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Canada - Engine - Cylinder Head Bolt Threads Damaged






Bulletin
T-TCI-3584

Issue Date
October 7, 2011

Market
Canada

Title
CYLINDER HEAD BOLT THREADS DAMAGED (2AZ-FE)

Service Category
Engine/Hybrid System

Section
Engine Mechanical

Market
Canada






Applicability

Introduction

Some vehicles equipped with the 2AZ-FE engine may exhibit damaged cylinder head bolts. Please follow the Repair Procedure to install Time Sert(R)thread repair inserts into the cylinder block.






Warranty Information

Parts Information






* Order ONLY if engine block replacement is necessary.
2002-2006 Camry






* Order ONLY if engine block replacement is necessary.
2002 - 2006 Solara






* Order ONLY if engine block replacement is necessary.
2001 - 2007 Highlander






* Order ONLY if engine block replacement is necessary.
2004 - 2005 RAV4











Required Tools & Equipment

NOTE
Additional Time Sert(R)kits and components may be ordered by calling Wurth at 1 800 263-5002.






Time Sert(R)M11 x 1.5 Universal Head Bolt Repair Kit

HINT
- 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 this procedure.

Repair Procedure Overview

1. 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.

Precautions for All Operations

CAUTION
- Protective goggles, a protective mask, and other necessary protective equipment must be worn while working.

Brake Cleaner:
- As brake cleaner is highly flammable, do not use it near fire or hot sections. If you get brake cleaner 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 any damage 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 2 bolt holes front and rear of cylinder block).

Inspection Procedure

1. Remove the engine assembly.
Refer to the applicable model and model year Repair Manual section(s) on E-TAS / TIS library

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 E-TAS / TIS library.

NOTE
If 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 cylinder head for warpage.

Maximum Warpage: 0.05 mm (0.002 in.)







4. Inspect the depth of counter bore in head bolt hole.
Using a rule or vernier caliper, measure the depth of counter bore.
Maximum Depth: 79.0 mm (3.11 in.)

NOTICE
Replace the cylinder block if the depth of any head bolt hole exceeds the standard.







5. Inspect the cylinder head for flatness.
Using a precision straight edge and a feeler gauge, measure the surface contacting the cylinder block 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.)







6. Inspect the cylinder head set bolt.
A. Check that the thread of cylinder head set bolt is free of debris or other foreign materials. Clean the head bolt if necessary.
B. Using a vernier caliper, measure the length of the head bolts from the seat to the end.

Specified Bolt Length: 161.3 - 164.2 mm (6.35 - 6.46 in.)

Repair Procedure







1. Attach the cylinder block to the engine stand and make sure that it can be rotated.







2. Clean the tools.
Before beginning work, clean off any cutting particles or other substances from the tools which will be used.







3. Clean the cylinder block.
A. Remove the remaining gasket from the top surface of the cylinder block.
B. Remove any oil or other substances from the top surface of the cylinder block.







4. Mark the core drill positions.
A. Insert a rule into the bolt hole and place the end of the rule against the start of the threads.







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.

C. Insert the core drill into the drill bushing.







D. Align the rule, core drill, and bushing positions as shown in the figure. Mark the position of the top surface of the drill bushing on the core drill.

Marking position: Height of Dimension A + Drill Bushing Height

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 same height as the marking on the core drill.

NOTE
Work carefully so the markings do not rub off during the repair.

6. Provisionally install the drill fixture.

NOTICE
Move the pistons from the Top Dead Center position in order to avoid contact between pistons and 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 then temporarily install 2 head bolts to fix the drill fixture.

NOTICE
- Always use 2 bolts to fix the drill fixture.
- Avoid using bolt holes with damaged threads for this procedure and install the bolts diagonally whenever possible.

7. Center and fasten the drill fixture.

NOTICE
If the drill fixture is NOT correctly centered, the bolt holes may be drilled at an angle, and the cylinder block will need to be replaced.







A. Press the alignment pin gently and make sure that the pin is inserted all the way down into the hole.







B. Hold the drill fixture so that it does not become displaced, and tighten the 2 bolts.
C. Remove the alignment pin, and visually check that the bolt hole and drill fixture are centered.







8. Protect the cylinder block.

NOTICE
If the cutting particles that are produced during the drilling and tapping process enter the engine, they can cause engine damage, so be sure to apply protection.

Use tape or a shop cloth to cover the parts shown and protect the cylinder block so that cutting particles do NOT enter it.
- Drill fixture bolt holes
- Top surface of the cylinder block
- Cylinder block component installation holes

NOTICE
Use a new shop cloth and tape for each repair as the old ones may have cutting particles attached to them.

9. Repair the bolt hole.







A. Tilt the cylinder block so that the cutting particles will fall downwards.
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 the cutting particles from the hole.
- Apply WD-40(R)regularly to lubricate the drill.

C. Remove the core drill and drill bushing.







D. Invert the cylinder block so that it is upside-down.







E. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.







F. Return the cylinder block to a tilted position as shown in Figure 23.







G. Repeat steps 9B through 9F until the marking on the core drill is aligned with the top surface of the drill bushing.

10. Tap the bolt hole.
A. Position the cylinder block vertically.







B. Use the tap and tap handle to cut new threads in the bolt hole.







C. Remove the tap and drill bushing.







D. Invert the cylinder block so that it is upside-down.







E. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.







F. Return the cylinder block to a tilted position as shown in Figure 29.







G. Repeat steps 10B through 10F until the marking on the tap is aligned with the top surface of the bushing.

11. Check the bolt hole.
A. Invert the cylinder block so that it is upside-down.







B. Insert the nozzle all the way into the bolt hole and spray brake cleaner into the hole in order to flush out the cutting particles from inside it.







C. Use an air blower and dry the hole fully.

IMPORTANT
- Because Loctite(R)will be used to fasten the insert in place, be sure to dry the bolt hole fully.
- Position the cylinder block upside-down during this work.

D. Use a cylinder leak down tester and check the head bolt holes.
1. Wrap the tip of the tester with seal tape so it is thick enough to fill the gap between the tip of the tester and the holes.
2. Apply 44 psi (300 kPa) to the head bolt hole.
3. Confirm the air pressure does NOT decrease after 15 seconds.

NOTICE
- If air leaks through the head bolt hole into the short block, replace the cylinder block.
- Make sure to perform the leak check BEFORE inserting the insert to the bolt holes.

12. Install the insert.







A. Apply a small amount of driver oil to the threads of the insert driver.







B. Screw the insert onto the insert driver all the way until it stops.

NOTICE
Do not apply oil to the outer threads of the insert.







C. Apply a small amount of Loctite(R)to the outer threads of the insert.
D. Insert the insert driver with the insert into the bolt hole and slowly screw it into the hole until the marking on the driver matches the top surface of the drill bushing.







E. When the marking is aligned with the top surface of the bushing, turn the driver in the opposite direction to remove it.







F. Remove the drill bushing and screw the head bolt into the hole by hand to verify that there is no problem with the threads.

HINT
Apply a small amount of engine oil to the threads of the head bolt.

G. Remove the shop cloth and protective tape.

NOTICE
Work carefully so the cutting particles do not fall on the engine.

H. Remove the drill fixture.

13. Repeat the insert installation process (steps 2 - 12) on the remaining bolt holes.

NOTE
The insert installation process MUST be performed on all 6 bolt holes regardless of the condition of the bolt hole. (See the Notice in "Precautions for All Operations" in this TSB).

14. Reassemble the engine assembly.
Refer to the applicable model and model year Repair Manual section(s) on E-TAS / TIS library.

15. Install the engine assembly into the vehicle.
Refer to the applicable model and model year Repair Manual section(s) on E-TAS / TIS library.

16. Test drive to confirm the repair.

NOTE:
Issue of this Technical Service Bulletin is to ensure that proper repair information is available. IT DOES NOT CONSTITUTE AN AUTHORIZATION FOR REPAIR. Normal provisions of the formal warranty policy, as applicable, will apply.
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