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Home >> Toyota Truck >> 2007 >> Tundra 2WD V6-4.0L (1GR-FE) >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Cylinder Head Assembly >> Service and Repair >> Removal and Replacement >> Cylinder Head Gasket (for Bank 1)

Cylinder Head Gasket (for Bank 1)

CYLINDER HEAD GASKET (for Bank 1)

COMPONENTS (Part 1):




COMPONENTS (Part 2):




COMPONENTS (Part 3):




COMPONENTS (Part 4):




COMPONENTS (Part 5):





COMPONENTS (Part 6):





REMOVAL
1. REMOVE ENGINE ASSEMBLY
(a) Remove the engine assembly from the vehicle.
2. REMOVE IGNITION COIL ASSEMBLY
3. REMOVE SPARK PLUG
4. REMOVE VVT SENSOR
5. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
8. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE





9. REMOVE HEATER WATER PIPE SUB-ASSEMBLY
(a) Remove the 2 bolts and disconnect the 3 water hoses.
10. REMOVE REAR WATER BY-PASS JOINT
(a) Disconnect the engine coolant temperature sensor connector.





(b) Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.





(c) Remove the O-ring from the No. 1 water outlet pipe.
11. REMOVE OIL CONTROL VALVE FILTER
12. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
13. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
14. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY
15. REMOVE CRANKSHAFT PULLEY
16. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY
17. REMOVE OIL STRAINER SUB-ASSEMBLY
18. REMOVE OIL PAN SUB-ASSEMBLY
19. DISCONNECT NO. 2 OIL COOLER HOSE
20. DISCONNECT OIL COOLER HOSE
21. REMOVE WATER INLET HOUSING
22. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
23. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
24. REMOVE FRONT CRANKSHAFT OIL SEAL
25. SET NO. 1 CYLINDER TO TDC / COMPRESSION
26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
27. REMOVE CHAIN TENSIONER SLIPPER
28. REMOVE NO. 1 IDLE GEAR SHAFT
29. REMOVE NO. 2 CHAIN VIBRATION DAMPER
30. REMOVE NO. 1 CHAIN
31. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN
32. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY
33. REMOVE NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT

NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.





(a) Rotate the camshafts counterclockwise using a wrench so that the cam lobes of the No. 1 cylinder face each direction as shown in the illustration.





(b) Uniformly loosen and remove the 16 bearing cap bolts in the sequence shown in the illustration.
(c) Remove the 8 bearing caps and 2 camshafts.





34. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH
(a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

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





(b) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.





35. REMOVE NO. 1 CAMSHAFT BEARING





36. REMOVE NO. 2 CAMSHAFT BEARING
37. REMOVE CYLINDER HEAD GASKET

INSPECTION
1. INSPECT CYLINDER HEAD SET BOLT
2. INSPECT CYLINDER HEAD SUB-ASSEMBLY

INSTALLATION
1. INSTALL CYLINDER HEAD GASKET
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.





(b) Apply seal packing to a new cylinder head gasket as shown in the illustration.
Seal packing: Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
Standard seal diameter: 2.5 to 3.0 mm (0.0984 to 0.118 in.)

Seal packing application range:





HINT:
^ Remove any oil from the contact surface.
^ Install the cylinder head gasket within 3 minutes after applying the seal packing.
^ Do not add engine oil within 2 hours of installation.





(c) Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE: Be careful of the installation direction.

2. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH
3. INSTALL NO. 1 CAMSHAFT BEARING
4. INSTALL NO. 2 CAMSHAFT BEARING
5. INSTALL NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT

NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.





(a) Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when the camshaft is installed, causing damage. Always set the crankshaft at the correct angle.

(b) Apply a light coat of engine oil to the thrust portions and journals of the camshafts.





(c) Place the 2 camshafts onto the cylinder head with the cam lobes of the No. 1 cylinder facing each direction as shown in the illustration.
(d) Apply a light coat of engine oil to the 8 bearing caps.





(e) Install the 8 bearing caps in their proper locations.
(f) Apply a light coat of engine oil to the threads and under the heads of the 16 bearing cap bolts.





(g) Uniformly install the 16 bearing cap bolts in several steps in the order shown in the illustration.
Torque:
for 10 mm head 9.0 N*m (92 kgf*cm, 80 in.*lbf)
for 12 mm head 24 N*m (245 kgf*cm, 18 ft.*lbf)





(h) Using a wrench, turn the camshafts clockwise until the camshaft knock pin is at a position 90° to the cylinder head.
6. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
7. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN
8. INSTALL CHAIN TENSIONER SLIPPER
9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
10. INSTALL NO. 1 CHAIN
11. INSTALL NO. 2 CHAIN VIBRATION DAMPER
12. INSTALL NO. 1 IDLE GEAR SHAFT
13. INSTALL FRONT CRANKSHAFT OIL SEAL
14. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
15. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
16. INSTALL WATER INLET HOUSING
17. CONNECT OIL COOLER HOSE
18. CONNECT NO. 2 OIL COOLER HOSE
19. INSTALL OIL PAN SUB-ASSEMBLY
20. INSTALL OIL STRAINER SUB-ASSEMBLY
21. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
22. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
23. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
24. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE





25. INSTALL REAR WATER BY-PASS JOINT
(a) Install a new O-ring to the water outlet pipe, and set 2 new gaskets to the water ports LH and RH.
(b) Apply soapy water to the O-ring.





(c) Install the rear water by-pass joint with the 2 bolts and 4 nuts.
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(d) Connect the engine coolant temperature sensor connector.





26. INSTALL HEATER WATER PIPE SUB-ASSEMBLY
(a) Temporarily install the heater water pipe, and then tighten the 2 bolts in the order shown in the illustration.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(b) Connect the 3 water hoses.
27. INSTALL CRANKSHAFT PULLEY
28. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
29. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
30. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
31. INSTALL OIL CONTROL VALVE FILTER
32. CONNECT HEATER WATER PIPE SUB-ASSEMBLY
33. INSTALL SPARK PLUG
34. INSTALL VVT SENSOR
35. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
36. INSTALL IGNITION COIL ASSEMBLY
37. INSTALL ENGINE ASSEMBLY
(a) Install the engine assembly to the vehicle.

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