CYLINDER HEAD INSTALLATION

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

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


  1. INSTALL CYLINDER HEAD GASKET


    1. A01E1XTE01

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

    2. A01DWGGE01

      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.

      Piston protrusion
      0.005 to 0.255 mm (0.0002 to 0.0100 in.)

      Tech Tips

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

    4. A01DXBTE01

      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. A01E1R6E01

      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. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


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

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


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

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

    3. A01E12RE01

      Install and uniformly tighten the 18 cylinder head bolts, 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.)
      Bolt length B
      167 mm (6.57 in.)

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

    4. A01DYXOE02

      Mark the front of the cylinder head bolts with paint.

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

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

    7. Check that the painted marks are now facing rearward.

  3. INSTALL CAMSHAFT

    A01E2S9E01

    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. A01DXL7E01

      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.

      3. A01DV15E01

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

    3. A01DYANE02

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

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

      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 contact the oil passage of the bearing cap.

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

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


      1. A01E2XHE01

        Install the 5 bearing caps in their proper locations.

      2. A01E0JJE02

        Apply a light coat of engine oil on 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 }

    5. Install the camshaft oil seal.

  4. INSPECT AND ADJUST VALVE CLEARANCE

    Click here

  5. INSTALL CYLINDER BLOCK INSULATOR (w/ EGR Cooler)


    1. Install the cylinder block insulator to the cylinder head.

  6. INSTALL NO. 2 TIMING BELT COVER


    1. A01E1J8E01

      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 its 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 }

  7. INSTALL CAMSHAFT TIMING PULLEY


    1. A01DV9RE01

      Install the camshaft timing pulley.

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

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

  8. CONNECT WIRE HARNESS

  9. INSTALL EXHAUST MANIFOLD


    1. Install a new gasket, manifold, 8 new collars and 8 spacers to the cylinder head with 8 new nuts.

      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.

  10. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


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

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

  11. CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)


    1. Connect the cooler compressor with the 4 bolts.

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

  12. INSTALL TURBOCHARGER SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  13. INSTALL TURBOCHARGER SUB-ASSEMBLY (w/o EGR Cooler)

    Click here

  14. INSTALL INJECTOR ASSEMBLY (w/ EGR Cooler)

    Click here

  15. INSTALL INJECTOR ASSEMBLY (w/o EGR Cooler)

    Click here

  16. INSTALL TIMING BELT

    Click here

  17. INSTALL COMMON RAIL ASSEMBLY (w/ EGR Cooler)

    Click here

  18. INSTALL COMMON RAIL ASSEMBLY (w/o EGR Cooler)

    Click here

  19. INSTALL GLOW PLUG ASSEMBLY (w/ EGR Cooler)

    Click here

  20. INSTALL GLOW PLUG ASSEMBLY (w/o EGR Cooler)

    Click here

  21. INSTALL INTAKE MANIFOLD (w/ EGR Cooler)

    Click here

  22. INSTALL INTAKE MANIFOLD (w/ EGR System without EGR Cooler)

    Click here

  23. INSTALL INTAKE MANIFOLD (w/o EGR System)

    Click here

  24. TIGHTEN FUEL TANK CAP ASSEMBLY

  25. ADD ENGINE OIL


    1. Wipe the oil pan and drain plug before installing the plug.

    2. Install a new gasket and the drain plug.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }

    3. Add new oil.

      Oil capacity
      Item Capacity
      Drain and refill with oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. qts)
      Drain and refill without oil filter change 6.6 liters (7.0 US qts, 5.8 Imp. qts)
      Dry fill 7.4 liters (7.8 US qts, 6.5 Imp. qts)

    4. Install the oil filler cap.

  26. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  27. BLEED AIR FROM FUEL SYSTEM


    1. A01DYNDE02

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

      Note


      • Hand pump pumping speed: Max. 2 strokes/ sec.

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

      • 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.

    2. Start the engine.

      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.

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

    3. Turn the ignition switch off.

    4. Connect the intelligent tester to the DLC3.

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

    6. Clear the DTCs Click here.

    7. Start the engine.*1

    8. A01DVKYE03

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

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

    10. Allow the engine to idle for 3 minutes or more after performing the Active Test for the fifth time.

      A01DYT1E05

      Tech Tips

      When the Active Test "Test the Fuel Leak" is used to change the pump control mode, the actual fuel pressure inside the common rail drops below the target fuel pressure when the Active Test is off, but this is normal and does not indicate a pump malfunction.

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

    12. Read Current DTCs.

    13. Clear the DTCs Click here.

      Tech Tips

      It is necessary to clear the DTCs as DTC P1604 or P1605 may be stored when air is bled from the fuel system after replacing or repairing fuel system parts.

    14. Repeat steps *1 to *3.

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

    16. Read Current DTCs.

      OK
      No DTCs are output.

  28. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes.


    2. Perform pilot quantity learning.


  29. INSPECT FOR OIL LEAK

  30. INSPECT FOR FUEL LEAK

    A01E2P1E01

    CAUTION:


    • During Active Test mode, engine speed becomes high and combustion noise becomes loud, so pay attention.

    • During Active Test mode, fuel becomes high-pressured. Be extremely careful not to expose your eyes, hands, or body to escaped fuel.


    1. Check that there are no leaks from any part of the fuel system when the engine is stopped. If there is fuel leakage, repair or replace parts as necessary.

    2. Start the engine and check that there are no leaks from any part of the fuel system. If there is fuel leakage, repair or replace parts as necessary.

    3. Disconnect the return hose from the common rail.

    4. Start the engine and check for fuel leaks from the return pipe.

      If there is fuel leakage, replace the common rail.

    5. Connect the intelligent tester to the DLC3.

    6. Start the engine and push the intelligent tester main switch ON.

    7. Select the Fuel Leak test from the Active Test mode on the intelligent tester.

    8. If the intelligent tester is not available, fully depress the accelerator pedal quickly. Increase the engine speed to the maximum and maintain that speed for 2 seconds. Repeat this operation several times.

    9. Check that there are no leaks from any part of the fuel system.

      Note

      A return pipe leakage of less than 10 cc (0.6 cu in.) per minute is acceptable.

      If there is fuel leakage, repair or replace parts as necessary.

    10. Reconnect the return hose to the common rail.

  31. INSPECT ENGINE OIL LEVEL


    1. Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low and full level marks.

      If the oil level is low, check for leakage and add oil up to the full level mark.

      Note

      Do not fill engine oil above the full level mark.

  32. INSTALL NO. 1 ENGINE UNDER COVER (for 4WD and Pre-Runner)

    Torque:
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }