CYLINDER HEAD GASKET INSTALLATION


  1. SELECT CYLINDER HEAD GASKET


    1. 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. A00OUH8E02
        Text in Illustration
        *1 Measuring Tip
        *2 Protrusion
        *3 Measuring Point

        Place a dial indicator on the cylinder block, and set 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 perpendicular to the cylinder block gasket surface and piston head when taking the measurements.

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

      6. 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.

        Standard piston protrusion
        0.300 to 0.560 mm (0.0118 to 0.0220 in.)

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

    2. A00OUAWE04

      Select a new cylinder head gasket.

      New Installed Cylinder Head Gasket Thickness
      Cutout Mark Specified Condition
      A 1.00 to 1.10 mm (0.0394 to 0.0433 in.)
      B 1.05 to 1.15 mm (0.0413 to 0.0453 in.)
      C 1.10 to 1.20 mm (0.0433 to 0.0472 in.)
      D 1.15 to 1.25 mm (0.0453 to 0.0492 in.)
      E 1.20 to 1.30 mm (0.0472 to 0.0512 in.)
      Text in Illustration
      A00OV9Z Front

      Tech Tips

      Cylinder head gaskets are marked A, B, C, D or E accordingly.


      1. Select the largest piston protrusion value from the measurements and then select a new appropriate gasket according to the table below.

        Gasket Size
        Item Specified Condition
        Piston protrusion 0.300 to 0.355 mm (0.0118 to 0.0140 in.) 0.355 to 0.405 mm (0.0140 to 0.0159 in.) 0.405 to 0.455 mm (0.0159 to 0.0179 in.) 0.455 to 0.505 mm (0.0179 to 0.0199 in.) 0.505 to 0.560 mm (0.0199 to 0.0220 in.)
        Gasket to be used A B C D E

  2. INSTALL CYLINDER HEAD GASKET

  3. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    1. A00OR5UE01

      Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

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

    3. Place the cylinder head on the cylinder block.

      Note

      Be careful of the installation direction.

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

    5. Temporarily install the cylinder head bolts.

      Tech Tips

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

    6. Step 1:

      For new bolts, perform steps 1 to 3. For used bolts, perform only step 1.


      1. A00OUBVE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Uniformly tighten the 10 cylinder head bolts, in several steps in the sequence shown in the illustration.

        Torque:
        50 N*m  { 510 kgf*cm, 37 ft.*lbf }

        Tech Tips

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

      2. Mark the front of the cylinder head bolts with paint.

      3. Tighten the cylinder head bolts by 90° in the sequence shown in the illustration.

      4. Perform the step above twice.

      5. A00OROEE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    7. Step 2:


      1. A00OUHRE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Loosen the cylinder head bolts by 90° in the sequence shown in the illustration.

      2. Perform the step above again.

      3. A00ORLFE03
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    8. Step 3:


      1. A00OSGLE02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.

      2. Perform the above step twice.

      3. A00OSO0E02
        Text in Illustration
        *1 Paint Mark
        *a Front

        Check that the paint marks are positioned as shown in the illustration.

    9. A00OUF0E02
      Text in Illustration
      *1 Cylinder Head
      *2 Cylinder Block
      *3 Seal Packing
      *a 15 mm or more

      Apply seal packing between the cylinder head and cylinder block in the areas shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard seal packing application length
      15 mm (0.591 in.) or more

      Note


      • Before applying seal packing, clean the cylinder head and cylinder block surfaces near the head gasket. Be sure to remove any oil that has seeped in between the gasket and cylinder head or cylinder block.

      • When the contact surfaces are wet, wipe them off with an oil-free cloth before applying seal packing.

      • Wipe off any seal packing that seeps out from the groove in the cylinder head.

      • Do not start the engine for at least 4 hours after installation.

  4. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 10 mm deep socket wrench, install the 4 glow plugs.

      Torque:
      12 N*m  { 125 kgf*cm, 9 ft.*lbf }

    2. Install the glow plug connector with the 4 nuts.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    3. Install the 4 grommets.

  5. INSTALL FUEL INJECTOR SEAL


    1. Install a new fuel injector seal to the exhaust fuel addition injector.

  6. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Note

    If there is foreign matter on the installation surface of the exhaust fuel addition injector, be sure to clean the injector before installation.


    1. Install a new gasket, the exhaust fuel addition injector, the nozzle holder clamp, and the washer with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Align the nozzle holder clamp with the cutouts of the injector as shown in the illustration.

      A00ORGFE01
      Text in Illustration
      *1 Nozzle Holder Clamp

  7. INSTALL CAMSHAFT

    Click here

  8. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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