CYLINDER HEAD GASKET(w/ Glow Plug Controller) INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B0043EUC01
      *a Protrusion
      *b Measurement Points
      B0042CO Front of Engine

      Inspect the protrusion height of the piston heads.


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

        Note

        Make sure that the dial indicator is at a right angle to the cylinder block sub-assembly top surface.

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

    2. B0043N1N02

      Select a new cylinder head gasket.


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

        Piston Protrusion

        Piston Protrusion

        mm (in.)

        		 Number of Gasket Cutouts Gasket Size

        0.525 to 0.575

        (0.0207 to 0.0226)

        		 1 (A)

        0.576 to 0.625

        (0.0227 to 0.0246)

        		 2 (B)

        0.626 to 0.675

        (0.02465 to 0.02657)

        		 3 (C)

        0.676 to 0.725

        (0.0266 to 0.0285)

        		 4 (D)

        0.726 to 0.775

        (0.0286 to 0.0305)

        		 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 sub-assembly as shown in the illustration.

        B00449GC02
        *1 Cylinder Head Gasket - -
        *a Cylinder Head Side *b Cylinder Block Side
        *c Seal Packing *d Lot No.
        *e 18.0 mm (0.709 in.) *f 1.0 to 6.0 mm (0.0394 to 0.236 in.)
        *g 18.5 mm (0.728 in.) - -
        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 sub-assembly 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 sub-assembly again 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.

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

        • Do not start the engine for at least 2 hours after installing the cylinder head gasket.

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  3. CONNECT WATER INLET HOSE RH


    1. B0044JLC01
      *a View (A)
      *b Upper of Engine
      *c Rear of Engine

      Connect the water inlet hose RH to the water outlet sub-assembly and slide the hose clip to secure it.

      Note

      Perform the installation with the hose clip at the correct angle.

  4. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  5. INSTALL CAMSHAFT

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  6. INSTALL CHAIN SUB-ASSEMBLY

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  7. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  8. INSTALL CHAIN TENSIONER SLIPPER

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  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  10. INSTALL TIMING CHAIN COVER OIL SEAL

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  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  12. CONNECT WATER INLET HOSE LH

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  13. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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  14. INSTALL CAMSHAFT POSITION SENSOR

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  15. INSTALL NO. 2 TIMING CHAIN COVER

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  16. INSTALL ENGINE MOUNTING BRACKET RH

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  17. CHECK VALVE CLEARANCE

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  18. ADJUST VALVE CLEARANCE

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  19. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  20. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  21. INSTALL VACUUM PUMP ASSEMBLY

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  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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  23. INSTALL NO. 2 OIL COOLER HOSE

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  24. INSTALL INJECTION NOZZLE SEAT

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  25. INSTALL INJECTOR ASSEMBLY

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  26. INSTALL NOZZLE HOLDER CLAMP SEAT

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  27. INSTALL NO. 1 NOZZLE HOLDER CLAMP

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  28. INSTALL COMMON RAIL ASSEMBLY

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  29. INSTALL GLOW PLUG ASSEMBLY

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  30. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  31. INSTALL SUPPLY PUMP ASSEMBLY

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  32. INSTALL FUEL PUMP PROTECTOR

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  33. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

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  34. CONNECT NO. 2 FUEL HOSE

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  35. CONNECT NO. 1 FUEL HOSE

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  36. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

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  37. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  38. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  39. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

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  40. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

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  41. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  42. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

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  43. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  44. INSTALL ENGINE OIL LEVEL DIPSTICK

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  45. INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

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  46. INSTALL HARNESS BRACKET (for LHD)

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  47. INSTALL HARNESS BRACKET (for RHD)

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  48. INSTALL NO. 1 EGR COOLER BRACKET

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  49. INSTALL EGR WITH COOLER PIPE ASSEMBLY

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  50. INSTALL GENERATOR BRACKET

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  51. INSTALL GENERATOR ASSEMBLY

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  52. INSTALL ENGINE COVER BRACKET

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  53. REMOVE ENGINE FROM ENGINE STAND

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