PROCEDURE
SELECT CYLINDER HEAD GASKET
Check the piston protrusion for each cylinder.
Clean the cylinder block sub-assembly with non-residue solvent.
Set the piston of the cylinder to be measured to slightly before TDC.
Place a dial indicator on the cylinder block sub-assembly, and set the measuring tip as shown in the illustration.
*a | Measuring Tip |
*b | Protrusion |
*c | Measurement Point |
Front |
Set the dial indicator to 0 mm (0 in.).
Make sure that the measuring tip is perpendicular to the cylinder block gasket surface and piston head when taking the measurements.
Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.
Measure each cylinder at the 2 places shown in the illustration, making a total of 8 measurements.
For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.
Standard Piston Protrusion |
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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 them.
Select a new cylinder head gasket.
Front |
New Cylinder Head Gasket Thickness | ||||||||||||
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|
Cylinder head gaskets are marked A, B, C, D or E accordingly.
Select the largest piston protrusion value from the measurements and then select the appropriate new cylinder head gasket according to the table below.
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 |
INSTALL CYLINDER HEAD GASKET
Install a new cylinder head gasket.
INSTALL CYLINDER HEAD SUB-ASSEMBLY
Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.
Place the cylinder head gasket on the cylinder block sub-assembly.
Place the cylinder head sub-assembly on the cylinder block sub-assembly.
Pay attention to the installation direction.
Apply a light coat of engine oil to the threads and under the heads of the cylinder head set bolts.
Install the 10 plate washers to the cylinder head set bolts.
Temporarily install the cylinder head set bolts.
If any cylinder head set bolt is broken or deformed, replace it.
Step 1:
For new bolts, perform steps 1 to 3. For used bolts, perform only step 1.
Uniformly tighten the 10 cylinder head set bolts, in several steps in the order shown in the illustration.
*a | Paint Mark |
Front |
If any one of the cylinder head set bolts does not meet the torque specification, replace the cylinder head set bolt.
Mark the front of the cylinder head set bolts with paint.
Further tighten the cylinder head set bolts 90° in the order shown in the illustration.
Perform the above step twice.
Check that the paint marks are positioned as shown in the illustration.
*a | Paint Mark |
Front |
Step 2:
Loosen the cylinder head set bolts 90° in the order shown in the illustration.
*a | Paint Mark |
Front |
Perform the step above again.
Check that the paint marks are positioned as shown in the illustration.
*a | Paint Mark |
Front |
Step 3:
Further tighten the cylinder head set bolts 90° in the order shown in the illustration.
*a | Paint Mark |
Front |
Perform the above step twice.
Check that the paint marks are positioned as shown in the illustration.
*a | Paint Mark |
Front |
Apply seal packing between the cylinder head sub-assembly and cylinder block sub-assembly in the areas shown in the illustration.
*1 | Cylinder Head Sub-assembly |
*2 | Cylinder Block Sub-assembly |
*a | 15 mm or more |
*b | Seal Packing |
Seal Packing |
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Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent |
Standard Seal Packing Application Length |
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15 mm (0.591 in.) or more |
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 gasket and cylinder head sub-assembly or cylinder block sub-assembly.
When there is oil on the contact surfaces, 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.
INSTALL GLOW PLUG ASSEMBLY
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INSTALL NO. 1 GLOW PLUG CONNECTOR
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INSTALL FUEL INJECTOR SEAL
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INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY
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INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY
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INSTALL CAMSHAFT
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