CYLINDER HEAD GASKET INSTALLATION

PROCEDURE

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. 

         *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.).

         Tip:

         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. 

      Front

      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.)

      Tip:

      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.

         Table 1. 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. 

      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 set bolts.

   5. Temporarily install the cylinder head set bolts.

      Tip:

      If any cylinder head set 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. 

         *1	Paint Mark
         	Front

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

         50 N*m

         510 kgf*cm

         37 ft.*lbf

         Tip:

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

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

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

      4. Perform the step above twice.

      5. 

         *1	Paint Mark
         	Front

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

   7. Step 2:

      1. 

         *1	Paint Mark
         	Front

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

      2. Perform the step above again.

      3. 

         *1	Paint Mark
         	Front

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

   8. Step 3:

      1. 

         *1	Paint Mark
         	Front

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

      2. Perform the above step twice.

      3. 

         *1	Paint Mark
         	Front

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

   9. 

      *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 cylinder 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

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5. INSTALL FUEL INJECTOR SEAL

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6. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

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7. INSTALL CAMSHAFT

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8. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

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9. 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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