Toyota 11115-28040
Head Gasket

Motorcyclists should start the cylinder head gasket replacement process by closing off garage vents to contain fuel leakage. Then they must remove the front suspension upper brace center (W/ FRONT SUSPENSION BRACE UPPER CENTER) as well as the chain sub-assembly. You must drain the coolant system before disconnecting the radiator hose outlet and the connector tube hose union and heater inlet and fuel tube sub-assembly. The intake manifold replacement demands two water by-pass hose removal from throttle body followed by five bolt removal along with two nuts to extract the intake manifold along with its gasket. Control the engine wire before you remove intake manifold insulator No. 1 and exhaust manifold heat insulator No. 1 then separate the exhaust manifold converter sub-assembly by unbolt the three bolts and two nuts from the No. 1 and No. 2 exhaust manifold stay with additional removal of five nuts for the exhaust manifold and gasket. Secondly remove the No. 2 camshaft by first disassembling the specified sequence of No. 2 and No. 3 camshaft bearing caps. First remove the No. 1 camshaft by unbolting the specified No. 1 and No. 3 camshaft bearing caps and then take off the camshaft clearing No. 2 and the camshaft timing oil control valve assembly. A 10 mm bi-hexagon wrench should be used to loosen and remove ten cylinder head bolts according to the specified sequence through multiple pasages to avoid washer drops into the cylinder head. Use vernier calipers to measure head bolt lengths starting from the seat to the end of each bolt before replacement if any measure beyond 164.2 mm (6.465 inch) maximum. Place a new cylinder head gasket on top of the cylinder block surface while maintaining the Lot No. stamp in the upward direction. During installation always wipe off any oil residue from the contact area and exercise caution regarding the direction of placement. Place the cylinder head carefully onto position before applying engine oil to the threads and under the cylinder bolt heads where the ward washers will be mounted for installation. A 10 mm bi-hexagon wrench should be used to tighten alternating passes of ten cylinder head bolts and plate washers until they reach 79 Nm (806 kgf-cm, 58 ft. lbs.), after which you should paint mark the front side of the bolt and align the bolt to a 90 degrees angle toward the front. First install the camshaft timing oil control valve assembly then proceed to install camshaft bearing No. 2 and finally the camshaft secured with camshaft bearing cap No. 1 and No. 3 tightened to 30 Nm (301 kgf-cm, 22 ft. lbs.) and 9.0 Nm (92 kgf-cm, 80 inch lbs.), respectively. The installation of camshaft bearing cap No. 2 and No. 3 should be completed with equal torques as specified in the instruction. The work requires mounting the exhaust manifold converter sub-assembly to the exhaust manifold using new gasket material and five nuts that should tighten to 37 Nm (378 kgf-cm, 27 ft. lbs.). Afterward install the No. 1 and No. 2 exhaust manifold stay with three bolts and two nuts to 44 Nm (449 kgf-cm, 32 ft. lbs.). First install heat insulator No. 1 at 12 Nm torque before installing the intake manifold with new gasket and five bolts and two nuts tightened to 30 Nm torque. The technician must complete fuel tube sub-assembly connection followed by chain sub-assembly installation with Special Service Tool: 09309-37010 and oil and coolant filling before conducting leak inspections for oil, engine coolant and fuel. The last phase includes an inspection of idle speed together with ignition timing and CO/HC level assessment.

Because of its important position inside the 2AZ-FE engine mechanical system the cylinder head gasket communicates the cylinder head to the engine block to stop leaks while keeping engine oil and coolant contained and also adjusting compression. Working on the cylinder head gasket correctly means looking at it for damage while cleaning both surfaces before tightening it according to specific torque values.

The first step for cylinder head gasket removal from the 2ZR-FE starts by uninstalling the engine along with transaxle before installing the engine stand. Start by taking out the intake manifold before unhooking the fuel tube sub-assembly and removing the fuel delivery pipe sub-assembly followed by removal of the fuel injector assembly. The next step requires removal of all components starting from ignition coil assembly then moving to oil level dipstick sub-assembly, proceeding to No. 1 exhaust manifold heat insulator, and finishing with manifold stay, exhaust manifold, ventilation hose, No. 3 water by-pass hose, No. 1 water by-pass pipe, water by-pass hose, inlet water hose, inlet water, and lastly the thermostat. Detach both the radio setting condenser and the cylinder head cover sub-assembly from service. To set the No. 1 cylinder at TDC/compression alignment must occur between the crankshaft pulley groove and timing mark "0" on the timing chain cover while maintaining proper alignment of the camshaft timing gear and sprocket marks. Extract the crankshaft pulley while taking away the No. 1 chain tensioner assembly followed by the timing chain cover sub-assembly and timing chain cover oil seal and chain tensioner slipper. To release the No. 1 chain vibration damper workers must first remove two bolts and Clockwise turn the camshaft timing gear assembly by holding the hexagonal camshaft portion. The camshaft timing gear assembly requires a chain removal while the camshaft is turned clockwise until it reaches its original position. Next remove the No. 2 chain vibration damper from the camshaft assembly and proceed to inspect the camshaft timing gear assembly as well as the camshaft timing exhaust gear assembly before taking these components together with the camshaft bearing cap and camshaft out of the unit. Detach the No. 2 camshaft with additional items such as the No. 1 camshaft bearing and No. 1 valve rocker arm sub-assembly then remove the valve lash adjuster assembly and No. 2 camshaft bearing alongside the camshaft housing sub-assembly. Finished by applying a 10 mm bi-hexagon wrench to uniformly loosen then remove the 10 cylinder head bolts joined with 10 plate washers in the designated order. Afterward, carefully separate the cylinder head from the cylinder block using a pry tool. The last step removes the cylinder head gasket. The technician should conduct inspections on both No. 1 valve rocker arm sub-assembly and valve lash adjuster assembly and on the cylinder head set bolt when required.

All components involved in a 2AZ-FE engine mechanical cylinder head gasket service must receive both inspection and necessary replacement. Follow the specified tools together with the provided procedures to get the best possible outcomes.

The necessary tools and procedures for maintaining the 2009 Toyota Matrix AWD L4-2.4L (2AZ-FE) cylinder head gasket service fall under the repair components. Work with Special Service Tool: 09960-10010 as the proper equipment for this task. The installation procedures combined with all specifications and part numbers must be followed to achieve correct cylinder head gasket installation along with proper functionality.

Carefully detach the cylinder head, taking care to note the order of the bolts for reinstallation.

The No. 1 engine cover sub-assembly, drain the engine coolant and oil, and separate the center and front exhaust pipe assemblies.

The transverse engine mounting bracket, V-ribbed belt tensioner assembly, and crankshaft position sensor.

Install with a torque of 43 Nm (438 kgf-cm, 32 ft. lbs.).

49 Nm (500 kgf-cm, 36 ft-lbf).

Apply seal packing in a bead shape, install the cylinder head within 3 minutes, and tighten the cylinder head bolts in two progressive steps to 79 Nm (806 kgf-cm, 58 ft. lbs.), marking the front side of the bolts and retightening by 90°.

Prevent gasoline from spilling by disconnecting the fuel pump connector, starting the engine until it stops, turning the ignition switch to LOCK (OFF), and then disconnecting the negative (-) terminal cable from the battery before reconnecting the fuel pump connector.

Detach the center exhaust pipe assembly for both 2WD and 4WD configurations, the front exhaust pipe assembly, the V-ribbed belt, and the generator assembly.