CYLINDER HEAD GASKET INSTALLATION

PROCEDURE

1. Click here

   INSTALL CYLINDER HEAD GASKET

   
   

   1. Inspect the protrusion height of the piston heads.

      
      

      1. Place a dial indicator on the cylinder block as shown in the illustration.

         Table 1. Text in Illustration

         	Engine Front
         *a	Protrusion
         *b	Measuring Point

         Note:

         Make sure that the dial indicator is at right angles to the cylinder block top surface.

      2. Measure the protrusion height of the piston head of each cylinder at 2 places as shown in the illustration.

   2. 

      Select a new cylinder head gasket.

      
      

      1. Select the highest protrusion height among the 8 measurements recorded. It is used to select a new cylinder head gasket.

         Piston Protrusion
         Piston Protrusion mm (in.) Gasket Cutout Gasket Size 0.525 to 0.575 (0.020 to 0.023) 1 A 0.576 to 0.625 (0.023 to 0.025) 2 B 0.626 to 0.675 (0.025 to 0.027) 3 C 0.676 to 0.725 (0.027 to 0.029) 4 D 0.726 to 0.775 (0.029 to 0.031) 5 E

   3. Install the cylinder head gasket.

      
      

      1. Apply seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) to the cylinder block side as shown in the illustration.

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

         Note:

         Remove any oil from the contact surface.

      2. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

      3. 

         Apply seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.)) to the top surface of the cylinder head again as shown in the illustration.

         Table 2. Text in Illustration

         *1	Cylinder Head Gasket	-	-
         *a	Cylinder Head Side	*b	Cylinder Block Side

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

      4. 

         Install the cylinder head gasket onto the cylinder block.

         Note:
         

         • Remove any oil from the contact surface.

         • Install the cylinder head within 3 minutes, and tighten the bolts within 15 minutes of applying the seal packing.

2. Click here

   INSTALL CYLINDER HEAD SUB-ASSEMBLY

   Click here

3. Click here

   CONNECT WATER INLET HOSE RH

   
   

   1. Connect the water inlet hose RH.

      Table 3. Text in Illustration

      *a	View A
      *b	Upper
      *c	Rear

4. Click here

   INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

   Click here

5. Click here

   INSTALL CAMSHAFT

   Click here

6. Click here

   INSTALL CHAIN SUB-ASSEMBLY

   Click here

7. Click here

   INSTALL NO. 1 CHAIN VIBRATION DAMPER

   Click here

8. Click here

   INSTALL CHAIN TENSIONER SLIPPER

   Click here

9. Click here

   INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

   Click here

10. Click here

    INSTALL TIMING CHAIN COVER OIL SEAL

    Click here

11. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/ DPF)

    Click here

12. Click here

    INSTALL TIMING CHAIN COVER SUB-ASSEMBLY (w/o DPF)

    Click here

13. Click here

    CONNECT WATER INLET HOSE LH

    Click here

14. Click here

    INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

    Click here

15. Click here

    INSTALL NO. 3 TIMING CHAIN COVER (w/o DPF)

    Click here

16. Click here

    INSTALL NO. 2 TIMING CHAIN COVER (w/ DPF)

    Click here

17. Click here

    INSTALL NO. 2 TIMING CHAIN COVER (w/o DPF)

    Click here

18. Click here

    INSTALL ENGINE MOUNTING BRACKET RH

    Click here

19. Click here

    CHECK VALVE CLEARANCE

    Click here

20. Click here

    ADJUST VALVE CLEARANCE

    Click here

21. Click here

    INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

22. Click here

    INSTALL HARNESS BRACKET

    Click here

23. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

24. Click here

    INSTALL VACUUM PUMP ASSEMBLY

    Click here

25. Click here

    INSTALL CAMSHAFT POSITION SENSOR

    Click here

26. Click here

    INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

27. Click here

    INSTALL NO. 4 WATER BY-PASS HOSE

    Click here

28. Click here

    INSTALL NO. 2 OIL COOLER HOSE

    Click here

29. Click here

    INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

30. Click here

    INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

31. Click here

    INSTALL COMMON RAIL ASSEMBLY

    Click here

32. Click here

    INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

    Click here

33. Click here

    TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

    Click here

34. Click here

    INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

35. Click here

    INSTALL NO. 2 FUEL HOSE

    Click here

36. Click here

    INSTALL INJECTION NOZZLE SEAT

    Click here

37. Click here

    INSTALL INJECTOR ASSEMBLY

    Click here

38. Click here

    INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

39. Click here

    INSTALL NO. 1 NOZZLE HOLDER CLAMP

    Click here

40. Click here

    INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

41. Click here

    INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

    Click here

42. Click here

    INSTALL NO. 1 FUEL PIPE

    Click here

43. Click here

    INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

44. Click here

    INSTALL GLOW PLUG ASSEMBLY

    Click here

45. Click here

    INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

46. Click here

    INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

47. Click here

    INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

48. Click here

    INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

49. Click here

    INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

    Click here

50. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

    Click here

51. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

52. Click here

    INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

53. Click here

    INSTALL HARNESS BRACKET

    Click here

54. Click here

    INSTALL NO. 1 EGR COOLER BRACKET

    Click here

55. Click here

    INSTALL EGR WITH COOLER PIPE ASSEMBLY

    Click here

56. Click here

    INSTALL GENERATOR BRACKET

    Click here

57. Click here

    INSTALL GENERATOR ASSEMBLY

    Click here

58. Click here

    INSTALL ENGINE COVER BRACKET

    Click here

59. Click here

    INSTALL ENGINE ASSEMBLY

    (Click here)