Cylinder Head Gasket Installation

Check the piston protrusion for each cylinder.

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

   Text in Illustration

   *a	Measuring Tip
   *b	Protrusion





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

   Text in Illustration

   *a	Measuring Point
   	Front

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.
   

Select a new cylinder head gasket.

Text in Illustration

*1	Cutout Mark
	Front

HINT:

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

Install the selected cylinder head gasket to the cylinder block.

NOTICE:

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

Be careful of the installation direction.

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

Turn

Place the cylinder head on the cylinder block.

NOTICE:

1. Make sure that no oil is on the mounting surface of the cylinder head.
   
2. Place the cylinder head on the cylinder block gently in order not to damage the gasket with the bottom part of the head.
   

Install the plate washers to the cylinder head bolts.

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

Step 1:

1. 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}

   HINT:

   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.
   

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.
   

Step 3:

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

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

Remove any old packing (FIPG material).

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

Seal packing:

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

Install the gasket to the cylinder head cover.

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}

Install the wiring harness clamp bracket with the bolt.

Torque:

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

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}

Attach the 4 wire harness clamps.

Install the generator wire with the nut.

Torque:

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

Install the terminal cap.

Connect the generator connector and cooler compressor connector.

for RHD:

1. Attach the 5 wire harness clamps.
   

for LHD:

1. Attach the 4 wire harness clamps.
   





2. Attach the 3 wire harness clamps.
   

Install the 2 lower clamps to the intake manifold.

Install the 4 injection pipes.

Torque:

25 N*m{250 kgf*cm, 18 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 2 upper pipe clamps with the 2 nuts.

Torque:

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

Connect the 2 water hoses.

Install the heater water hose clamp with the bolt.

Torque:

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

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}

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

Install the O-ring to the dipstick guide.

Install the dipstick guide with the 2 bolts.

Torque:

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

Install the dipstick.

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

Torque:

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

Connect the generator with the bolt.

Temporarily install the cooler compressor with the 2 bolts.

Temporarily install the idle pulley bracket with the 4 bolts.

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}

Connect the wire harness with the bolt.

Torque:

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

Connect the cooler compressor connector.

Install the diesel throttle body (LandCruiser RM0000012UX00HX.html).

Install the timing belt (LandCruiser RM00000126H00LX.html).

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}

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

Torque:

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

Install the clamp with the bolt.

Torque:

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

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

Tighten the radiator drain cock plug by hand.

Tighten the cylinder block drain cock plug.

Torque:

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

Slowly fill the system with engine coolant.

Standard capacity:

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

NOTICE:

Do not substitute plain water for engine coolant.

HINT:

1. 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.)
   
2. 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
   

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

Install the reservoir cap.

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.

Install the radiator cap.

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

HINT:

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.

Maintain the engine speed at 2000 to 2500 rpm.

NOTICE:

1. Make sure that the radiator reservoir still has some coolant in it.
   
2. Pay attention to the needle of the water temperature meter. Make sure that the needle does not show an abnormally high temperature.
   
3. If there is not enough coolant, the engine may burn out or overheat.
   
4. 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.
   
5. Run the engine at 2000 rpm until the coolant level has stabilized.
   

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

CAUTION:

1. Wear protective gloves. Heat areas on the parts may injure your hands.
   
2. Be careful as the radiator hoses are hot.
   
3. Keep your hands away from the fan.
   

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.

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.

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.

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

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

Tighten the union nut.

Torque:

25 N*m{250 kgf*cm, 18 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).

Perform the procedures above for each injection pipe.

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

Warm up the engine.

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.

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

HINT:

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

Warm up the engine.

When using the intelligent tester:

1. Connect the intelligent tester to the DLC3.
   

   Idle speed:

   720 to 820 rpm
   

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the idling speed, the shift lever should be in neutral.
      

   HINT:

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

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
   

   Text in Illustration

   *a	Front View of DLC3

   NOTICE:

   1. Turn all the electrical systems and the A/C off.
      
   2. When checking the idling speed, the shift lever should be in neutral.
      
   3. Confirm the terminal number before connecting them. Connecting the wrong terminal can be damage the engine.
      

Start the engine.

Fully depress the accelerator pedal.

Check the maximum speed.

Maximum engine speed:

4850 to 4950 rpm