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Cylinder Head Gasket No. 2 (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 RADIATOR LOWER AIR DEFLECTOR (See  REMOVAL & INSTALLATION  ) 
  7. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS) (See  REPLACEMENT  ) 
  8. REMOVE V-BANK COVER SUB-ASSY (See  REPLACEMENT  ) 
  9. REMOVE AIR CLEANER INLET ASSY (See  REMOVAL & INSTALLATION  ) 
  10. REMOVE AIR CLEANER CAP SUB-ASSY (See  REPLACEMENT  ) 
  11. REMOVE AIR CLEANER CASE (See  REMOVAL & INSTALLATION  ) 
  12. REMOVE EMISSION CONTROL VALVE SET (See  REPLACEMENT  ) 
  13. REMOVE INTAKE AIR SURGE TANK (See  REPLACEMENT  ) 
  14. REMOVE INTAKE MANIFOLD (See  REPLACEMENT  ) 
  15. REMOVE WATER OUTLET (See  REPLACEMENT  ) 
  16. REMOVE FRONT FENDER APRON SEAL RH 
  17. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See  REPLACEMENT   ) 
  18. REMOVE VANE PUMP V BELT (See  REPLACEMENT   ) 
  19. REMOVE ENGINE MOVING CONTROL ROD (See  REPLACEMENT   ) 
  20. REMOVE ENGINE MOUNTING STAY NO. 2 RH (See  REPLACEMENT   ) 
  21. REMOVE GENERATOR BRACKET NO. 2 (See  REPLACEMENT   ) 
  22. REMOVE CRANKSHAFT PULLEY (See  REPLACEMENT   ) 

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

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

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

  30. REMOVE TIMING BELT NO. 3 COVER (See  REPLACEMENT   ) 
  31. REMOVE MANIFOLD STAY NO. 2 (See  REPLACEMENT   ) 
  32. SEPARATE EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  33. REMOVE OIL LEVEL GAGE GUIDE 
    1. Remove the bolt which secures the oil level gage guide from the cylinder head LH.
    2. Pull out the oil level gage guide and oil level gage together from the cylinder block.
    3. Remove the O-ring from the oil level gage guide.
      Fig 1: Locating Bolt
      G00904172Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE WATER INLET PIPE (See  REPLACEMENT  ) 
  35. REMOVE IGNITION COIL ASSY 
  36. REMOVE CYLINDER HEAD COVER SUB-ASSY LH (See  ADJUSTMENT   ) 
  37. REMOVE NO. 3 CAMSHAFT SUB-ASSY (See  REPLACEMENT   ) 
  38. REMOVE NO.4 CAMSHAFT SUB-ASSY (See  REPLACEMENT   ) 
  39. REMOVE CYLINDER HEAD LH 
    1. Disconnect the VVT sensor connector.
    2. Disconnect the camshaft timing oil control valve connector.
    3. Disconnect the air fuel ratio sensor connector.
    4. Remove the bolt, then disconnect the ground cable.
    5. Remove the bolt and wire harness clamp bracket.
      Fig 2: Locating Cylinder Head LH Bolts
      G00904173Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using a socket hexagon wrench 8, remove the hexagon bolt.
      Fig 3: Locating Bolt
      G00904174Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. 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.
        Fig 4: Identifying Bolts Loosening Sequence
        G00904175Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE CYLINDER HEAD GASKET NO. 2 
  41. INSPECT CYLINDER HEAD SET BOLT (See  REPLACEMENT   ) 
  42. INSTALL CYLINDER HEAD GASKET NO. 2 
    1. Place a new cylinder head gasket on the cylinder block with the L 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.
        Fig 5: Identifying Cylinder Head Gasket
        G00904176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. INSTALL CYLINDER HEAD LH 
    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 washer to the cylinder head bolt.
    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 6: Identifying Bolts Tightening Sequence
      G00904177Courtesy 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 7: Identifying Painted Mark
      G00904178Courtesy 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. Install the wire harness clamp bracket with the bolt.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

    9. Connect the ground cable with the bolt.

      Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) 

      Fig 8: Locating Bolt
      G00904179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. INSTALL NO.4 CAMSHAFT SUB-ASSY (See  REPLACEMENT   ) 
  45. INSTALL NO. 3 CAMSHAFT SUB-ASSY (See  REPLACEMENT   ) 
  46. INSTALL CYLINDER HEAD COVER SUB-ASSY LH (See  ADJUSTMENT   ) 
  47. INSTALL IGNITION COIL ASSY (See  ADJUSTMENT   ) 
  48. INSTALL WATER INLET PIPE (See  REPLACEMENT  ) 
  49. INSTALL OIL LEVEL GAGE GUIDE 
    1. Install a new O-ring to the oil level gage guide.
    2. Apply soapy water to the O-ring.
    3. Push in the oil level gage guide end into the guide hole of the cylinder block.
    4. Install the oil level gage guide with the bolt.

      Torque: 8.0 N.m (82 kgf.cm, 71 in.lbf) 

    5. Install the oil level gage.
      Fig 9: Installing O-Ring
      G00904180Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. INSTALL EXHAUST PIPE ASSY FRONT (See  REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY  ) 
  51. INSTALL MANIFOLD STAY NO. 2 (See  REPLACEMENT   ) 
  52. INSTALL TIMING BELT NO. 3 COVER (See  REPLACEMENT   ) 
  53. INSTALL CAMSHAFT TIMING PULLEY (See  REPLACEMENT   ) 

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

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

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

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

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

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

    SST 09843-18040

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

    SST 09992-00500

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