CYLINDER HEAD GASKET INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement

    • Injector assembly (including shuffling the injector assemblies between the cylinders)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET


    1. B0027CFC01
      *a Measuring Tip
      *b Protrusion

      Check the piston protrusions for each cylinder.


      1. Clean the cylinder block sub-assembly 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 sub-assembly, and position the measuring tip as shown in the illustration.

      4. Set the dial indicator at 0 mm (0 in.)

        Tech Tips

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

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

    3. B0026LFC01
      *a Measuring Point

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

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

      Standard piston protrusion
      0.005 to 0.255 mm (0.000197 to 0.0100 in.)

      Tech Tips

      When installing the piston and connecting rod sub-assembly, if the protrusion is not as specified, remove the piston and connecting rod sub-assembly and reinstall them.

    5. B00286DC01
      *a Cutout Mark
      B0068HS Front

      Select a new cylinder head gasket.

      Tech Tips

      New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

      New Cylinder Head Gasket Thickness
      Mark Specified Condition
      A 0.80 to 0.90 mm (0.0315 to 0.0354 in.)
      B 0.85 to 0.95 mm (0.0335 to 0.0374 in.)
      C 0.90 to 1.00 mm (0.0354 to 0.0394 in.)
      D 0.95 to 1.05 mm (0.0374 to 0.0413 in.)
      E 1.00 to 1.10 mm (0.0394 to 0.0433 in.)

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

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.005 to 0.054 mm (0.000197 to 0.00213 in.) 0.055 to 0.104 mm (0.00217 to 0.00409 in.) 0.105 to 0.154 mm (0.00413 to 0.00606 in.) 0.155 to 0.204 mm (0.00610 to 0.00803 in.) 0.205 to 0.255 mm (0.00807 to 0.0100 in.)
        Gasket to be used A B C D E

    6. Place the cylinder head sub-assembly on the cylinder block sub-assembly.

      Note

      Make sure the cylinder head gasket is installed facing the proper direction.

      B0027LAC01
      B0068HS Front

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Tech Tips


    • The cylinder head set bolts are tightened in 3 progressive steps.

    • If any cylinder head set bolt is broken or deformed, replace it.


    1. Place the cylinder head sub-assembly on the cylinder head gasket.

    2. Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.

    3. B0028SWC01
      B0068HS Bolt A
      B006964 Bolt B

      Install and uniformly tighten the 18 cylinder head set bolts and 18 washers in several passes in the sequence shown in the illustration.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Standard Bolt Length
      Item Specified Condition
      Bolt A 110 mm (4.33 in.)
      Bolt B 167 mm (6.57 in.)

      If any of the cylinder head set bolts does not meet the torque specification, replace it.

    4. B00292EC07
      *a Front
      *b Paint Mark

      Mark the front of each cylinder head set bolt with paint.

    5. Further tighten the cylinder head set bolts by 90° in the sequence shown in the illustration above.

    6. Finally, tighten the cylinder head set bolts by an additional 90°.

    7. Check that the painted mark are now facing rearward.

  3. INSTALL VALVE LIFTER

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  4. INSTALL CAMSHAFT SUB-ASSEMBLY

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  5. INSTALL NO. 2 TIMING BELT COVER


    1. B00266JC01
      *a Seal Packing

      Apply seal packing (FIPG) to the specified areas shown in the illustration.

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

      Note

      After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

    2. Clean the bolts and their holes.

    3. Apply adhesive to 2 or 3 threads at the end of 4 bolts.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    4. Install the No. 2 timing belt cover to the cylinder head sub-assembly and timing gear cover with the 4 bolts and nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  6. INSTALL CAMSHAFT TIMING PULLEY


    1. B0024F1

      Install the camshaft timing pulley to the intake camshaft sub-assembly.

    2. Fasten the bolt of the camshaft timing pulley by holding the intake camshaft sub-assembly with a wrench.

      Torque:
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

  7. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

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  8. INSTALL TIMING BELT

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  9. INSPECT AND ADJUST VALVE CLEARANCE

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  10. INSTALL NO. 1 TIMING BELT COVER

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  11. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

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  12. CONNECT COOLER COMPRESSOR ASSEMBLY

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  13. INSTALL FAN SHROUD

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  14. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

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  15. INSTALL COMMON RAIL ASSEMBLY

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  16. INSTALL INJECTOR ASSEMBLY

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  17. INSTALL GLOW PLUG ASSEMBLY

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  18. INSTALL INTAKE MANIFOLD

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  19. ADD ENGINE OIL

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  20. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

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  21. BLEED AIR FROM FUEL SYSTEM

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  22. ADD ENGINE COOLANT

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  23. INSPECT FOR COOLANT LEAK

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  24. INSPECT FOR OIL LEAK

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  25. INSPECT FOR FUEL LEAK

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  26. INSPECT ENGINE OIL LEVEL

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