Check the idle speed.

        Idle speed
        720 to 820 rpm (A/C OFF)
        750 to 850 rpm (A/C ON)

        Note

        Switch off all accessories.

  23. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Depress the accelerator pedal all the way.

    3. Check the maximum speed.

      Maximum speed
      4,850 to 4,950 rpm

  24. PERFORM INITIALIZATION

    Click here