Cylinder Head Gasket Installation

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

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

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 (0.000197 to 0.0100 in.)

HINT:

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.

Select a new cylinder head gasket.

Text in Illustration

*1	Cutout Mark
	Front

HINT:

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

New Cylinder Head Gasket Thickness:

Mark	Specified Condition
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 gasket to the table below.
   
   

   Gasket Size:

   
   

   Item	Specified Condition
   Piston protrusion	0.005 to 0.054 mm (0.000197 to 0.00213 in.)	0.055 to 0.104 mm (0.00217 to 0.00409 in.)	0.105 to 0.154 mm (0.00413 to 0.00606 in.)	0.155 to 0.204 mm (0.00610 to 0.00803 in.)	0.205 to 0.255 mm (0.00807 to 0.0100 in.)
   Use gasket	A	B	C	D	E

Place the cylinder head gasket on the cylinder block.

Text in Illustration

Front

NOTICE:

Make sure the gasket is installed facing the proper direction.

Place the cylinder head on the cylinder head gasket.

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

Install the 18 washers with the 18 cylinder head bolts, and uniformly tighten the 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.)

Mark the front of each cylinder head bolt with paint.

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

Tighten the cylinder head bolts by an additional 90°.

Check that the painted marks are now facing rearward.

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

HINT:

Set the No. 1 cylinder to 90° BTDC/compression to prevent the top of the piston from hitting against the valve head.

Install the camshaft.

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

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

   Text in Illustration

   *1	Key Groove
   *a	Upward





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

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

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 (0.157 in.)

NOTICE:

1. Do not allow seal packing to contact the oil passage of the bearing cap.
   
2. After applying seal packing, install the camshaft bearing caps within 3 minutes and tighten the bolts within 15 minutes.
   
3. Do not start the engine for at least 2 hours after installation.
   

1. Install the 5 bearing caps to their proper locations.
   





2. 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}

Install a new camshaft oil seal.

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

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the surfaces of the camshaft bearing cap and cylinder head.
   

   SST

   09608-06041
   

Install the cylinder block insulator to the cylinder head.

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

Seal packing:

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

NOTICE:

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

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

Torque:

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

Install the camshaft timing pulley.

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

Torque:

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

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

Torque:

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

Check that the idler pulley moves smoothly.
If the idler pulley does not move smoothly, check the installation condition of the idler and washer.

Install the timing belt (LandCruiser RM000001479026X.html).

Install 4 new injection nozzle seats to the cylinder head.

Apply a small amount of clean engine oil to 4 new O-rings.

Install an O-ring to each injector as shown in the illustration.

Insert the 4 injectors into the cylinder head.

NOTICE:

1. Insert the injector until it touches the injection nozzle seat surface.
   
2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
   
3. Always return an injector to the same place it was removed from.
   

For an injector that has been replaced with a new injector, register the injector compensation code (LandCruiser RM0000012XK0ARX.html).

Temporarily install 4 new washers and the 4 No. 1 nozzle holder clamps with the 4 bolts.

HINT:

Apply a small amount of engine oil to the threads and under the heads of the clamp bolts.

NOTICE:

1. 
   
2. The fork portion of the nozzle holder clamp must be set on the injector.
   
3. Before tightening the bolts, check that the No. 1 nozzle holder clamp is set properly.
   
4. When installing the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque in the following step.
   
5. When tightening the bolts, pay attention so as not to tilt the bolt and the clamp.
   
6. Do not reuse the washer.
   
7. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.
   

   Text in Illustration

   *1	Nozzle Clamp Holder

Temporarily install the 4 injection pipes with the union nuts.

HINT:

To position the injectors, loosely tighten the union nut.

Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
If scratches or dents are present, replace the nozzle leakage pipe.

Set the leakage pipe and 5 new gaskets in place.

Apply a small amount of oil to the 4 injector hollow screws and union bolt.

Temporarily install the leakage pipe with the 4 injector hollow screws and union bolt.

Tighten the 4 holder clamp bolts.

Torque:

22 N*m{220 kgf*cm, 16 ft.*lbf}

Tighten the 4 hollow screws in order from 1 to 4.

Torque:

16 N*m{163 kgf*cm, 12 ft.*lbf}

NOTICE:

If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

Tighten the union bolt.

Torque:

13 N*m{127 kgf*cm, 9 ft.*lbf}

NOTICE:

If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

Remove the 4 injection pipes.

Check that there are no leaks from the nozzle leakage pipe connection.

1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).
   

   Part No.:

   23762-27010 (No. 2 nozzle leakage pipe)
   

   90904-30012 (Gasket)
   

   SST

   09280-00010
   

   Torque:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

2. Apply a small amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.
   





3. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, maintain 100 kPa (1.0 kgf/cm², 15 psi) of pressure for 60 seconds and check that no bubbles form.
   

   SST

   09992-00242
   

4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.
   

5. Remove SST, the No. 2 nozzle leakage pipe and gasket.
   

   NOTICE:

   Never reinstall the disassembled union bolt to the engine.

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

NOTICE:

1. Do not install the No. 3 cylinder head cover gaskets at an angle.
   
2. Check that there is no foreign matter at the installation location of the No. 3 cylinder head cover gaskets.
   

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

Apply seal packing to the areas shown in the illustration.

Seal packing:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installation.
   

Install a new gasket and the cylinder head cover with the 10 bolts and 2 nuts.

Torque:

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

Install 4 new nozzle holder seals.

Install the No. 3 vacuum transmitting pipe with the bolt.

Torque:

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

Connect the vacuum hose.

Install the No. 2 cylinder head cover with the 4 bolts.

Torque:

for bolt A:

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

for bolt B:

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

Install the common rail and No. 2 intake manifold insulator with the 2 bolts.

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Connect the fuel pressure sensor connectors and pressure discharge valve connector.

Install the No. 2 intake manifold insulator.

Temporarily install the fuel inlet pipe with the union nuts.

NOTICE:

1. When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.
   
2. Keep the fuel inlet pipe free of foreign matter.
   

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

Torque:

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

NOTICE:

Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench (LandCruiser RM000003YMD00TX.html).

Install the clamp with the bolt.

Torque:

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

NOTICE:

1. Install the clamp between the spools.
   
2. Do not overlap the clamp and spool.
   

Install the glow plugs (LandCruiser RM000000JIQ01GX.html).

Install the intake manifold (LandCruiser RM0000044GC015X.html).

Install the exhaust manifold with turbocharger (LandCruiser RM000002S6C00YX.html).

Add new engine oil.

Standard Oil Grade:

Oil Grade	Oil Viscosity (SAE)
G-DLD1, API CF-4, CF or ACEA B1 (You may also use API CE or CD)	- 5W-30 - 10W-30 - 15W-40 - 20W-50

Standard Capacity:

Item	Specified Condition
Drain and refill without oil filter change	6.7 liters (7.1 US qts, 5.9 Imp. qts)
Drain and refill with oil filter change	7.0 liters (7.4 US qts, 6.2 Imp. qts)
Dry fill	7.5 liters (7.9 US qts, 6.6 Imp. qts)

Install the oil filler cap.

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

NOTICE:

1. The maximum hand pump pumping speed is 2 strokes per second.
   
2. The hand pump must be pushed with a full stroke during pumping.
   
3. When the fuel pressure at the supply pump inlet port reaches a saturated pressure, the hand pump resistance increases.
   
4. 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.
   
5. 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.
   
6. 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.
   

Start the engine.

NOTICE:

1. 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.
   
2. Do not crank the engine continuously for more than 20 seconds. The battery may be discharged.
   
3. 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.
   

Turn the ignition switch off.

Connect the intelligent tester to the DLC3.

Turn the ignition switch on (IG) and turn the intelligent tester on.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

Start the engine.*1

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

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

Allow the engine to idle for 3 minutes or more after performing the Active Test for the 5th time.

HINT:

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.

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

Read Current DTCs.

Clear the DTCs (LandCruiser RM000000PDK1DJX.html).

HINT:

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.

Repeat steps *1 to *3.

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

Read Current DTCs.

OK:

No DTCs are output.

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Fill the radiator with TOYOTA Super Long Life Coolant (SLLC) to the B line of the reservoir tank.

Standard Capacity:

Item		Specified Condition
for Automatic Transmission	w/ Rear Heater	14.9 liters (15.7 US qts, 13.1 Imp. qts)
	w/o Rear Heater	13.1 liters (13.8 US qts, 11.5 Imp. qts)
for Manual Transmission	w/ Rear Heater	15.0 liters (15.8 US qts, 13.2 Imp. qts)
	w/o Rear Heater	13.2 liters (13.9 US qts, 11.6 Imp. qts)

HINT:

1. TOYOTA vehicles are filled with TOYOTA SLLC at the factory. In order to avoid damage to the engine cooling system and other technical problems, only use TOYOTA SLLC or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, 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).
   
2. Please contact your TOYOTA dealer for further details.
   
3. for Cold Area Specification Vehicles:
   Please contact any authorized TOYOTA dealer or repairer or another duly qualified and equipped professional for further details.
   

NOTICE:

Never use water as a substitute for engine coolant.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.
If the coolant level drops below the B line, add TOYOTA SLLC to the B line.

Install the radiator reservoir cap.

Using a wrench, install the vent plug.

Torque:

2.0 N*m{20 kgf*cm, 18 in.*lbf}

Bleed air from the cooling system.

1. Warm up the engine until the thermostat opens. While the thermostat is open, circulate the coolant for several minutes.
   

2. Maintain the engine speed at 2500 to 3000 rpm.
   

3. Press the inlet and outlet radiator hoses several times by hand to bleed air.
   

   CAUTION:

   When pressing the radiator hoses:

   1. Wear protective gloves.
      
   2. Be careful as the radiator hoses are hot.
      
   3. Keep your hands away from the radiator fan.
      

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

   CAUTION:

   Do not remove the radiator reservoir cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

After the coolant cools down, check that the coolant level is at the FULL line.
If the coolant level is below the FULL line, add TOYOTA SLLC to the FULL line.

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

Warm up the engine.

Using the 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 and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.

Start the engine. Make sure that there are no oil leaks from the areas that were worked on.

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.

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.

Disconnect the return hose from the common rail.

Start the engine and check for fuel leaks from the return pipe.
If there is fuel leakage, replace the common rail.

Connect the intelligent tester to the DLC3.

Start the engine and turn the intelligent tester on.

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

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.

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

NOTICE:

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

Reconnect the return hose to the common rail.

Warm up the engine, stop the engine and wait 5 minutes. The engine oil level should be between the dipstick low level mark and full level mark.
If low, check for leakage and add oil up to the full level mark.

NOTICE:

Do not fill engine oil above the full level mark.

HINT:

A certain amount of engine oil will be consumed while driving. In the following situations, engine oil consumption may increase, and engine oil may need to be refilled in between oil maintenance intervals.

1. When the engine is new, for example directly after purchasing the vehicle or after replacing the engine.
   
2. If low quality engine oil or oil of an inappropriate viscosity is used.
   
3. When driving at high engine speed or with a heavy load, when towing, or when driving while accelerating or decelerating frequently.
   
4. When leaving the engine idling for a long time, or when driving frequently through heavy traffic.
   

Install the No. 1 engine under cover with the 4 bolts.

Torque:

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

Install the lower front bumper cover with the clip and 5 bolts.

Torque:

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