Cylinder Head Bolt Threads Damaged (2AZ-FE)
T-SB-0015-11March 2, 2011Cylinder Head Bolt Threads Damaged (2AZ-FE)ServiceCategoryEngine/Hybrid SystemSectionEngine ITIONAL INFORMATION2002 – 2006CamryEngine(s): 2AZTransmission(s): 4AT, 5MT, 5ATVDS(s): BE30K, BE32KWMI(s): 4T1, JTD2001 – 2007HighlanderEngine(s): 2AZTransmission(s): 4AT, 5ATVDS(s): DD21A, GD21A, HD21AWMI(s): JTE2004 – 2005RAV4Engine(s): 2AZTransmission(s): 5MT, 4ATVDS(s): GD20V, HD20VWMI(s): JTE2002 – 2006SolaraEngine(s): 2AZTransmission(s): 4AT, 5MT, 5ATVDS(s): CE22P, CE28P, CE30P, CE38P, FE22P,FE28PWMI(s): 4T1IntroductionSome vehicles equipped with the 2AZ-FE engine may exhibit damaged cylinder head bolts. Pleasefollow the Repair Procedure to install Time Sert thread repair inserts into the cylinder block.Warranty InformationOP CODEDESCRIPTIONTIMEOFPT1T2N/ANot Applicable to Warranty–––– 2011 Toyota Motor Sales, USAPage 1 of 29
March 2, 2011T-SB-0015-11Page 2 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Parts Information2002–2006 CamrySPECPZEV & Non-PZEVNon-PZEVPZEVPZEV & Non-PZEVPREVIOUS PARTNUMBERCURRENT PARTNUMBERPART NAMEQTY11400-28311SameBlock Assy, Short*90910-02141SameBolt (for Cylinder Head Set)*11213-0H010SameGasket, Cylinder Head Cover111115-28040SameGasket, Cylinder Head117173-28010SameGasket, Exhaust Manifold to Head117177-0H010SameGasket, Intake Manifold toHead, No. 1117177-28040SameGasket, Intake Manifold toHead, No. 1117171-28020SameGasket, Intake to Exhaust Manifold190917-A6001SameGasket, Exhaust Pipe12002 – 2006 SolaraPREVIOUS PART NUMBERCURRENT PART NUMBERPART NAMEQTY11400-28311SameBlock Assy, Short*90910-02141SameBolt (for Cylinder Head Set)*11213-0H010SameGasket, Cylinder Head Cover111115-28040SameGasket, Cylinder Head117173-28010SameGasket, Exhaust Manifold to Head117177-0H010SameGasket, Intake Manifold to Head, No. 1190917-A6001SameGasket, Exhaust Pipe1 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 3 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Parts Information (Continued)2001 – 2007 HighlanderPREVIOUS PART NUMBERCURRENT PART NUMBERPART NAMEQTY11400-28311SameBlock Assy, Short*90910-02141SameBolt (for Cylinder Head Set)*11213-0H010SameGasket, Cylinder Head Cover111115-28040SameGasket, Cylinder Head117173-28010SameGasket, Exhaust Manifold to Head117177-0H010SameGasket, Intake Manifold to Head, No. 1117451-0D020SameGasket, Exhaust Pipe1PREVIOUS PART NUMBERCURRENT PART NUMBERPART NAMEQTY11400-28311SameBlock Assy, Short*90910-02141SameBolt (for Cylinder Head Set)*11213-0H010SameGasket, Cylinder Head Cover111115-28040SameGasket, Cylinder Head117173-28010SameGasket, Exhaust Manifold to Head117177-0H010SameGasket, Intake Manifold to Head, No. 1117451-74040SameGasket, Exhaust Pipe12004 – 2005 RAV4* Order ONLY if engine block replacement is necessary. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 4 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Required Tools & EquipmentREQUIRED TOOLS & MATERIALQUANTITYBrake Cleaner (for Cleaning Bolt Holes)As NeededEngine Oil (for lubrication of Head Bolt Inserts)As NeededWD-40 (for Lubrication of Core Drill and Tap)As NeededPower Drill1Tap Handle1Seal Tape (for Airtight Check of Bolt Holes)As NeededShop Cloth (for Preventing Intrusion of Foreign Particles into Cylinder Block)As NeededTape (for Preventing Intrusion of Foreign Particles into Cylinder Block)As NeededPARTNUMBERQTYTFC22001TFC111556Loctite TFC6020As NeededTime Sert Driver OilTFC6010As NeededREQUIRED EQUIPMENTSUPPLIERTime Sert M11 x 1.5 Universal Head Bolt Repair Kit(Includes 10 Thread Repair Inserts)Time Sert M11 x 1.5 x 30 mm Thread Repair InsertsADENOTEAdditional Time Sert kits and components may be ordered by calling Approved Dealer Equipment(ADE) at 1-800-368-6787. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 5 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Required Tools & Equipment (Continued)Time Sert M11 x 1.5 Universal Head Bolt Repair KitFigure 1. Kit Components Needed for Repair Procedure2314567891Alignment Pin (Line Pin)7Core Drill2Drill Bushing8Tap3Insert (x10)9Insert Driver10Metal Rule4Loctite5Long Bolt (4.0 in.) (x2)11Ink Marker6Drill Fixture12Driver Oil 101112HINT Figure 1 shows the tools needed for this repair. The short Bolt (2.5 in.) and medium Bolt (3.5 in.) included in the kit are not needed for thisprocedure. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 6 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure Overview1. Confirm the cylinder head bolt(s) is loose due to damaged threads.2. Remove the short block assembly from the vehicle.3. Inspect the cylinder block assembly for flatness to ensure it meets specifications for reuse.4. Prepare the block for the insert repairs.5. Use the core drill to repair the bolt holes.6. Use the tap to cut new threads for the insert.7. Use the insert driver to install the insert.8. Reassemble and install the short block assembly with inserts installed.Figure 2. Repair Procedure Work Flow3a2a4a4b1a12341Before Work3aTap1aDamaged Threads4Install the Insert2Repair Bolt Hole4aInsert Driver2aCore Drill4bInsert3Cut New Threads for Insert5Finished 2011 Toyota Motor Sales, USA5
March 2, 2011T-SB-0015-11Page 7 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Precautions for All OperationsCAUTION Protective goggles, a protective mask, and other necessary protective equipment must beworn while working.Brake Cleaner: As brake cleaner is highly flammable, do not use it near fire or hot sections. If you get brakecleaner on your clothes, keep away from fire and hot sections until clothes are dry. Be careful to prevent spattering while working. For details, refer to the brake cleaner’s handling instructions.NOTICE Never perform insert work on the 2 bolt holes at the front and rear of the cylinder block. If anydamage is found in such sections, replace the cylinder block. Make sure to perform insert work on all 6 holes regardless of the condition of holes (except 2bolt holes front and rear of cylinder block).Figure 3.21211Inserts MUST Be Installed in These Holes2Inserts CANNOT Be Installed in These Holes 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 8 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Inspection Procedure1. Remove the engine assembly.Refer to the applicable model and model year Repair Manual section(s) on the TechnicalInformation System (TIS).2. Disassemble the engine assembly to gain access to the cylinder block deck, cylinder head,and manifold mounting surfaces.Refer to the applicable model and model year Repair Manual section(s) on TIS.NOTEIf the following specifications are not met, replace the short block assembly.3. Inspect the cylinder block for flatness.Using a precision straight edge and feeler gauge, measure the surface contacting the cylinderhead for warpage.Maximum Warpage: 0.05 mm (0.002 in.)Figure 4. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 9 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Inspection Procedure (Continued)4. Inspect the depth of counter bore in head bolthole.Figure 5. Head Bolt Hole.Using a rule or vernier caliper, measure the depthof counter bore.Maximum Depth: 79.0 mm (3.11 in.)1NOTICE3Replace the cylinder block if the depth of anyhead bolt hole exceeds the standard.21Top Surface of Cylinder Block2Start of Threads3Depth of Counter Bore 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 10 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Inspection Procedure (Continued)5. Inspect the cylinder head for flatness.Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinderblock and the manifolds for warpage.Maximum Warpage:Cylinder Block Side: 0.05 mm (0.002 in.)Exhaust Manifold Side: 0.08 mm (0.003 in.)Figure 6.121Cylinder Block Side2Intake Manifold Side336. Inspect the cylinder head set bolt.Exhaust Manifold SideFigure 7.A. Check that the thread of cylinder head set boltis free of debris or other foreign materials.Clean the head bolt if necessary.B. Using a vernier caliper, measure the length ofthe head bolts from the seat to the end.Specified Bolt Length: 161.3 – 164.2 mm(6.35 – 6.46 in.) 2011 Toyota Motor Sales, USA.
T-SB-0015-11March 2, 2011Page 11 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure1. Attach the cylinder block to the engine stand andmake sure that it can be rotated.Figure 8.112. Clean the tools.Engine StandFigure 9.Before beginning work, clean off any cuttingparticles or other substances from the tools whichwill be used. 2011 Toyota Motor Sales, USA.
March 2, 2011T-SB-0015-11Page 12 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)3. Clean the cylinder block.Figure 10.A. Remove the remaining gasket from the topsurface of the cylinder block.B. Remove any oil or other substances from thetop surface of the cylinder block.4. Mark the core drill positions.Figure 11.21211Inserts MUST Be Installed in These Holes2Inserts CANNOT Be Installed in These HolesA. Insert a rule into the bolt hole and place the end of the rule against the start of the threads. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 13 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)B. Mark the position of the top surface of the cylinder block on the rule at this time, and recordthe dimension.Dimension A: mm ( in.)NOTICEIf dimension A exceeds 79 mm (3.11 in.), replace the cylinder block.Figure 12.123A41Metal Rule4Start of Threads2Mark on Metal RuleADimension A3Top Surface of Cylinder BlockC. Insert the core drill into the drill bushing. 2011 Toyota Motor Sales, USA
T-SB-0015-11March 2, 2011Page 14 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)D. Align the rule, core drill, and bushing positionsas shown in the figure. Mark the position of thetop surface of the drill bushing on the core drill.Figure 13.Marking position:Height of Dimension A Drill Bushing Height132A41Marking Position2Lower Edge of Drill Bushing3Marking4Core Drill StepADimension A 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 15 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)5. Mark the tap and insert the driver.A. Align the front tips of the core drill, tap, and insert driver.B. Mark the tap and insert driver at the sameheight as the marking on the core drill.Figure 14.NOTEWork carefully so the markings do not ruboff during the repair.32411Align Front Tips2Same Height3Core Drill Marking4Mark on Tap and Insert Driver 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 16 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)6. Provisionally install the drill fixture.NOTICEMove the pistons from the Top Dead Center position in order to avoid contact between pistonsand drill fixture.A. Install the drill bushing and alignment pin.B. Align the round hole of the drill fixture with the bolt hole which will be repaired, and thentemporarily install 2 head bolts to fix the drill fixture.Figure 15.1523441Alignment Pin4Provisional Installation2Drill Bushing5Align with Bolt Hole3Drill FixtureNOTICE Always use 2 bolts to fix the drill fixture. Avoid using bolt holes with damaged threads for this procedure and install the boltsdiagonally whenever possible. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 17 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)7. Center and fasten the drill fixture.NOTICEIf the drill fixture is NOT correctly centered, the bolt holes may be drilled at an angle, andthe cylinder block will need to be replaced.A. Press the alignment pin gently and make surethat the pin is inserted all the way down intothe hole.Figure 16.12B. Hold the drill fixture so that it does not becomedisplaced, and tighten the 2 bolts.1Press Gently2Align PositionFigure 17.2211Hold2TightenC. Remove the alignment pin, and visually check that the bolt hole and drill fixture are centered. 2011 Toyota Motor Sales, USA
March 2, 2011T-SB-0015-11Page 18 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)8. Protect the cylinder block.Figure 18.3NOTICEIf the cutting particles that are produced duringthe drilling and tapping process enter theengine, they can cause engine damage, so besure to apply protection.21Use tape or a shop cloth to cover the parts shownand protect the cylinder block so that cuttingparticles do NOT enter it.4 Drill fixture bolt holes Top surface of the cylinder block Cylinder block component installation holesNOTICE1Shop ClothUse a new shop cloth and tape for each repairas the old ones may have cutting particlesattached to them.2Tape3Bolt Holes4Component Installation Holes9. Repair the bolt hole.A. Tilt the cylinder block so that the cutting particles will fall downwards.Figure 19. 2011 Toyota Motor Sales, USA
T-SB-0015-11March 2, 2011Page 19 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)B. Use the core drill and repair the bolt hole.NOTICE Hold the drill perpendicular to the top surface of the block.If the bolt holes are drilled at an angle, the cylinder block will need to be replaced. Drill the hole in 4 progressively deeper steps, retracting the drill each time, to clear thecutting particles from the hole. Apply WD-40 regularly to lubricate the drill.Figure 20.12131Core Drill3Divide into 4 Steps2Perpendicular4Do NOT Complete in One StepC. Remove the core drill and drill bushing. 2011 Toyota Motor Sales, USA4
March 2, 2011T-SB-0015-11Page 20 of 29Cylinder Head Bolt Threads Damaged (2AZ-FE)Repair Procedure (Continued)D. Invert the cylinder block so that it is upside-down.Figure 21.211Invert2Clean with Block InvertedE. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in orderto flush out the cutting particles from inside it.Figure 22.11Insert A
B. Mark the position of the top surface of the cylinder block on the rule at this time, and record the dimension. Dimension A: _ mm (_ in.) NOTICE If dimension A exceeds 79 mm (3.11 in.), replace the cylinder block. Figure 12. 1 2 3 A 4 1 Metal Rule 2 Mark on Metal Rule 3 Top Surface of Cylinder Block 4 Start of Threads A Dimension A
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