CYLINDER HEAD GASKET INSTALLATION


  1. INSTALL CYLINDER HEAD GASKET


    1. A01KEELE01

      Check 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, set the measuring tip as shown in the illustration.

      4. 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.

      5. A01KG0QE01
        Text in Illustration
        *a Measuring Tip
        *b Protrusion

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

      6. A01KEK7E01
        Text in Illustration
        *a Front
        *b Measuring Point

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

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

        Protrusion
        0.68 - 0.97 mm (0.00268 - 0.0382 in.)

        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.

        (See cylinder block disassembly and assembly)

    2. A01KGB7E01
      Text in Illustration
      *a Cutout Mark
      *b Front

      Select new cylinder head gasket

      Tech Tips

      There are 3 sizes of new cylinder head gaskets, marked "B", "D" or "F" accordingly.

      New installed cylinder head gasket thickness
      Mark B 1.40 - 1.50 mm (0.0551 - 0.0591 in.)
      Mark D 1.50 - 1.60 mm (0.0591 - 0.0630 in.)
      Mark F 1.60 - 1.70 mm (0.0630 - 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.

        Piston protrusion (mm (in.)) Gasket size
        0.68 - 0.77 (0.0268 - 0.0303) Use B
        0.78 - 0.87 (0.0307 - 0.0343) Use D
        0.88 - 0.97 (0.0346 - 0.0382) Use F
    3. A01KFGF

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

      Note

      Be careful of the installation direction.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    A01KE9PE01

    Tech Tips

    Set the No.1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.

    Text in Illustration
    *a Turn

    1. Using the crankshaft pulley bolt, turn the crankshaft 90° counterclockwise, and put the timing mark of the crankshaft timing pulley with the protrusion of the timing belt case.

    2. Place the cylinder head in position on the cylinder head gasket.

    3. A01KHS8E01

      Install cylinder head bolts

      Tech Tips


      • The cylinder head bolts are tightened in 3 progressive steps (steps (2), (4) and (5)).

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


      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:
        78 N*m  { 800 kgf*cm, 58 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.

      3. A01KIB3E01
        Text in Illustration
        *a Front
        *b Painted Mark

        Mark the front of the cylinder head bolt with paint.

      4. Re-tighten the cylinder head bolts 90° in the numerical order shown.

      5. Re-tighten cylinder head bolts by an additional 90°.

      6. Check that the painted mark is now facing rearward.

  3. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01KEP0E01
      Text in Illustration
      *a Seal Packing

      Remove any old packing (FIPG) material.

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

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

    3. Install the gasket to the cylinder head cover.

    4. Install the cylinder head cover with 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

  4. INSTALL CYLINDER HEAD COVER NO.2 (w/ Cylinder Head Cover No.2)


    1. Install the cylinder head cover silencer to the cylinder head cover.

    2. Install the cylinder head cover with the 4 plate washers and nuts.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  5. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  6. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. Install the intake air connector with the 3 nuts and bolt.

      Torque:
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }

  7. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.4

    Click here

  8. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.3

    Click here

  9. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.2

    Click here

  10. INSTALL INJECTION PIPE SUB-ASSEMBLY NO.1

    Click here

  11. INSTALL THROTTLE CONTROL CABLE SUPPORT

    Torque:
    19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  12. INSTALL EXHAUST PIPE ASSEMBLY FRONT

    Click here

  13. INSTALL EXHAUST FRONT PIPE ASSEMBLY NO.2

    Click here

  14. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A01KFQME01

      Install the heat insulator with the 3 bolts.

      Torque:
      A
      12 N*m  { 120 kgf*cm, 9 ft.*lbf }
      B
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  15. INSTALL ENGINE HANGER NO.2

  16. REMOVE TIMING BELT

    Click here

  17. INSTALL RADIATOR ASSEMBLY

    Click here

  18. INSTALL WATER BY-PASS HOSE NO.2 (w/ ACSD)

  19. INSTALL WATER BY-PASS HOSE (w/ ACSD)

  20. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT) (W/ HEATER)

  21. INSTALL HEATER WATER INLET HOSE A (W/ HEATER)

  22. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1

  23. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Torque:
    11.5 N*m  { 115 kgf*cm, 8.5 ft.*lbf }

  24. INSTALL PARKING BRAKE SHOE LEVER SUB-ASSEMBLY (W/O TILT CAB CAB TYPE)

    Click here

  25. INSTALL TRANSMISSION FLOOR SHIFT ASSEMBLY (W/O TILT CAB CAB TYPE)



  26. INSTALL FRONT SEAT ASSEMBLY (DRIVER SEAT) (W/O TILT CAB CAB TYPE)


    1. Temporarily install front side of the front seat assembly RH with the 2 bolts.

    2. Install the 2 rear side bolts.

      Torque:
      39.0 N*m  { 398 kgf*cm, 29 ft.*lbf }

    3. Tighten the 2 front side bolts.

      Torque:
      39.0 N*m  { 398 kgf*cm, 29 ft.*lbf }

    4. Install the seat track cover.

  27. CHECK ENGINE COOLANT LEAK

  28. REFILL ENGINE COOLANT

  29. BLEED INJECTION PIPE


    1. Move the priming pump in the upper part of the fuel filter assembly up and down, and fill the injection pump assembly and fuel system with fuel.

    2. Loosen one of the flare nuts (in the nozzle side).

    3. Crank the engine until fuel comes out from the flare nut (in the nozzle side).

    4. Tighten the flare nut.

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

    5. The above operations should be carried out in each injection pipe.

  30. CHECK FUEL LEAK