CYLINDER HEAD GASKET INSTALLATION


  1. SELECT CYLINDER HEAD GASKET


    1. 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. A01IT5OE02
        Text in Illustration
        *1 Measuring Tip
        *2 Protrusion
        *3 Measuring Point

        Place a dial indicator on the cylinder block sub-assembly, 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. A01IONIE04

      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
      A01ISM9 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. A01INX8E01

      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 sub-assembly.

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

      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. A01IORYE02
        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. A01IUSOE02
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    7. Step 2:


      1. A01IO47E02
        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. A01IQP3E03
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    8. Step 3:


      1. A01ISDIE02
        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. A01IRI5E02
        Text in Illustration
        *1 Paint Mark
        *a Front

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

    9. A01INQYE02
      Text in Illustration
      *1 Cylinder Head Sub-assembly
      *2 Cylinder Block Sub-assembly
      *3 Seal Packing
      *a 15 mm or more

      Apply seal packing between the cylinder head sub-assembly and cylinder block sub-assembly 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 sub-assembly and cylinder block sub-assembly surfaces near the head gasket. Be sure to remove any oil that has seeped in between the cylinder head gasket and cylinder head sub-assembly or cylinder block sub-assembly.

      • 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 sub-assembly.

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

  4. INSTALL GLOW PLUG ASSEMBLY


    1. A01IO0HE01
      Text in Illustration
      *A for DPF
      *B for CCo
      *1 Color (White)
      *2 Mark (7V)
      *3 Color (Red)
      *4 Mark (11V)

      Check the insulator color and the mark on each glow plug assembly, and then, using a 10 mm deep socket wrench, install the 4 glow plugs.

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

      Note

      As the engine may be damaged, do not install any glow plug other than the type indicated in the illustration.

  5. INSTALL NO. 1 GLOW PLUG CONNECTOR (for DPF)


    1. Install the No. 1 glow plug connector with the 4 nuts.

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

    2. Attach the clamp to the bracket.

    3. Install the 4 grommets.

  6. INSTALL NO. 1 GLOW PLUG CONNECTOR (for CCo)


    1. Install the No. 1 glow plug connector with the 4 nuts.

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

    2. Connect the wire harness with the nut.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Install the 5 grommets.

  7. INSTALL FUEL INJECTOR SEAL (for DPF)


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

  8. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)

    Note

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


    1. Install a new gasket, the exhaust fuel addition injector assembly, 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.

      A01INO9E01
      Text in Illustration
      *1 Nozzle Holder Clamp

  9. INSTALL CAMSHAFT

    Click here

  10. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


  11. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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