Toyota 11115-31031
Head Gasket

The first step for Cylinder Head Gasket No. 2 replacement involves stopping gasoline from leakage. Disassemble the chain sub-assembly and exhaust front pipe assembly No. 2 and manifold stay No. 2 using the removal of their respective 3 bolts. Begin by disconnecting the A/F sensor connector followed by removing 6 nuts that separate exhaust manifold from the gasket for taking out the exhaust manifold sub-assembly LH. Begin the body of work by disconnecting sub-assemblies No. 1 and No. 2 of the fuel pipes and then detach the intake manifold followed by water by-pass joint RR and finally chain vibration damper No. 1 through its 2 bolt removal. After pushing down chain tensioner No. 3 and inserting a 1.0 mm pin remove the camshaft timing gears together with timing chain No. 2 (LH bank) from the engine while the hexagonal portion of the camshaft must be held in place with a wrench to unfist the 2 bolts and timing gear assembly. Release chain tensioner assembly No. 3 before properly removing the camshafts with a method to maintain their horizontal position to prevent any damage. Uniform bolt removal from the 16 bearing cap results in extraction of the 8 bearing caps and 2 camshafts. Beginning with a ground cable separation and subsequent 2 cylinder head bolt loosening, proceed to remove the 8 cylinder head bolts in the correct order until the cylinder head can be lifted from the dowels onto wooden blocks. The cylinder head set bolt requires examination with a vernier caliper to ensure it meets the specifications of 10.85 - 11.00 mm standard outside diameter with 10.7 mm minimum. Install a new cylinder head gasket after cleaning old packing material and apply a continuous bead of seal packing (Part No. 08826-00080) within 3 minutes, placing the gasket in its appropriate position. Begin by placing the cylinder head gasket on its surface and then install the 8 cylinder head bolts with light engine oil on the threads before stepwise tightening to reach 36 Nm torque and front-side paint marking for each bolt before retightening them 180 degreres and installing the 2 additional cylinder head bolts at 30 Nm torque. The ground cable needs reinstalling with 8.0 Nm of torque. Install the camshafts in level position then set crankshaft correctly while applying new engine oil on the camshafts before installing the 8 bearing caps with 16 bearing cap bolts receiving specified torques based on head thickness. Following the installation of assembly No. 3 chain tensioner comes the installation of camshaft timing gears and No. 2 chain alternating the marks properly while tightening all bolts to 100 Nm. We need to install chain vibration damper No. 1 together with water by-pass joint RR and intake manifold and fuel pipe sub-assemblies No. 1 and No. 2. Mount the LH exhaust manifold assembly with its new gasket before securing the 6 nuts to 30 Nm torque specification followed by installing manifold stay No. 2 and its 3 bolts to 40 Nm torque. Then install the exhaust front pipe assembly No. 2 along with the chain sub-assembly. The last procedure includes inspecting fuel and exhaust gas leaks while using Special Service Tool: 09843-18030 to measure engine idle speed and evaluating CO/HC levels.

The 1GR-FE engine cylinder head gasket removal starts by separating the engine assembly from its vehicle assembly. You must remove the ignition coil assembly followed by spark plug together with the VVT sensor and the camshaft timing oil control valve assembly. The maintenance procedure involves removing both right and left cylinder head cover sub-assemblies along with the engine oil level dipstick guide, heater water pipe sub-assembly, rear water by-pass joint, oil control valve filter and its components which include V-ribbed belt tensioner assembly, No. 2 idler pulley sub-assembly, No. 1 idler pulley sub-assembly, crankshaft pulley, No. 2 oil pan sub-assembly, oil strainer sub-assembly, and oil pan sub-assembly. The maintenance technician detaches the No. 2 oil cooler hose and the oil cooler hose before separating the water inlet housing and the oil filter bracket sub-assembly along with timing chain cover sub-assembly. The mechanic must execute the following steps: first remove the front crankshaft oil seal followed by setting No. 1 cylinder to TDC/compression then they must remove the No. 1 chain tensioner assembly, chain tensioner slipper, No. 1 idle gear shaft and all components including the No. 2 chain vibration damper, No. 1 chain, No. 1 chain vibration damper and camshaft timing gears and No. 2 chain. During the removal process maintain a level position of camshafts while removing both the No. 3 chain tensioner assembly and both the No. 3 camshaft and No. 4 camshaft. First step is to loosen then remove the 16 bearing cap bolts installed in proper sequence followed by extraction of 8 bearing caps and 2 camshafts. The left side cylinder head sub-assembly removal requires following these steps: loosening the 2 cylinder head bolts while removing the 8 cylinder head bolts with plate washers in order; then lifting the cylinder head from the dowels on the cylinder block by placing it on wooden blocks. Washers securing the contact surfaces must be handled with care while the No. 2 cylinder head gasket needs to be taken out.

Installation of 1GR-FE cylinder head gaskets begins with removing old FIPG packing while preventing contact surfaces of the cylinder head and cylinder block from getting contaminated by oil. Seal Packing Black from Toyota Genuine should be applied to a new cylinder head gasket together with Three Bond 1207B or equivalent material with a standard seal diameter between 2.5 and 3.0 mm (0.0984 to 0.118 in.) before installing the gasket within three minutes of application while avoiding contact with engine oil for two hours post-installation. When installing the cylinder head gasket onto the cylinder block, put the front face of the Lot No. stamp upward while maintaining the correct installation orientation. The cylinder head sub-assembly RH installation should be followed by No. 1 and No. 2 camshaft bearings while also installing No. 1 and No. 2 camshafts with maintenance of camshaft level positioning to avoid damage during assembly. Place the components together with the No. 1 cylinder cam lobes facing correct directions while utilizing the crankshaft pulley set bolt for positioning and applying light engine oil on camshaft journals and thrust portions. After applying engine oil to the 8 bearing caps the technician should install them correctly before adding oil to the threads and under the heads of the 16 bearing cap bolts while following a specific torque sequence of 9.0 Nm (92 kgf-cm, 80 in-lbf) for 10 mm head bolts and 24 Nm (245 kgf-cm, 18 ft-lbf) for 12 mm head bolts. The mechanics will rotate the camshafts in a clockwise direction so the camshaft knock pin faces directly at a 90-degree angle toward the cylinder head. After installing the manifold front sub-assembly and connecting all oil cooler hoses, you should proceed with the installation of the No. 2 chain tensioner assembly, camshaft timing gears, No. 2 chain, chain tensioner slipper, No. 1 chain tensioner assembly, No. 1 chain, No. 2 chain vibration damper, No. 1 idle gear shaft, front crankshaft oil seal, timing chain cover sub-assembly, oil filter bracket sub-assembly, water inlet housing. The installation process starts with sub-assemblies of oil pan then oil strainer and finally No. 2 oil pan while finishing with cylinder head covers RH and LH as well as an engine oil level dipstick guide. When assembling the rear water bypass joint, install an O-ring on the water outlet pipe while setting new gaskets to water ports LH and RH. Apply soapy water on the O-ring before fastening the joint with 2 bolts and 4 nuts under 9.0 Nm (92 kgf-cm, 80 in-lbf), then connect the engine coolant temperature sensor. The heater water pipe sub-assembly requires 9.8 Nm (100 kgf-cm, 87 in-lbf) of torque for both bolts and the 3 water hoses need to be connected. After the engine assembly installation onto the vehicle the technician should install the crankshaft pulley and No. 1 and No. 2 idler pulley sub-assemblies as well as the V-ribbed belt tensioner assembly and oil control valve filter before connecting the heater water pipe sub-assembly and finishing up with the spark plug and VVT sensor and camshaft timing oil control valve assembly and ignition coil assembly installations.

Ensure cleanliness and install the camshafts while keeping them level, applying new engine oil to the thrust portion and journal.

Install camshaft bearing No.2, then the camshafts while keeping them level, applying new engine oil, and tightening 16 bearing cap bolts to specified torque values.

Install the cylinder head within 3 minutes and tighten the bolts within 15 minutes.

First, remove the engine assembly from the vehicle.

Remove the front crankshaft oil seal and set the No. 1 cylinder to TDC/compression.