This document provides information to assist in replacing a cylinder head on a vehicle. It details the steps involved and highlights potential time-saving methods.
Problem
Replacing a cylinder head is a significant undertaking. This information provides insight into how to approach the task and avoid common pitfalls.
Solution
The procedure for replacing a cylinder head involves a series of steps that can be optimized by considering specific strategies.
Preparation and Disassembly:
- Component Removal:
- Remove batteries, air filter box, intercooler, belts, fan, and radiator.
- Disconnect or bypass the transmission cooler lines. A bent 3/8" copper tube can loop the hoses to bypass the radiator.
- Unbolt the air conditioning compressor from its mounting bracket (4 bolts) and tie it clear. Then, unbolt the bracket from the head.
- Remove the front wheels and plastic body-to-chassis trims for better access to the turbo oil banjo and support bracket.
- Turbocharger Removal (Potentially Optional):
- The turbocharger dump can be difficult to remove. Remove the front pipe as well to avoid dropping anything.
- The turbo and manifold can be removed as a unit. Plug the oil feed and drain holes with rags after removal.
- Alternatively, consider leaving the exhaust manifold and turbo in place by loosening the bottom support stay, removing the Torx-headed exhaust manifold studs, and carefully maneuvering the head out.
- Inlet Manifold and Fuel System:
- Remove injector lines and the inlet manifold. It’s easier to remove the oil filter first. Plug the area with rags, or screw the filter back on.
- Heater Pipe:
- Unbolt the steel heater pipe running from the left side, across the rear, and up to the rubber heater hoses. Note the support bolt behind the head.
- Earth Points:
- Note the location of a multi-earth point, which can be difficult to access.
- Camshaft Preparation:
- Remove the cambelt cover, belt, and tensioner. Rotate the crank off TDC to prevent valve-piston contact.
- Remove the cam cover. Hold the cam with a large shifter and remove the cam center bolt. Use a 2-jaw puller to remove the cam pulley, and catch the woodruff key. Remove the alloy seal housing.
- Final Disassembly:
- Remove injectors and glow plugs.
- Remove head studs and carefully lift off the head, noting that it is heavier than expected.
Inspection and Reassembly:
- Gasket Check: Before reassembly, check the new gasket set for completeness.
- Component Cleaning: Clean all surfaces before installing the new head.
- Manifold Studs: Consider replacing the exhaust manifold studs with steel exhaust studs and brass or stainless steel nuts (e.g., VL Commodore studs, M10x1.25mm) to prevent thread stripping in the aluminum head.
- Glow Plug Test: Test the glow plugs before reinstallation.
- Reassembly: Follow the reverse order of disassembly, ensuring proper torque settings.
- Oil Change: Perform an initial oil and filter change with cheap oil to flush any coolant contamination, followed by a change with your normal oil and a quality filter.
Relevant Parts
- Gasket Set: Ensure all necessary gaskets and washers are included. Be aware that copper washers for the turbo oil supply banjo, the turbo oil drain gasket, and a gasket for the coolant pipe may be missing from aftermarket kits.
- Oil Filter: Toyota filters are recommended over Ryco. Part number 90915-300028T or equivalent, may be made in Thailand. Consider purchasing genuine filters online.
- Exhaust Manifold Studs: VL Commodore studs, M10x1.25mm, with washers and nuts.
This technical summary was auto-generated based on recovered archives. Do not rely on its factual accuracy. Refer to the original thread. Source: View Original Conversation
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