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Home >> Scion >> 2005 >> tC L4-2.4L (2AZ-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Cylinder Head Gasket

Cylinder Head Gasket


































CYLINDER HEAD GASKET (2AZ-FE)
REPLACEMENT





NOTICE: When disconnecting the battery negative terminal, initialize the system(s) shown after the terminal is reconnected.

1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE HOOD SUB-ASSEMBLY
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE FRONT FENDER APRON SEAL RH
8. REMOVE ENGINE COVER SUB-ASSEMBLY NO.1
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE FR WIPER ARM LH
11. REMOVE FR WIPER ARM RH
12. REMOVE HOOD TO COWL TOP SEAL
13. REMOVE COWL TOP VENTILATOR LOUVER LH
14. REMOVE WIPER LINK ASSEMBLY
15. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
16. REMOVE COWL BODY MOUNTING BRACKET LOWER LH
17. DRAIN ENGINE COOLANT
18. DRAIN ENGINE OIL
19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
20. REMOVE THROTTLE BODY ASSEMBLY
21. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
SST 09268-21010
22. REMOVE INTAKE MANIFOLD
23. REMOVE INTAKE MANIFOLD INSULATOR NO.1
24. REMOVE EXHAUST PIPE ASSEMBLY FRONT
25. REMOVE FAN AND GENERATOR V-BELT
SST 09249-63010
26. REMOVE GENERATOR ASSEMBLY
27. SEPARATE VANE PUMP ASSEMBLY
SST 09249-63010
28. REMOVE ENGINE MOUNTING INSULATOR RH
29. REMOVE IGNITION COIL ASSEMBLY
30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
31. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
32. REMOVE CRANKSHAFT POSITION SENSOR
33. REMOVE OIL PAN SUB-ASSEMBLY
SST 09032-00100
34. SET NO.1 CYLINDER TO TDC/COMPRESSION
35. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
36. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
37. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
38. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
39. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
40. REMOVE TIMING CHAIN GUIDE
41. REMOVE CHAIN TENSIONER SLIPPER
42. REMOVE CHAIN SUB-ASSEMBLY
43. REMOVE CHAIN VIBRATION DAMPER NO.1
44. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY





45. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt, then remove the oil level gage guide.
b. Remove the O-ring from the oil level gage guide.





46. REMOVE MANIFOLD STAY
a. Remove the bolt and nut, then remove the manifold stay.





47. REMOVE MANIFOLD STAY NO.2
a. Remove the bolt and nut, then remove the manifold stay No. 2.





48. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Disconnect the air fuel ratio sensor connector.





b. Remove the 3 bolts and nut, then remove the exhaust manifold heat insulator.





49. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Remove the 5 nuts, then remove the exhaust manifold converter.
b. Remove the gasket from the cylinder head.
50. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





51. REMOVE CAMSHAFTS
a. Using several steps, uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
b. Remove the 10 bearing caps, then remove the camshaft and No. 2 camshaft.





52. REMOVE CAMSHAFT BEARING NO.2
a. Remove the camshaft bearing No. 2 from the cylinder head.





53. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Disconnect the radiator hose inlet.





b. Disconnect the radio setting condenser connector.
c. Disconnect the engine oil pressure switch connector.
d. Disconnect the engine coolant temperature sensor connector.
e. Disconnect the camshaft position sensor connector.
f. Remove the bolt, then disconnect the engine earth.





g. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.

NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- Head warpage or cracking could result from removing the bolts in the wrong order.

54. REMOVE CYLINDER HEAD GASKET





55. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of the head bolts from the seat to the end.
Standard bolt length: 161.3 to 162.7 mm (6.350 to 6.406 inch)
Maximum bolt length: 164.2 mm (6.465 inch)
If the bolt length is greater than maximum, replace the bolt.





56. INSTALL CYLINDER HEAD GASKET
a. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head gently in order to avoid damaging the gasket.

57. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





b. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 78.5 Nm (800 kgf-cm, 58 ft. lbs.)





c. Mark the front of the cylinder head bolts with paint.
d. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
e. Check that the painted mark is now at a 90° angle to the front.





f. Connect the engine earth with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
g. Connect the camshaft position sensor connector.
h. Connect the engine coolant temperature sensor connector.
i. Connect the engine oil pressure switch connector.
j. Connect the radio setting condenser connector.
k. Connect the heater water inlet hose.
l. Connect the radiator hose inlet.
58. INSTALL CAMSHAFT BEARING NO.2
a. Clean the contact surfaces of the bearing and the cylinder head.





b. Install the camshaft bearing No. 2 onto the cylinder head.

NOTICE: Do not apply engine oil to the bearing and its contact surface.

59. INSTALL CAMSHAFTS
a. Apply a light coat of engine oil to the journal portion of the camshaft.





b. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.





c. Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then install the bearing caps onto the cylinder head.
d. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





e. Using several steps, uniformly tighten the 20 bearing cap bolts in the sequence shown in the illustration.
Torque:
29.5 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 1 and No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3

NOTICE:
- Tighten the bolts after deciding the position in the thrust direction of the camshaft by the bearing cap No. 1 and No. 2.
- Install the camshaft with its timing mark of the cam timing chain.

60. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
61. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket onto the cylinder head.
b. Temporarily tighten the exhaust manifold converter with the 5 nuts.





c. Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





62. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator with the 3 bolts and nut.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
b. Connect the air fuel ratio sensor connector.





63. INSTALL MANIFOLD STAY NO.2
a. Install the manifold stay No. 2 with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)





64. INSTALL MANIFOLD STAY
a. Install the manifold stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)





65. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring and install it onto the oil level gage guide.
b. Install the oil level gage guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
66. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
67. INSTALL CHAIN VIBRATION DAMPER NO.1
68. INSTALL CHAIN SUB-ASSEMBLY
SST 09309-37010
69. INSTALL CHAIN TENSIONER SLIPPER
70. INSTALL TIMING CHAIN GUIDE
71. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
72. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
SST 09223-22010
73. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
74. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
75. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
76. INSTALL OIL PAN SUB-ASSEMBLY
77. INSTALL CRANKSHAFT POSITION SENSOR
78. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
79. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
80. INSTALL IGNITION COIL ASSEMBLY
81. INSTALL ENGINE MOUNTING INSULATOR RH
82. INSTALL VANE PUMP ASSEMBLY
SST 09249-63010
83. INSTALL GENERATOR ASSEMBLY
84. INSTALL FAN AND GENERATOR V-BELT
SST 09249-63010
85. INSTALL EXHAUST PIPE ASSEMBLY FRONT
86. INSTALL INTAKE MANIFOLD INSULATOR NO.1
87. INSTALL INTAKE MANIFOLD
88. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
89. INSTALL THROTTLE BODY ASSEMBLY
90. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
91. ADD ENGINE COOLANT
92. ADD ENGINE OIL
93. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
94. CHECK FOR FUEL LEAKAGE
95. CHECK FOR ENGINE COOLANT LEAKAGE
96. CHECK FOR ENGINE OIL LEAKAGE
97. CHECK FOR EXHAUST GAS LEAKAGE
98. CHECK IGNITION TIMING
SST 09843-18040
99. INSPECT ENGINE IDLING SPEED
SST 09843-18030
100. INSPECT COMPRESSION
SST 09992-00500
101. INSPECT CO/HC
102. INSTALL COWL BODY MOUNTING BRACKET LOWER LH
103. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
104. INSTALL WIPER LINK ASSEMBLY
105. INSTALL COWL TOP VENTILATOR LOUVER LH
106. INSTALL HOOD TO COWL TOP SEAL
107. INSTALL FR WIPER ARM RH
108. INSTALL FR WIPER ARM LH
109. INSTALL FRONT WIPER ARM HEAD CAP
110. INSTALL ENGINE COVER SUB-ASSEMBLY NO.1
111. INSTALL FRONT FENDER APRON SEAL RH
112. INSTALL ENGINE UNDER COVER LH
113. INSTALL ENGINE UNDER COVER RH
114. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
115. INSTALL HOOD SUB-ASSEMBLY


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