CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. Check the piston protrusion for each cylinder.


      1. A01DMBXE02
        Text in Illustration
        *a Measuring Tip
        *b Protrusion

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

      2. A01DTCDE04
        Text in Illustration
        *a Measuring Point
        A01DQPB Front

        Measure the protrusion of each cylinder at 2 places 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 that cylinder.

        Standard protrusion
        0.68 to 0.98 mm (0.0268 to 0.0386 in.)

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

    2. A01DM2RE04
      Text in Illustration
      *1 Cutout Mark
      A01DQPB Front

      Select a new cylinder head gasket.

      Tech Tips

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

      New Cylinder Head Gasket Thickness
      Item Specified Condition
      Mark B 1.40 to 1.50 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.

        Gasket Size
        Piston Protrusion Gasket Size
        0.68 to 0.78 mm (0.0268 to 0.0307 in.) Use B
        0.78 to 0.88 mm (0.0307 to 0.0346 in.) Use D
        0.88 to 0.98 mm (0.0346 to 0.0385 in.) Use F
    3. A01DOGSE01

      Install the selected cylinder head gasket to the cylinder block.

      Note

      Make sure that the gasket is installed facing the proper direction.

      Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


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

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

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


    1. A01DPVB

      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.

      Text in Illustration
      A01DQPB Turn

    2. Place the cylinder head on the cylinder block.

      Note


      • Make sure that no oil is on the mounting surface of the cylinder head.

      • Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.

    3. Install the plate washers to the cylinder head bolts.

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

    5. Step 1:


      1. A01DS00E01

        Install and uniformly tighten the 18 cylinder head bolts, in several steps, in the sequence shown in the illustrations.

        Torque:
        78 N*m  { 795 kgf*cm, 58 ft.*lbf }

        Tech Tips

        Each bolt length is indicated below.

        Standard Bolt
        Item Length
        Bolt A 107 mm (4.21 in.)
        Bolt B 127 mm (5.00 in.)

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

    6. Step 2:


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

      2. Tighten the cylinder head bolts 90° in the sequence shown in step 1.

    7. Step 3:


      1. Tighten the cylinder head bolts another 90° in the sequence shown in step 1.

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

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old packing (FIPG material).

    2. A01DOCTE05
      Text in Illustration
      *1 Seal Packing

      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 nut in several steps.

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

  4. INSTALL WIRING HARNESS CLAMP BRACKET (for LHD)


    1. Install the wiring harness clamp bracket with the bolt.

      Torque:
      22 N*m  { 219 kgf*cm, 16 ft.*lbf }

  5. CONNECT WIRE HARNESS


    1. A01DSLIE01
      Text in Illustration
      *1 Nut
      *2 Washer
      *3 No. 2 Glow Plug Resistor Insulator
      *4 Engine Wire
      *5 No. 1 Glow Plug Connector
      *6 No. 1 Glow Plug Resistor Insulator
      *7 Bolt

      Connect the engine wire and install the No. 2 glow plug resistor insulator and washer with the nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01DPXQ

      Attach the 4 wire harness clamps.

    3. Install the generator wire with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Install the terminal cap.

    5. Connect the generator connector and cooler compressor connector.

    6. for RHD:


      1. A01DSJ1

        Attach the 5 wire harness clamps.

    7. for LHD:


      1. A01DRCX

        Attach the 4 wire harness clamps.

      2. A01DODL

        Attach the 3 wire harness clamps.

  6. INSTALL INJECTION PIPE SET


    1. Install the 2 lower clamps to the intake manifold.

    2. A01DQ8QE01
      Text in Illustration
      *a for Injection Nozzle Side
      *b for Injection Pump Side

      Install the 4 injection pipes.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Install the 2 upper pipe clamps with the 2 nuts.

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

  7. INSTALL HEATER WATER HOSE SUB-ASSEMBLY


    1. Connect the 2 water hoses.

    2. Install the heater water hose clamp with the bolt.

      Torque:
      14 N*m  { 138 kgf*cm, 10 ft.*lbf }

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01DT3XE01

      Install the insulator with the 3 bolts.

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

  9. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the 2 bolts.

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

    4. Install the dipstick.

  10. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

      Torque:
      81 N*m  { 829 kgf*cm, 60 ft.*lbf }

    2. Connect the generator with the bolt.

  11. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. A01DQ7FE01

      Temporarily install the cooler compressor with the 2 bolts.

    2. Temporarily install the idle pulley bracket with the 4 bolts.

    3. Tighten the 6 bolts in the sequence shown in the illustration.

      Torque:
      for bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      except bolt A
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    4. Connect the wire harness with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

    5. Connect the cooler compressor connector.

  12. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install the diesel throttle body Click here.

  13. INSTALL TIMING BELT


    1. Install the timing belt Click here.

  14. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for Long Wheelbase)


    1. Install a new gasket and the front exhaust pipe to the exhaust manifold with 3 new nuts.

      Torque:
      54 N*m  { 554 kgf*cm, 40 ft.*lbf }

    2. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

    3. Install the clamp with the bolt.

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

  15. BLEED AIR FROM FUEL SYSTEM


    1. A01DOMR

      Using the hand pump mounted on the fuel filter cap, bleed the air from the fuel system. Continue pumping until the pump resistance increases.

  16. ADD ENGINE COOLANT


    1. Tighten the radiator drain cock plug by hand.

    2. Tighten the cylinder block drain cock plug.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    3. Slowly fill the system with engine coolant.

      Standard capacity
      8.6 liters (9.0 US qts, 7.6 Imp. qts)

      Note

      Do not substitute plain water for engine coolant.

      Tech Tips


      • 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.)

      • New Toyota vehicles are filled with Toyota Super Long Life Coolant. When replacing the coolant, Toyota Super Long Life Coolant (color is pink, premixed ethylene glycol concentration is approximately 50% and freezing temperature is -35°C (-31°F)) is recommended

    4. Slowly pour coolant into the radiator reservoir until it reaches the Full line.

    5. Install the reservoir cap.

    6. Press the No. 1 and No. 2 radiator hoses several times by hand, and then check the coolant level. If the coolant level is low, add coolant.

    7. Install the radiator cap.

    8. Start the engine and warm it up until the thermostat opens.

      Tech Tips

      The thermostat opening timing can be confirmed by pressing the No. 2 radiator hose by hand and checking when the engine coolant starts to flow inside the hose.

    9. Maintain the engine speed at 2000 to 2500 rpm.

      Note


      • Make sure that the radiator reservoir still has some coolant in it.

      • Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.

      • If there is not enough coolant, the engine may burn out or overheat.

      • Immediately after starting the engine, if the radiator reservoir does not have any coolant, perform the following: 1) stop the engine, 2) wait until the coolant has cooled down, and 3) add coolant until the coolant is filled to the F line.

      • Run the engine at 2000 rpm until the coolant level has stabilized.

    10. Press the No. 1 and No. 2 radiator hoses several times by hand to bleed air.

      CAUTION:


      • Wear protective gloves. Heat areas on the parts may injure your hands.

      • Be careful as the radiator hoses are hot.

      • Keep your hands away from the fan.

    11. Stop the engine, and wait until the engine coolant cools down to ambient temperature.

      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.

    12. Check that the coolant level is between the Full and Low lines.

      If the coolant level is below the Low line, repeat all of the steps above.

      If the coolant level is above the Full line, drain coolant so that the coolant level is between the Full and Low lines.

  17. BLEED INJECTION PIPE


    1. Move the hand pump on the upper part of the fuel filter up and down and fill the injection pump and fuel system with fuel.

    2. Loosen one of the union nuts (on the nozzle side).

    3. Crank the engine until fuel comes out from the union nut connection (on the nozzle side).

    4. Tighten the union nut.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    5. Perform the procedures above for each injection pipe.

  18. INSPECT FOR COOLANT LEAK

    CAUTION:

    To avoid being burned, do not remove the radiator reservoir cap while the engine and radiator are still hot. Thermal expansion may cause hot engine coolant and steam to blow out from the radiator.


    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 123 kPa (1.3 kgf/cm2, 18 psi), and check that the pressure does not drop.

      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.

  19. INSPECT FOR FUEL LEAK


    1. Check that there are no fuel leaks anywhere in the fuel system after performing maintenance.

      Tech Tips

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

  20. INSPECT FOR EXHAUST GAS LEAK

  21. INSPECT ENGINE IDLE SPEED


    1. Warm up the engine.

    2. When using the intelligent tester:


      1. Connect the intelligent tester to the DLC3.

        Idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        Tech Tips

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

    3. A01DR2AE08
      Text in Illustration
      *a Front View of DLC3

      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.

        Standard idle speed
        720 to 820 rpm

        Note


        • Turn all the electrical systems and the A/C off.

        • When checking the idling speed, the shift lever should be in neutral.

        • Confirm the terminal number before connecting them. Connecting the wrong terminal can be damage the engine.

  22. INSPECT MAXIMUM ENGINE SPEED


    1. Start the engine.

    2. Fully depress the accelerator pedal.

    3. Check the maximum speed.

      Maximum engine speed
      4850 to 4950 rpm