2002 2.4 Head gasket repair journey

[BigNev]

Heck of a job you're into there mate!

Good luck with progress, I'll keep watching out for updates!

[Michael Brown]

Very good pictures again and your updates on what you are doing. Fingers crossed you will be successful and have Alphie back on the road in no time.

 

Good Luck

[crazymac680]

Day 13 - 2 hours

So I spent a lot of time waiting for parts. When I was ready to install the head bolts. I realised that the new ones didn't come with washers and I'd thrown away the old😂.

Didn't want to risk buying something similar and decided to ask Toyota. It was about £2.50 per washer but £28.99 delivery! I emailed asking them if they could get me a better deal on the delivery but after 3 days I had no reply. So I ordered from Amayama. It took about 3 weeks but only cost £16.90 inc delivery! Great service. I spent the first hour checking that my holes were clear or debris and oil. Then confirming that my holes were deep enough. 

Gave the head and block a final clean. 

Fitted the gasket and head. 

Greased the washer and thread of each bolt with engine oil. 

Torqued to 30 - 42- 55 - 70. In the order in the images. 

Final 90 degree turn in the same order. 

Feel like I'm on the home straight. Time for bed now. 

 

[crazymac680]

Day 14. 2 hours. 

Another successful night regardless of the 40mph wind and showers. Luckily mostly sheltered by the house. 

Put the block to TDC.

Cleaned up the camshafts as there was some rust starting to form in the followers. 

Oiled all the surfaces.

Installed the camshafts and torqued the bearing caps to 9nm for the small ones and 29 for the big one. 

 

[Michael Brown]

Keep up the work you are doing Daniel, fingers crossed you will have Alfie back on the road again soon

[MonsterS]

Ah i see the problem. it's a 2.4 not a 3L.

[crazymac680]

1 hour ago, MonsterS said:

Ah i see the problem. it's a 2.4 not a 3L.

🤣 Yeah most of the work was removing the timing chain cover

[crazymac680]

Day 15. 2 hours. 

Another good night. Slow and steady progress. 

Cleaned up the timing chain cover. Getting it ready for gasket sealant. 

I had to drill out 2 studs from the cover. Tonight I installed 2 helicoils to keep the bolts the same size as the originals. 

I really struggled to remove the crank oil seal. I had to very carefully cut it with the hack saw. The new one went in by hand. 

I then dialed in my timing marks and installed the chain guides. 

Tomorrow I'll hopefully clean up the engine and install the timing chain cover. 

 

[crazymac680]

Day 16. 1 hour. 

Cleaned up the block in preparation for the timing chain cover.

Noticed the pink powder around the bottom of the water pump. So decided to replace it. Very easy to remove. Just 5 10mm bolts.