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.
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 | ||||||||||||||||||
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|
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 |
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 |
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.
INSTALL CYLINDER HEAD SUB-ASSEMBLY
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CONNECT INLET WATER HOSE RH
Connect the inlet water hose RH to the outlet water sub-assembly.
*a | Upper |
*b | Rear |
*c | View A |
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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INSTALL CAMSHAFT
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INSTALL CHAIN SUB-ASSEMBLY
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INSTALL NO. 1 CHAIN VIBRATION DAMPER
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INSTALL CHAIN TENSIONER SLIPPER
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INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
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CONNECT INLET WATER HOSE LH
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INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
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INSTALL NO. 2 TIMING CHAIN COVER
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INSTALL ENGINE MOUNTING BRACKET RH
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CHECK VALVE CLEARANCE
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ADJUST VALVE CLEARANCE
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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INSTALL HARNESS BRACKET
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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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INSTALL VACUUM PUMP ASSEMBLY
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INSTALL CAMSHAFT POSITION SENSOR (w/o Stop And Start System)
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INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
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INSTALL NO. 4 WATER BY-PASS HOSE
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INSTALL NO. 2 OIL COOLER HOSE
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INSTALL NO. 2 CYLINDER HEAD COVER
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INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
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INSTALL COMMON RAIL ASSEMBLY
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INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING
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TEMPORARILY INSTALL SUPPLY PUMP ASSEMBLY
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INSTALL FUEL INLET PIPE SUB-ASSEMBLY
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INSTALL NO. 2 FUEL HOSE
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INSTALL INJECTION NOZZLE SEAT
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INSTALL INJECTOR ASSEMBLY
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INSTALL NOZZLE HOLDER CLAMP SEAT
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INSTALL NO. 1 NOZZLE HOLDER CLAMP
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INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY
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INSTALL NOZZLE LEAKAGE PIPE SET CLAMP
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INSTALL NO. 2 INTAKE MANIFOLD INSULATOR
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INSTALL GLOW PLUG ASSEMBLY
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INSTALL NO. 1 GLOW PLUG CONNECTOR
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INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY
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INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY
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INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY
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INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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INSTALL ENGINE OIL LEVEL DIPSTICK
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INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)
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INSTALL HARNESS BRACKET
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INSTALL NO. 1 EGR COOLER BRACKET
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INSTALL EGR WITH COOLER PIPE ASSEMBLY
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INSTALL GENERATOR BRACKET
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INSTALL GENERATOR ASSEMBLY
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INSTALL ENGINE COVER BRACKET (w/ No. 1 Engine Cover)
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REMOVE ENGINE STAND
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