CYLINDER HEAD GASKET INSTALLATION

Check the piston protrusions for each cylinder.

1. Clean the cylinder block with solvent.

2. Set the piston of the cylinder to be measured to slightly before TDC.

3. 

   Place a dial indicator on the cylinder block, and set the dial indicator at 0 mm (0 in.).

   Tech Tips

   
   

   • Use a dial indicator measuring tip as shown in the illustration.

   • Make sure that the measuring tip is square to the cylinder block gasket surface and piston head when taking the measurements.

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

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

   

   Text in Illustration

   *1	Measuring Tip	-	-
   *a	Front	*b	X Measuring Point
   *c	Protrusion	-	-

6. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

   Tech Tips

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

Text in Illustration

*a

Front

Select a new cylinder head gasket.

1. Select the largest piston protrusion value from the measurements made, then select the appropriate cylinder head gasket according to the table below.

   Piston protrusion mm (in.)	Gasket size
   0.005 - 0.054 (0.00019 - 0.00213)	Use A
   0.055 - 0.104 (0.00217 - 0.00409)	Use B
   0.105 - 0.154 (0.00413 - 0.00606)	Use C
   0.155 - 0.204 (0.00610 - 0.00803)	Use D
   0.205 - 0.255 (0.00807 - 0.01004)	Use E

Place a new cylinder head gasket in position on the cylinder block.

Install the cylinder head bolts.

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

2. Install and uniformly tighten the 18 cylinder head bolts, in several passes, in the sequence shown.

   Torque:

   85 N*m  { 867 kgf*cm, 63 ft.*lbf }

   Tech Tips

   Each bolt length is indicated in the illustration.

   Bolt length
   107 mm (4.12 in.) for A
   127 mm (5.00 in.) for B

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

Text in Illustration

*a	Front
*b	Painted Mark

Mark the front of the cylinder head bolt with paint.

Text in Illustration

*1	Key Groove

Rotate the crankshaft about 90° counterclockwise from the TDC position to lower the piston.

Text in Illustration

*a	Gear Point Mark
*b	Timing Mark

Mesh the gear point marks of the camshaft No. 1 and No. 2.

Text in Illustration

*a	Seal Packing
*b	Seal Width: 4 mm

Apply seal packing to the camshaft bearing cap No. 1 as shown in the illustration.

• Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.

  Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.

  Thoroughly clean all components to remove all the loose material.

  Using a non-residue solvent, clean both sealing surfaces.

• Apply seal packing to the bearing cap as shown in the illustration.

  Install a nozzle that has been cut to a 4 mm (0.16 in.) opening.

  Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

  Immediately remove nozzle from the tube and reinstall cap.

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

  Note

  Prevent FIPG from being stuck to the oil passage of the bearing cap No. 1.

Install the 5 bearing caps in their proper locations.

Install and uniformly tighten the 10 bearing cap bolts in several passes in the sequence shown.

Torque:

19 N*m  { 194 kgf*cm, 14 ft.*lbf }

Install the camshaft oil seal.

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

2. Using SST and a hammer, tap in the oil seal until its surface is flush with the oil seal retainer edge.

   SST

   09608-06041

Install a new gasket and intake manifold with the 4 bolts and 2 nuts.

Torque:

29 N*m  { 296 kgf*cm, 21 ft.*lbf }

Install the VSV assembly and 2 bolts.

Torque:

29 N*m  { 296 kgf*cm, 21 ft.*lbf }

Install the 2 gaskets, EGR control valve and EGR pipe sub-assembly.

Install the set key to the key groove of the camshaft.

Install the intake air connector with diesel throttle body assembly, new gasket, 2 bolts and 2 nuts.

Torque:

A

20 N*m  { 204 kgf*cm, 15 ft.*lbf }

B

19 N*m  { 194 kgf*cm, 14 ft.*lbf }