CYLINDER HEAD GASKET(w/o Glow Plug Controller) INSTALLATION
PROCEDURE
INSTALL CYLINDER HEAD GASKET
-
*a
Front
*b
Protrusion
*c
X: Measurement Points
Inspect the protrusion height of the piston heads.
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.
Measure the protrusion height of the piston head of each cylinder at 2 points as shown in the illustration.
-
Select a new cylinder head gasket.
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
Install the cylinder head gasket.
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.
*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.
Place a new cylinder head gasket on the cylinder block sub-assembly with the Lot No. stamp facing upward.
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.
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INSTALL CYLINDER HEAD SUB-ASSEMBLY
CONNECT INLET WATER HOSE RH
-
*a
Upper
*b
Rear
*c
View A
Connect the inlet water hose RH to the outlet water sub-assembly.
-
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL CAMSHAFT
INSTALL CHAIN SUB-ASSEMBLY
INSTALL NO. 1 CHAIN VIBRATION DAMPER
INSTALL CHAIN TENSIONER SLIPPER
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
CONNECT INLET WATER HOSE LH
INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
INSTALL NO. 2 TIMING CHAIN COVER
INSTALL ENGINE MOUNTING BRACKET RH
CHECK VALVE CLEARANCE
ADJUST VALVE CLEARANCE
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
INSTALL HARNESS BRACKET
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
INSTALL VACUUM PUMP ASSEMBLY
INSTALL CAMSHAFT POSITION SENSOR (w/o Stop And Start System)
INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
INSTALL NO. 4 WATER BY-PASS HOSE
INSTALL NO. 2 OIL COOLER HOSE
INSTALL NO. 2 CYLINDER HEAD COVER
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
INSTALL COMMON RAIL ASSEMBLY
INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING
TEMPORARILY INSTALL SUPPLY PUMP ASSEMBLY
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
INSTALL NO. 2 FUEL HOSE
INSTALL INJECTION NOZZLE SEAT
INSTALL INJECTOR ASSEMBLY
INSTALL NOZZLE HOLDER CLAMP SEAT
INSTALL NO. 1 NOZZLE HOLDER CLAMP
INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY
INSTALL NOZZLE LEAKAGE PIPE SET CLAMP
INSTALL NO. 2 INTAKE MANIFOLD INSULATOR
INSTALL GLOW PLUG ASSEMBLY
INSTALL NO. 1 GLOW PLUG CONNECTOR
INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY
INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY
INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY
INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
INSTALL ENGINE OIL LEVEL DIPSTICK
INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)
INSTALL HARNESS BRACKET
INSTALL NO. 1 EGR COOLER BRACKET
INSTALL EGR WITH COOLER PIPE ASSEMBLY
INSTALL GENERATOR BRACKET
INSTALL GENERATOR ASSEMBLY
INSTALL ENGINE COVER BRACKET (w/ No. 1 Engine Cover)
REMOVE ENGINE STAND