CYLINDER HEAD GASKET INSTALLATION

PROCEDURE


  1. INSTALL CYLINDER HEAD GASKET

    A005GLPE01

    1. Inspect the protrusion height of the piston heads.


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

        Text in Illustration
        A005GO2 Engine Front
        *a Protrusion
        *b Measuring Point

        Note

        Make sure that the dial indicator is at right angles to the cylinder block top surface.

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

    2. A005KV3E01

      Select a new cylinder head gasket.


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

        Piston Protrusion
        Piston Protrusion mm (in.) Gasket Cutout Gasket Size

        0.525 to 0.575

        (0.020 to 0.023)

        		 1 A

        0.576 to 0.625

        (0.023 to 0.025)

        		 2 B

        0.626 to 0.675

        (0.025 to 0.027)

        		 3 C

        0.676 to 0.725

        (0.027 to 0.029)

        		 4 D

        0.726 to 0.775

        (0.029 to 0.031)

        		 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 side 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.

      2. Place a new cylinder head gasket on the cylinder block 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 again as shown in the illustration.

        A005JC1E08
        Text in Illustration
        *1 Cylinder Head Gasket - -
        *a Cylinder Head Side *b Cylinder Block Side
        Seal packing
        Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      4. A005M4Q

        Install the cylinder head gasket onto the cylinder block.

        Note


        • Remove any oil from the contact surface.

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

  2. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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  3. CONNECT INLET WATER HOSE RH

    A005IZ0E01
    Text in Illustration
    *a View A
    *b Upper
    *c Rear

    1. Connect the inlet water hose RH.

  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. REPLACE TIMING CHAIN COVER OIL SEAL

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  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  12. CONNECT INLET WATER HOSE LH

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  13. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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  14. INSTALL NO. 2 TIMING CHAIN COVER

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  15. INSTALL ENGINE MOUNTING BRACKET RH

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  16. CHECK VALVE CLEARANCE

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  17. ADJUST VALVE CLEARANCE

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  18. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  19. INSTALL HARNESS BRACKET

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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 CAMSHAFT POSITION SENSOR

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  23. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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  24. INSTALL NO. 4 WATER BY-PASS HOSE

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  25. INSTALL NO. 2 OIL COOLER HOSE

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  26. INSTALL NO. 2 CYLINDER HEAD COVER

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  27. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

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  28. INSTALL COMMON RAIL ASSEMBLY

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  29. INSTALL SUPPLY PUMP DRIVE COUPLING

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  30. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

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  31. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  32. INSTALL NO. 2 FUEL HOSE

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  33. INSTALL INJECTION NOZZLE SEAT

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  34. INSTALL INJECTOR ASSEMBLY

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  35. INSTALL NOZZLE HOLDER CLAMP SEAT

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  36. INSTALL NO. 1 NOZZLE HOLDER CLAMP

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  37. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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  38. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

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  39. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

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  40. INSTALL GLOW PLUG ASSEMBLY

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  41. INSTALL NO. 1 GLOW PLUG CONNECTOR

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  42. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

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  43. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

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  44. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

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  45. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

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  46. INSTALL NO. 1 OIL HOSE

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  47. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

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  48. INSTALL ENGINE OIL LEVEL DIPSTICK

  49. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  50. INSTALL HARNESS BRACKET

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  51. INSTALL NO. 1 EGR COOLER BRACKET

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  52. INSTALL EGR WITH COOLER PIPE ASSEMBLY

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  53. INSTALL GENERATOR BRACKET

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  54. INSTALL GENERATOR ASSEMBLY

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  55. INSTALL ENGINE COVER BRACKET

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  56. INSTALL ENGINE ASSEMBLY

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