CYLINDER HEAD GASKET(w/o Glow Plug Controller) INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. A01LZISC01
      *a Front
      *b Protrusion
      *c X: Measurement Points

      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. A01M0UMN02

      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 Cutout Gasket Size

        0.525 to 0.575

        (0.02067 to 0.02264)

        		 1 A

        0.576 to 0.625

        (0.02268 to 0.02461)

        		 2 B

        0.626 to 0.675

        (0.02465 to 0.02657)

        		 3 C

        0.676 to 0.725

        (0.02661 to 0.02854)

        		 4 D

        0.726 to 0.775

        (0.02858 to 0.03051)

        		 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.

        A01M1MWC01
        *1 Cylinder Head Gasket - -
        *a Cylinder Head Side *b Cylinder Block Side
        Seal packing
        Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent

        Note

        Remove any oil from the contact surfaces.

      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 as shown in the illustration.

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

        Note


        • Remove any oil from the contact surfaces.

        • 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 INLET WATER HOSE RH


    1. A01LYAJC01
      *a Upper
      *b Rear
      *c View A

      Connect the inlet water hose RH to the outlet water sub-assembly.

  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 SUB-ASSEMBLY

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  11. CONNECT INLET WATER HOSE LH

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  12. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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  13. INSTALL NO. 2 TIMING CHAIN COVER

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  14. INSTALL ENGINE MOUNTING BRACKET RH

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  15. CHECK VALVE CLEARANCE

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  16. ADJUST VALVE CLEARANCE

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  17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  18. INSTALL HARNESS BRACKET

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  19. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  20. INSTALL VACUUM PUMP ASSEMBLY

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  21. INSTALL CAMSHAFT POSITION SENSOR (w/o Stop And Start System)

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  22. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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  23. INSTALL NO. 4 WATER BY-PASS HOSE

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  24. INSTALL NO. 2 OIL COOLER HOSE

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  25. INSTALL NO. 2 CYLINDER HEAD COVER

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  26. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

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  27. INSTALL COMMON RAIL ASSEMBLY

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  28. INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

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  29. TEMPORARILY INSTALL SUPPLY PUMP ASSEMBLY

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  30. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  31. INSTALL NO. 2 FUEL HOSE

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  32. INSTALL INJECTION NOZZLE SEAT

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  33. INSTALL INJECTOR ASSEMBLY

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  34. INSTALL NOZZLE HOLDER CLAMP SEAT

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  35. INSTALL NO. 1 NOZZLE HOLDER CLAMP

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  36. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  37. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

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  38. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

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  39. INSTALL GLOW PLUG ASSEMBLY

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  40. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  41. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

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  42. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

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  43. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  44. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

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  45. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  46. INSTALL ENGINE OIL LEVEL DIPSTICK

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

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  48. INSTALL HARNESS BRACKET

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  49. INSTALL NO. 1 EGR COOLER BRACKET

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  50. INSTALL EGR WITH COOLER PIPE ASSEMBLY

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  51. INSTALL GENERATOR BRACKET

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  52. INSTALL GENERATOR ASSEMBLY

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  53. INSTALL ENGINE COVER BRACKET (w/ No. 1 Engine Cover)

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  54. REMOVE ENGINE STAND

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