OEM 2004 Toyota 4Runner Cylinder Head Gasket

2004 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to replace the Cylinder Head Gasket on 2004 Toyota 4Runner?

  A: The replacement process begins by stopping gasoline flow then removing the chain sub-assembly along with cool air inlet No.1 using two bolts and the air cleaner hose and proceeding with the transmission oil filler tube sub-assembly removal by removing the ATF level gauge as well as the bolt and O-ring. You must first detach the front exhaust pipe assembly and manifold stay with 3 bolts before removing the exhaust manifold sub-assembly RH through A/F sensor connector disconnect and 6 nuts with exhaust manifold and gasket. The separation of fuel pipe sub-assemblies No.1 and No.2 enables the removal of the intake manifold through fuel injector connector removal and 10 bolt detachment before extracting the intake manifold and its accompanying 2 gaskets. Uninstall the water by-pass joint RR by disconnecting the engine coolant temperature sensor connector and heater hose, taking out 2 bolts, 4 nuts, the water by-pass joint RR and 2 gaskets before removing the O-ring from the water outlet pipe. To access the camshaft timing gears together with No.2 chain (RH bank) lift chain tensioner No.2 and secure it with a 1.0 mm pin and unscrew the hexagonal portion of the camshaft using a wrench to remove 2 bolts followed by the camshaft timing gear assembly, its timing chain No.2 component and camshaft timing gear. Maintain the cylinder head and valve lifter from damage. Start by separating chain tensioner No.2 followed by precise removal of camshafts while maintaining their flat orientation to prevent damage, after which proceed with unbolted installation of 16 bearing cap bolts according to sequence and extract 8 bearing caps alongside 2 camshafts. The procedure starts with unfastening 2 ground cables and then using a 10 mm bi-hexagon wrench to loosen 8 cylinder head bolts uniformly before the mechanic lifts the cylinder head from the dowels on the cylinder block and places it on wooden blocks. Inspection of the cylinder head set bolt requires a vernier caliper for measuring the outside diameter to guarantee specifications. Place the cylinder block gasket onto the surface after applying a continuous bead of seal packing (Part No. 08826-00080 or equivalent) has been applied along with thorough cleaning of old packing materials. The gasket placement should occur with the Lot No. stamp facing upward. The cylinder head requires placement on the gasket before installing 8 cylinder head bolts which should receive engine oil on their threads followed by uniform tightening according to specifications to reach 36 Nm torque while applying paint marks to the front sides of each bolt then re-tightening 180 degrees as indicated. After securing the ground cables with two bolts at 8.0 Nm torque, clean Camshaft bearing No.2 before placing the camshafts correctly and applying new engine oil to both the thrust portion and journal. Finish the installation process by tightening 8 bearing caps that receive a light engine oil coating over their threads to 8.0 Nm torque. Secure each of the 16 bearing cap bolts with a uniform torque while installing the tensioner mechanism of assembly No.2 by pressing and pinning it before tightening the bolt to 19 Nm. Synchronize the marks of camshaft timing gears with No.2 chain (RH bank) before setting the bolts temporarily before torquing to 100 Nm. Fasten the water by-pass joint RR to its heater hose and engine coolant temperature sensor connector by using new O-rings and gaskets. Use new gaskets for the intake manifold then fit it correctly before securing all 10 bolts at 28 Nm torque. After joining fuel pipe sub-assemblies No.1 together with sub-assembly No.2 technicians should install the exhaust manifold sub-assembly RH applying new gasket material and securing 6 nuts to 30 Nm while reattaching the A/F sensor connector. Attach the manifold stay with 3 bolts at 40 Nm before installing the exhaust pipe front section and then fasten the transmission oil filler tube assembly while coating the O-ring with ATF beforehand. Complete the installation of cool air inlet No.1 while checking fuel and exhaust gas leaks and conducting engine idle speed checks with Special Service Tool: 09843-18030 and performing compression tests and CO/HC measurements.