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Cylinder Head Gasket (3MZ-FE): Replacement

WARNING: This page is about a different car, the 2004 Lexus ES 330. However, it is still accessible from the selected car via links, so may be relevant.
  1. DISCHARGE FUEL SYSTEM PRESSURE (See  FUEL SYSTEM (3MZ-FE)  ) 
  2. DISCONNECT BATTERY NEGATIVE TERMINAL 
  3. DRAIN ENGINE COOLANT (See  REPLACEMENT  ) 
  4. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  5. REMOVE FRONT WHEEL RH 
  6. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT  ) 
  7. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  8. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  9. REMOVE EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  10. REMOVE INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  11. REMOVE INTAKE MANIFOLD (See  REPLACEMENT  ) 
  12. REMOVE WATER OUTLET (See  REPLACEMENT  ) 
  13. REMOVE FRONT FENDER APRON SEAL RH 
  14. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See  REPLACEMENT   ) 
  15. REMOVE VANE PUMP V BELT (See  REPLACEMENT   ) 
  16. REMOVE ENGINE MOVING CONTROL ROD (See  REPLACEMENT   ) 
  17. REMOVE ENGINE MOUNTING STAY NO. 2 RH (See  REPLACEMENT   ) 
  18. REMOVE GENERATOR BRACKET NO. 2 (See  REPLACEMENT   ) 
  19. REMOVE CRANKSHAFT PULLEY (See  REPLACEMENT   ) 

    SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)

  20. REMOVE TIMING BELT NO. 1 COVER 
  21. REMOVE TIMING BELT NO. 2 COVER (See  REPLACEMENT   ) 
  22. REMOVE ENGINE MOUNTING BRACKET RH (See  REPLACEMENT   ) 
  23. REMOVE TIMING BELT GUIDE NO. 2 
  24. REMOVE TIMING BELT (See  REPLACEMENT   ) 
  25. REMOVE TIMING BELT IDLER SUB-ASSY NO. 2 
  26. REMOVE CAMSHAFT TIMING PULLEY (See  REPLACEMENT   ) 

    SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

  27. REMOVE TIMING BELT NO. 3 COVER (See  REPLACEMENT   ) 
  28. SEPARATE VANE PUMP ASSY 
  29. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  30. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  31. REMOVE EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1 
    1. Disconnect the air fuel ratio sensor connector.
    2. Remove the 3 bolts and exhaust manifold heat insulator.
      Fig 1: Locating Exhaust Manifold Insulator Nuts
      G00904153Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE EXHAUST MANIFOLD SUB-ASSY RH 
    1. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
    2. Remove the exhaust manifold RH and gasket from the cylinder head RH.
      Fig 2: Identifying Exhaust Manifold Nuts Loosening Sequence
      G00904154Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE IGNITION COIL ASSY 
  35. REMOVE CYLINDER HEAD COVER SUB-ASSY (See  ADJUSTMENT   ) 
  36. REMOVE CAMSHAFT (See  REPLACEMENT   ) 
  37. REMOVE NO. 2 CAMSHAFT (See  REPLACEMENT   ) 
    Fig 3: Locating VVT Sensor Connector
    G00904155Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CYLINDER HEAD SUB-ASSY 
    1. Disconnect the VVT sensor connector.
    2. Disconnect the camshaft timing oil control valve connector.
    3. Remove the nut, then disconnect the engine wire harness clamp.
      Fig 4: Locating Bolt
      G00904156Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a socket hexagon wrench 8, remove the hexagon bolt.
      Fig 5: Identifying Bolt Loosening Sequence
      G00904157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
      NOTE:
      • Be careful not to drop the washers into the cylinder head.
      • Head warpage or cracking could result from removing the bolts in an incorrect order.
  39. REMOVE CYLINDER HEAD GASKET 
  40. INSPECT CYLINDER HEAD SET BOLT 
    1. Using vernier calipers, measure the tension portion diameter of the bolt.

      Standard outside diameter: 

      8.95 to 9.05 mm (0.3524 to 0.3563 in.) 

      Minimum outside diameter: 8.75 mm (0.3445 in.) 

      If the diameter is less than minimum, replace the bolt. 

      Fig 6: Identifying Tension Portion
      G00904158Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. INSTALL CYLINDER HEAD GASKET 
    1. Place a new cylinder head gasket on the cylinder block with the R mark upward.
      NOTE:
      • Remove any oil from the contact surface.
      • Be careful of the installing orientation.
      • Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
  42. INSTALL CYLINDER HEAD SUB-ASSY 
    NOTE: The cylinder head bolts are tightened in 2 successive steps.
    1. Apply a light coat of engine oil to the threads of the cylinder head bolts.
    2. Install the plate washers to the cylinder head bolts.
      Fig 7: Identifying Cylinder Head Gasket
      G00904159Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.

      Torque: 54 N.m (550 kgf.cm, 40 ft.lbf) 

      Fig 8: Identifying Cylinder Head Tightening Sequence
      G00904160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
    5. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
    6. Check that each painted mark is now at a 90° angle to the front.
      Fig 9: Identifying Painted Mark
      G00904161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using a socket hexagon wrench 8, install the hexagon bolt.

      Torque: 19 N.m (189 kgf.cm, 14 ft.lbf) 

      8. Fig 10: Identifying Bolt
      G00904162Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Connect the engine wire harness clamp with the nut.

      Torque: 8.4 N.m (85 kgf.cm, 74 in.lbf) 

  43. INSTALL NO. 2 CAMSHAFT (See  REPLACEMENT   ) 
  44. INSTALL CAMSHAFT (See  REPLACEMENT   ) 
  45. INSTALL CYLINDER HEAD COVER SUB-ASSY (See  ADJUSTMENT   ) 
  46. INSTALL IGNITION COIL ASSY (See  ADJUSTMENT   ) 
  47. INSTALL EXHAUST MANIFOLD SUB-ASSY RH 
    1. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.

      Torque: 49 N.m (500 kgf.cm, 36 ft.lbf) 

    2. Retighten nuts 1 and 2 shown in the illustration.
      Fig 11: Identifying Exhaust Manifold Nuts Tightening Sequence
      G00904163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 

    Torque: 8.5 N.m (87 kgf.cm, 75 ft.lbf) 

  49. INSTALL EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  50. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET REAR (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  51. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  52. INSTALL VANE PUMP ASSY (See  REPLACEMENT   ) 
  53. INSTALL TIMING BELT NO. 3 COVER (See  REPLACEMENT   ) 
  54. INSTALL CAMSHAFT TIMING PULLEY (See  REPLACEMENT   ) 

    SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

  55. INSTALL TIMING BELT IDLER SUB-ASSY NO. 2 (See  REPLACEMENT   ) 
  56. INSPECT TIMING BELT (See  REPLACEMENT   ) 
  57. INSTALL TIMING BELT (See  REPLACEMENT   ) 

    SST 09960-10010 (09962-01000, 09963-01000)

  58. INSTALL TIMING BELT TENSIONER ASSY (See  REPLACEMENT   ) 
  59. INSTALL TIMING BELT GUIDE NO. 2 (See  REPLACEMENT   ) 
  60. INSTALL ENGINE MOUNTING BRACKET RH (See  REPLACEMENT   ) 
  61. INSTALL TIMING BELT NO. 2 COVER (See  REPLACEMENT   ) 
  62. INSTALL TIMING BELT NO. 1 COVER (See  REPLACEMENT   ) 
  63. INSTALL CRANKSHAFT PULLEY (See  REPLACEMENT   ) 

    SST 09213-54015 (91651-60855), 09330-00021

  64. INSTALL GENERATOR BRACKET NO. 2 (See  REPLACEMENT   ) 
  65. INSTALL ENGINE MOUNTING STAY NO. 2 RH (See  REPLACEMENT   ) 
  66. INSTALL ENGINE MOVING CONTROL ROD (See  REPLACEMENT   ) 
  67. INSTALL VANE PUMP V BELT (See  REPLACEMENT   ) 
  68. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See  REPLACEMENT   ) 
  69. INSPECT DRIVE BELT DEFLECTION AND TENSION (See  INSPECTION   ) 
  70. INSTALL WATER OUTLET (See  REPLACEMENT  ) 
  71. INSTALL INTAKE MANIFOLD (See  REPLACEMENT  ) 
  72. INSTALL INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  73. INSTALL EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  74. INSTALL AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  75. CHECK CONNECTION OF VACUUM HOSE (See  REPLACEMENT   ) 
  76. INSTALL V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  77. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT  ) 
  78. INSTALL FRONT WHEEL RH (See  REPLACEMENT   ) 
  79. ADD ENGINE OIL (See  REPLACEMENT  ) 
  80. ADD ENGINE COOLANT (See  REPLACEMENT  ) 
  81. CHECK FOR ENGINE OIL LEAKS 
  82. CHECK FOR ENGINE COOLANT LEAKS (See  INSPECTION  ) 
  83. INSPECT FOR FUEL LEAKS 
  84. CHECK FOR EXHAUST GAS LEAKS 
  85. INSPECT IGNITION TIMING (See  INSPECTION   ) 

    SST 09843-18040

  86. INSPECT ENGINE IDLE SPEED (See  INSPECTION   ) 
  87. INSPECT COMPRESSION (See  INSPECTION   ) 

    SST 09992-00500

  88. INSPECT CO/HC (See  INSPECTION   ) 
  89. SYSTEM INITIALIZATION (See  PRECAUTION  ) 
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