Toyota 4Runner 5vz-FE Engine Cylinder Head Replacing procedure?

Heare in this section,you will go through details for replacing toyota 4Runner Engine cylinder head.Its for 5VZ-FE model Engine.

The details are provided with proper diagrams,for you to follow and go through the disassemly procedure.


Removal & Installation
5vz-FE Engine

Before servicing the vehicle, refer to the Precautions section.
Disconnect the negative battery cable.
Relieve the fuel system pressure.
Remove the engine under-cover.
Drain the cooling system.
Remove or disconnect the following:

Front exhaust pipe
Air cleaner cap
Mass Air Flow (MAF) meter and the resonator

Disconnect the following cables:

Actuator cable with the bracket, if equipped with cruise control
Accelerator cable
Throttle cable, if equipped with an automatic transmission

Disconnect the following hoses:

Heater hose
Brake booster vacuum hose
Evaporative Emissions (EVAP) hose
Automatic Disconnecting Differential (ADD) vacuum hose, for 4-Wheel drive
Fuel inlet and fuel return hose

Remove or disconnect the following:

Spark plug wires with the ignition coils
Spark plugs
Intake chamber stay
No. 2 timing belt cover
Air intake chamber assembly

Remove the following connectors and hoses:

Throttle Position (TP) sensor connector
Idle Air Control (IAC) valve connector
Positive Crankcase Ventilation (PCV) hoses
Water bypass hoses
Air assist hose from the throttle body
Intake air connector

Disconnect the engine wiring harness protector, as follows:

6 injector connectors
Engine Coolant Temperature (ECT) sensor and sender gauge connectors
Engine wiring harness protector from the cylinder head

Remove or disconnect the following:

Fuel pressure regulator
Intake manifold assembly

Set the No. 1 cylinder at Top Dead Center (TDC) of the compression stroke, as follows:
Turn the crankshaft pulley and align its groove with the timing mark0
Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley 1 revolution (360 degrees).

Remove or disconnect the following:

Timing belt tensioner, by alternately loosening the 2 bolts
Timing belt

Remove the camshaft timing pulleys, as follows:
Using Variable Pin Wrench Set 09960-10010, remove the pulley bolt, the timing pulley and the knock pin.
Remove the 2 timing pulleys with the timing belt.

Remove or disconnect the following:

Bolt and the No. 2 idler pulley
Camshaft Position (CMP) sensor
No. 3 timing belt cover
Alternator from the engine
Alternator bracket
Power steering pump and move it aside without disconnecting the pump lines
Exhaust crossover pipe and gaskets, by removing the 6 nuts
Left-hand exhaust manifold, by removing the heat insulator and 6 nuts
Right-hand exhaust manifold, by removing the heat insulator and 6 nuts
8 bolts, seal washers, cylinder head cover and gasket.

See the Diagram shown Below:---

Cylinder heads and related parts-3.4L engine

NOTE

Remove both cylinder head covers

Semi-circular plugs

Right exhaust and intake camshafts

Left exhaust and intake camshafts

Valve lifters and shims from the cylinder head; arrange the valve lifters and shims in correct order

1. Remove the cylinder heads, as follows:
   
   
   Bolt and ground strap

   Cylinder head (recessed head) bolt on the cylinder head, using an 8mm hexagon wrench; then, repeat the procedure for the other side.

   8 cylinder head (12-pointed head) bolts, on each cylinder head.

NOTE

Loosen the bolts in several passes, in the sequence shown.

Fig. Head bolt loosening sequence-3.4L engine

16 cylinder head bolts and plate washers

Cylinder head

To install:

Fig. Cylinder head torque sequence-3.4L engine

1. Clean all surfaces.
2. Install or connect the following:
   
   
   New cylinder head gaskets

   Cylinder heads
3. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
4. Tighten the cylinder head bolts using several passes, in sequence, as follows:
   
   
   Step 1: 25 ft. lbs. (34 Nm)

   Step 2: Mark the front of the cylinder head bolt with paint

   Step 3: Turn 90 degrees

   Step 4: Check that the painted mark is now at a 90 degrees angle to the front
5. Install the recessed head cylinder head bolts, as follows:
   
   
   Step 1: Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts

   Step 2: Tighten the cylinder head bolts, using a 8mm hexagon wrench, to 13 ft. lbs. (18 Nm).

   Bolt and ground strap
6. Install or connect the following:
   
   
   Valve lifters and shims

NOTE

Check that the valve lifter rotates smoothly by hand.

Right intake and exhaust camshafts

Left intake and exhaust camshafts

1. Check and adjust the valve clearance.
2. Install or connect the following:
   
   
   Semi-circular plugs

   Cylinder head covers. Uniformly, tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).

   Exhaust manifolds with new gaskets. Tighten the nuts to 30 ft. lbs. (40 Nm).

   Exhaust manifold heat insulators. Tighten the nuts to 71 inch lbs. (8 Nm).

   Exhaust crossover pipe. Tighten the nuts to 33 ft. lbs. (45 Nm).

   Power steering pump

   Alternator bracket. Tighten the fasteners to 14 ft. lbs. (18 Nm).

   Alternator

   No. 3 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).

   CMP sensor. Tighten it to 71 inch lbs. (8 Nm).

   Timing belt

   No. 2 timing belt idler bolt. Tighten the bolt to 30 ft. lbs. (40 Nm).

NOTE

Check that the pulley bracket moves smoothly.

Left camshaft timing pulley

1. Set the No. 1 cylinder to TDC of the compression stroke, as follows:
   1. Connect the timing belt to the left camshaft timing pulley.
   2. Check that the installation mark on the timing belt is aligned with the end of the No. 1 timing belt cover.
   3. Install the right camshaft timing pulley and the timing belt.
   4. Set the timing belt tensioner. Alternately, tighten the bolts to 20 ft. lbs. (28 Nm).
2. Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
3. Check the valve timing.
4. Install or connect the following:
   
   
   New gaskets and the intake manifold assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).

   Intake manifold stay. Tighten the bolts to 14 ft. lbs. (18 Nm).

   Fuel pressure regulator
5. Connect the engine wiring harness to the intake manifold, as follows:
   
   
   Engine wiring harness to the cylinder head

   3 engine wiring harness clamps
6. Install or connect the following:
   
   
   6 injector connectors

   ECT sender gauge connector

   ECT sensor connector

   Intake air connector

   Air intake chamber assembly. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).

   Intake chamber stay

   No. 2 timing belt cover. Tighten the bolts to 80 inch lbs. (9 Nm).

   PCV hoses

   Water bypass hoses

   Air assist hose to the throttle body

   IAC valve connector

   TP sensor connector

   CMP sensor connector to the No. 2 timing belt cover

   3 spark plug wire clamps
7. Connect the following hoses:
   
   
   Brake booster vacuum hose

   EVAP hose

   Automatic Disconnecting Differential (ADD) vacuum hose, for 4-Wheel drive

   Fuel inlet and fuel return hose

   Heater hose
8. Install or connect the following:
   
   
   Oil dipstick and guide, using a new O-ring

   Spark plugs

   Spark plug wires, with the ignition coils

   Alternator drive belt
9. Connect the following cables:
   
   
   Actuator cable with the bracket, if equipped with cruise control

   Accelerator cable

   Throttle cable, if equipped with an automatic transmission

   MAF meter, resonator and air cleaner cap

   Front exhaust pipe

   Negative battery cable
10. Fill the radiator with engine coolant.
11. Start the engine and check for leaks.
12. Check the ignition timing.
13. Install the engine undercover.
14. Road test the vehicle.
15. Recheck all fluid levels.

Fig. Use a breaker bar and deep socket to remove the cylinder head bolts

Fig. Removing the cylinder head from the block

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. For additional information, please refer to the following topic(s): -Fuel System,- -Relieving Fuel System Pressure.-
3. Remove the engine under cover.
4. Drain the cooling system.
   
   
   

   

   Fig. Exploded view of the cylinder heads and related components-3.4L (5VZ-FE) Engine
5. Remove the front exhaust pipe.
6. Disconnect the air cleaner cap, Mass Air Flow (MAF) meter and the resonator.
7. Disconnect the following cables:
   
   
   Actuator cable with the bracket, if equipped with cruise control

   Accelerator cable

   Throttle cable if equipped with an automatic transmission
8. Disconnect the heater hose.
9. Disconnect the upper radiator hose from the engine.
10. Remove the power steering drive belt.
11. Remove the A/C drive belt by loosening the idle pulley nut and adjusting bolt.
12. Loosen the lock bolt, pivot bolt and adjusting bolt and the alternator drive belt.
13. Remove the fan shroud by removing the two clips.
14. Remove the fan with the fluid coupling and fan pulleys.
15. Disconnect the power steering pump from the engine and set aside. Do NOT disconnect the lines from the pump.
16. If equipped with A/C, remove the compressor mounting bolts and hang the compressor securely from the engine. Do NOT disconnect the refrigerant lines from the compressor.
17. If equipped with A/C, remove the A/C bracket.
18. Remove the spark plug wires with the ignition coils.
19. Remove the spark plugs.
20. Remove the timing belt cover.
21. Remove the fan bracket.
22. Set the No. 1 cylinder at TDC of the compression stroke.
    1. Turn the crankshaft pulley and align its groove with the timing mark Oof the No. 1 timing belt cover.
    2. Check that the timing marks of the camshaft timing pulleys and the No. 3 timing belt cover are aligned. If not, turn the crankshaft pulley one revolution (360°).
       
       NOTE

       If reusing the timing belt, make sure that you can still read the installation marks. If not, place new installation marks on the timing belt to match the timing marks of the camshaft timing pulleys.
23. Remove the timing belt tensioner by alternately loosening the two bolts.
24. Remove the camshaft timing pulleys. Using SST 09960-10010, or equivalent, to hold the pulley to keep it from turning, remove the pulley bolt, timing pulley, and straight pin. Remove the two timing pulleys with the timing belt.
25. Remove the bolt and the idler pulley.
26. Remove the alternator from the engine.
27. Remove the nuts and remove the EGR pipe and two gaskets.
28. Remove the oil filler tube and throttle cable clamp by removing the bolt and two nuts.
29. Remove the intake chamber stay by removing the two bolts.
30. Remove the following connectors:
    
    
    Vacuum Switching Valve (VSV) for the fuel pressure control

    Throttle Position (TP) sensor

    IAC valve

    Disconnect the EGR gas temperature wire

    Disconnect the VSV wire for the EGR valve
31. Disconnect the following hoses:
    
    
    PCV hoses

    Water bypass

    Air assist hose from the intake air wire

    Two vacuum sensing hoses from the VSV

    EVAP

    Air hose from the power steering

    If equipped with A/C, disconnect the air hose from the A/C idle up valve.
32. Remove the four bolts, two nuts and remove the air intake chamber assembly from the engine.
33. Remove the intake air connector as follows:
    1. Disconnect the engine wire from the intake air connector by removing the bolt.
    2. Disconnect the two fuel return hoses.
    3. Disconnect the brake booster vacuum hose from the intake air connector.
    4. Remove the bolt and disconnect the ground strap from the intake air harness.
    5. Disconnect the DLC1 from the bracket of the intake air harness.
    6. If equipped with A/C, disconnect idle up valve.
    7. Remove the intake air connector from the engine by removing the three bolts and two nuts.
34. Disconnect the engine wire from the intake manifold as follows:
    1. Tag for identification, then disconnect the wiring from the following:
       
       
       Oil pressure sensor

       Crankshaft position sensor

       Six injectors

       ECT sender gauge

       ECT sensor

       Knock sensor

       Camshaft position sensor
    2. Disconnect the three engine wire clamps.
    3. Remove the three bolts, and then disconnect the engine wire from the cylinder head.
35. Remove the camshaft position sensor.
36. Remove the (rear) timing belt cover by removing the six bolts.
37. Remove the fuel pressure regulator.
38. Remove the intake manifold assembly.
39. Remove the power steering pump bracket.
40. Remove the oil dipstick and guide.
41. Remove the exhaust crossover pipe and gaskets by removing the six nuts.
42. Remove the left hand exhaust manifold by unbolting the heat insulator and nuts for the exhaust manifold.
43. Remove the right hand exhaust manifold by unbolting the heat insulator and six nuts for the exhaust manifold.
44. Remove the eight bolts, seal washers, valve cover and gasket. Remove both valve covers.
45. Remove the semi-circular plugs.
46. Remove the right side exhaust camshaft.
    
    WARNING

    Do NOT pry on or attempt to force the camshaft with a tool or other object.
47. Remove the right side intake camshaft.
48. Remove the left side exhaust camshaft.
49. Remove the left side intake camshaft.
50. Remove the valve lifters and shims from the cylinder head. Arrange the valve lifters and shims in correct order.
51. Using a 8mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side.
52. Uniformly loosen and remove the 8-cylinder head (12-pointed head) bolts on each cylinder head. Loosen the bolts in several passes using the loosening sequence shown.
    
    WARNING

    Cylinder head warpage or cracking could result from removing the bolts in an incorrect order.
53. Remove the 16-cylinder head bolts and flat washers.
54. Lift the cylinder head from the dowels on the cylinder block.
    
    NOTE

    If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a suitable pry device. Be careful not to damage the contact surfaces of the cylinder head and block.
    
    
    
    
    

    

    Fig. The recessed bolts must be removed first-3.4L (5VZ-FE) Engine
    
    
    
    

    

    Fig. Cylinder head bolt loosening sequence-3.4L (5VZ-FE) Engine
    
    
    
    

    

    Fig. Cylinder head bolt tightening sequence-3.4L (5VZ-FE) Engine

To install:

1. Clean all parts well. Cylinder head rebuilding is best left to professionals. The head should be cleaned and inspected before installation.
   
   NOTE

   The head bolts used in this engine are designed to stretch and deform slightly. They should be carefully inspected. New service replacement head bolts are strongly recommended.
2. Place two new cylinder head gaskets in position on the cylinder block.
3. Place the two cylinder heads on the dowels of the cylinder block.
4. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
5. Install and uniformly tighten the cylinder head bolts on each cylinder as follows:
   1. In several passes and in the sequence shown, tighten the cylinder bolts to 25 ft. lbs. (34 Nm).
   2. Mark the front of the cylinder head bolt with paint.
   3. Retighten the cylinder head bolts in sequence by 90°.
   4. Check that the painted mark is now at a 90° angle to the front.
   5. Retighten the cylinder head bolts in sequence by an additional 90°
   6. Check that the painted mark is now facing rearward.
6. Apply a light coat of engine oil on the threads and under the heads of the recessed cylinder head bolts. Using a 8mm hexagon wrench, install the cylinder head bolt on each cylinder head, then repeat for the other side. Tighten the bolts to 13 ft. lbs. (18 Nm).
7. Install the valve lifters and shims. Check that the valve lifter rotates smoothly by hand.
8. Install the right intake camshaft.
9. Install the right exhaust camshaft.
10. Install the left intake camshaft.
11. Install the left exhaust camshaft.
12. Check and adjust the valve clearance.
13. Install the semi-circular plugs.
14. Install the cylinder head covers. Uniformly tighten the bolts, in several passes, to 53 inch lbs. (6 Nm).
15. Attach the exhaust manifolds with new gaskets; tighten the nuts to 30 ft. lbs. (40 Nm).
16. Install the exhaust manifold heat insulators with the nuts; tighten to 71 inch lbs. (8 Nm).
17. Install the exhaust crossover pipe and tighten the nuts to 33 ft. lbs. (45 Nm).
18. Install the alternator bracket and tighten the bolts to 14 ft. lbs. (18 Nm).
19. Install the oil dipstick and guide using a new O-ring.
20. Install the power steering bracket and tighten the mounting bolts to 14 ft. lbs. (18 Nm).
21. Install two new gaskets and the intake manifold assembly. Install the four flat washers, eight bolts, and four nuts. Tighten the bolts and nuts to 13 ft. lbs. (18 Nm).
22. Install the intake manifold stay with the two bolts. Tighten the bolts to 14 ft. lbs. (18 Nm).
23. Connect the fuel inlet hose.
24. Install the fuel pressure regulator.
25. Install the timing belt cover with the six bolts. Tighten the bolts to 80 inch lbs. (9 Nm).
26. Install the camshaft position sensor; tighten to 71 inch lbs. (8 Nm).
27. Connect the engine wire to the intake manifold as follows:
    1. Install the engine wire to the cylinder head by installing the three bolts.
    2. Connect the three engine wire clamps.
    3. Attach the following connectors:
       
       
       Oil pressure sensor

       Crankshaft position sensor

       Six injectors

       ECT sender gauge

       ECT sensor

       Knock sensor

       Camshaft position sensor
28. Install the intake air connector as follows:
    1. Install the intake manifold to the engine by installing the three bolts and two nuts. Tighten the bolts and nuts, evenly and in several passes, to 14 ft. lbs. (19 Nm).
    2. Attach the DLC1 to the bracket on the intake manifold.
    3. Attach the ground strap to the intake manifold by installing the bolt.
    4. Connect the brake booster vacuum hose to the intake air connector.
    5. Connect the two fuel return hoses.
    6. Connect the engine wire to the intake manifold by installing the bolt.
    7. If equipped with A/C, attach the idle up valve connector.
29. Install the air intake chamber assembly to the engine by installing the four bolts and two nuts. Tighten the bolts and nuts to 14 ft. lbs. (19 Nm).
30. Connect the following hoses:
    
    
    PCV

    Water bypass

    Air assist hose to the intake manifold

    Two vacuum sensing hoses to the VSV

    EVAP hose

    Air hose to the power steering

    If equipped with A/C, connect the air hose to the A/C idle up valve.
31. Attach the following connectors:
    
    
    VSV for the fuel pressure control

    Throttle position sensor

    Idle Air Control (IAC) Valve

    Connect the EGR gas temperature sensor

    Connect the VSV wire for the EGR valve
32. Install the intake chamber stay. Tighten to 30 ft. lbs. (40 Nm)
33. Install a new O-ring to the oil filler tube. Push in the oil filler tube end into the tube hole in the oil pan. Install the oil filler tube and throttle cable clamp and install the bolt and two nuts.
34. Install two new gaskets and the EGR pipe with the nuts. Tighten the clamp nuts to 71 inch lbs. (8 Nm) and the EGR pipe nuts to 14 ft. lbs. (19 Nm).
35. Install the alternator but do not tighten the bolts and nuts at this time.
36. Install the timing belt idler with the bolt; tighten to 30 ft. lbs. (40 Nm). Check that the pulley bracket moves smoothly.
37. Install the left camshaft timing pulley as follows:
    1. Install the knock pin to the camshaft.
    2. Align the knock pin hole of the camshaft with the knock pin groove of the timing pulley.
    3. Slide the timing pulley on the camshaft with the flange side facing outward. Tighten the pulley bolt to 81 ft. lbs. (110 Nm).
38. Set the No. 1 cylinder to TDC of the compression stroke:
    1. Turn the crankshaft pulley, and align its groove with the timing mark 0of the timing belt cover.
    2. Turn the camshaft, and then align the knock pin hole of the camshaft with the timing mark of the timing belt cover.
    3. Turn the camshaft timing pulley, and then align the timing marks of the camshaft timing pulley and the timing belt cover.
39. Connect the timing belt to the left camshaft timing pulley. Check that the installation mark on the timing belt is aligned with the end of the timing belt cover.
    1. Using SST 09960-01000 or equivalent, slightly turn the left camshaft timing pulley clockwise. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley, and hang the timing belt on the left camshaft timing pulley.
    2. Align the timing marks of the left camshaft pulley and the timing belt cover.
    3. Check that the timing belt has tension between the crankshaft timing pulley and the left camshaft timing pulley.
40. Install the right camshaft timing pulley and the timing belt as follows:
    1. Align the installation mark on the timing belt with the timing mark of the right camshaft timing pulley, and hang the timing belt on the right camshaft timing pulley with the flange side facing inward.
    2. Slide the right camshaft timing pulley on the camshaft. Align the timing marks on the right camshaft timing pulley and the timing belt cover.
    3. Align the knock pin hole of the camshaft with the knock pin groove of the pulley and install the knock pin. Install the bolt and tighten to 81 ft. lbs. (110 Nm).
41. Set the timing belt tensioner as follows:
    1. Using a press, slowly press in the pushrod using 220-2,205 lbs. (981-9,807 N) of force.
    2. Align the holes of the pushrod and housing, pass a 1.5mm hexagon wrench through the holes to keep the setting position of the pushrod.
    3. Release the press and install the dust boot to the tensioner.
42. Install the timing belt tensioner and alternately tighten the bolts to 20 ft. lbs. (28 Nm). Using pliers, remove the 1.5mm hexagon wrench from the belt tensioner.
43. Slowly turn the crankshaft pulley two revolutions from the TDC to TDC. Always turn the crankshaft pulley clockwise. Check that each pulley aligns with the timing marks. If the timing marks do not align, remove the timing belt and reinstall it.
44. Install the fan bracket with the bolt and nut.
45. Install the power steering adjusting strut with the nut.
46. Install the timing belt cover, tighten the bolts to 80 inch lbs. (9 Nm).
47. Connect the three clamps for the spark plug wires to the timing belt cover.
48. Connect the camshaft position sensor connector to the timing belt cover.
49. Install the spark plugs.
50. Install the spark plug wires with the ignition coils.
51. If equipped, install the A/C compressor bracket.
52. If equipped, install the A/C compressor.
53. Install the fan with the fluid coupling and fan pulleys, tighten the nuts to 48 inch lbs. (5 Nm).
54. Install the fan shroud.
55. Install the alternator drive belt.
56. Install the cooling fan, and then tighten the nuts to 4 ft. lbs. (5 Nm).
57. If equipped, install and adjust the A/C drive belt.
58. Install the power steering pump, the pump pulley, and the drive belt.
59. Connect the upper radiator hose.
60. Connect the heater hose.
61. Connect the following cables:
    
    
    On cruise control, attach the actuator cable with bracket

    Accelerator cable

    With A/T, the throttle cable
62. Install the MAF meter, resonator and air cleaner cap.
63. Install the front exhaust pipe.
64. Refill the cooling system to the correct level.
65. Because coolant can contaminate the oil system when cylinder heads are removed, it is important to drain the oil and refill with fresh oil. A filter change is recommended.
66. Connect the negative battery cable.
67. Start the engine and check for leaks.
68. Check the ignition timing.
69. Install the engine undercover.
70. Recheck all fluid levels and add as required.

These details will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html