Toyota 11101-39755 Head Sub-Assembly, Cylinder

First, before removing any of the engine components unscrew the cable from the negative terminal battery; other procedures worthy of a mention include draining the cooling system inclusive of the block. Then, six screws must be unbolted to release the throttle body, fuel rails, and injectors, then engine and transmission dipstick tubes. Remove the thermostat housing, and front and rear coolant passages along with a front coolant pipe assembly. Pull off the exhaust manifold(s), which one must know that the pipes can be detached so that the manifold can be pulled off conveniently. Move on to remove the alternator and both upper and the lower intake manifold together with all the other components that would hinder the process. First, the timing belt has to be taken off along with the camshaft sprockets, drivebelt idler pulley, and the drivebelt tensioner, then the upper timing belt cover number 3 has to be removed. Take out the camshaft(s), only loosen the cylinder head bolts to 1/4 turn before coming off, and stuff a piece of rag into the oil drain hole, a head bolt washer could be dropped here. Remove the cylinder head from the engine block, and use a wooden block and hammer if the heads don't come off easily; do the same with the other head. For installation, the mating surfaces of the cylinder heads and block should be clean, using a gasket scraper and brake system cleaner only. Sometimes the mating surfaces may be damaged hence it is important to check for any damage on the mating surfaces and repair it. Swab out the threads of the cylinder head bolt holes and blow off with compressed air. Clean the bolts by removing rust and examine them for elongation, change those bolts which are below the minimum diameter. Place the new gaskets on the dowel pins in the block properly adjust the head on the block without shifting the position of the gasket andlubricate the threads and washers of the bolts with clean engine oil and finally screw the bolts in the original locations and make them sheer tight. Next, it is advised to rotate all bolts along the sequence to bring them to the nominal torque while painting the bolt heads first for the sake of identification. Turn each of the bolts another ¼-turn, then another ¼-turn, with the paint marks being parallel to each other but in the opposite direction from the starting position, in this case 180-degrees apart. The same has to be done for the other cylinder head, and then, the rest of the installation processes have to be made in the reverse order to the removal. Last of all, refilling the cooling system, change the engine oil and filter, start the engine, and check for dripping.

That is the procedure to be followed for any of the cylinder heads. Start off with the engine on TDC compression for cylinder no. 1, and also, set the negative lead connection of the battery to be disconnected. Pull out the drain plug plug drain the engine oil and remove the coolant then unbolt the engine cover and also remove the air filter housing. Next, remove upper intake manifold or valve cover(s) if they are bolted to it. Remove the fuel supply and return hose from the fuel rail and unbolt the lower intake manifold and fuel rail together as one component. As you sit astride the model, locate the coolant passage at the back part of the engine, disconnect the Engine Coolant Temperature sensor and take off the heater hose. In this case, you have to take out the bolts and nuts of the coolant passage; the old gaskets and O-rings should be discarded. Remove the bolt and nut between the front exhaust pipe and the exhaust manifold and take out the exhaust manifold. Timing chain, Camshaft timing oil control valve, Oil control valve filter and VVT-i sensor should be detached and then the camshafts. Should the removal of the left cylinder head is needed, the two front bolts in the sequence should be loosened, then the cylinder head bolts with gradual and equal forces in the reverse order used to tighten it and finally the cylinder head can be removed. Remove the old cylinder head gasket, and if there is a second gasket for the second cylinder head apply the same. For installation ensure the mating surface of the cylinder heads and block are clean through the use of a gasket scraper and brake cleaner. Look for signs of harm on the external plane and check the interconnection of the thread with use of compressed air to clear the bolt holes. Clean the cylinder head bolts of any rust and check their gauge according to the standard and replace those bolts, which are not of the right size. Put RTV sealant on a new cylinder head gasket, place the gasket in the right position on the engine block, and then slowly set the cylinder head on it. Lubricate the cylinder head bolts lightly; Loosen the bolts with appropriate period and tighten it to the primary torque value and then turn another 180 degrees and tighten them again. In case of fixing the left cylinder head, it is important to again and again tighten the two front bolts in the sequence of their removal. If both were removed then installation of the other cylinder head must be done and then the intake and exhaust camshafts, camshaft timing oil control valve, oil control valve filter, and VVT-i sensor. Replace all the timing chains, timing chain cover as well as all the components that are fitted on this cover Then follow the other procedures that you have undone during the removal process. Gather more oil and coolant, connect the battery cable, start up the engine and look for any leaking.

Disconnect the cable from the negative terminal of the battery.

Disconnect the fuel supply and return lines from the fuel rail, then remove the lower intake manifold and the fuel rail as a single assembly.