Hey guys this info may be helpful for anyone looking to replace their head gasket on your CT, I recently did this job on a 2013 prius, Same engine just different chassis. Let me know if you have any questions.
0:00 YO
0:50 Disconnect auxillary battery and hybrid battery safety plug ("service plug grip" in repair manual)
1:13 Remove plastic engine cover
1:19 Remove wiper blades (3x 14mm nuts) and upper cowl panel
1:46 Remove wiper motor assembly (4x 10mm bolts, 1 wire connector) and lower cowl panel (10x 10mm bolts)
2:30 Unplug MAF sensor (1 wire connector); remove intake air cleaner assembly, air cleaner hose assembly, air cleaner cap sub-assembly, air cleaner hose assembly, air cleaner case (3x 10mm bolts)
3:29 Unplug ignition coils (4 wire connectors), variable valve timing solenoid (1 wire connector)
4:08 Remove ground wires (3x 10mm bolts)
4:46 Be mindful of damaging A/C compressor connector
5:07 Unplug A/C compressor, knock sensor, water pump, throttle body; Remove coolant lines and vacuum lines from throttle body; Remove intake manifold (2x 10mm bolts on EGR valve; 3x 12mm bolts, 2x 12mm nuts on cylinder head sub-assembly)
5:29 Double sneeze
5:36 Excuses
6:34 Remove intake manifold and throttle body as one unit
6:52 Remove cylinder head cover (12x 10mm bolts, 1x long 10mm bolt w/ non-replaceable seal washer)
7:30 Raise car; Remove splash shield
8:00 Drain engine oil and engine coolant
8:15 Unplug oxygen sensor, oil pressure sensor, crank position sensor
8:25 Excuses
8:30 Remove timing cover bolts (9x 14mm), crank pulley AFTER setting cylinder 1 to Top-Dead-Center/Compression (1x 19mm bolt), water pump (3x short 12mm bolts, 2x long 12mm bolts, non-reusable gasket)
9:13 Remove exhaust manifold (2x 14mm bolts, 1 bracket)
10:23 Remove EGR coolant hoses
10:41 Excuses
10:47 Remove radiator pipe from transmission (2x 12mm bolts); Remove radiator hose from engine block
11:15 Remove coolant reservoir (2x 10mm bolts); Remove A/C coolant line bracket (2x 10mm)
11:27 Remove motor mount (4x 17mm bolt, 1x 17mm nut, 1x 14mm nut)
12:36 How to set cylinder no. 1 to Top-Dead-Center/Compression
13:49 Remove timing chain tensioner (2x 10mm bolts, 1x non-reusable gasket); Remove water pump
14:55 Remove timing cover
15:28 Remove chain tensioner slipper and chain vibration damper; Remove timing chain
16:37 Remove EGR (4x 12mm bolts, 4x Torx E8 studs); Remove camshaft housing (15x 12mm bolts)
17:36 Remove radiator hose, remove fuel line
18:10 Remove valve rocker arms; Be mindful of losing valve stem covers
18:32 Remove head bolts (10x non-reusable 10mm bi-hexagon bolts); Be mindful of breaking bolts loose over multiple passes and from outside inwards to avoid warping, stripping, or other damage; Do not reuse head bolts as they are torqued upon installation and stretched
19:41 Remove cylinder head
20:35 Inspect pistons, engine block, and cylinder head for warpage; Resurface engine block and cylinder head; Clean camshaft housing and timing cover; Consider bringing engine head to an auto machine shop to resurface and inspect valve seals since you're already saving so much money replacing the head gasket yourself
22:10 Timing sprocket details
22:58 Apply replacement head gasket; Replace cylinder head
24:36 Add new head bolts (10x 10mm bi-hexagon bolts torqued 49Nm/36ftlb torque on first pass, 90 degree turn on second pass, 45 degree turn on third and final pass; Torque bolts from inside outwards on each pass for even torque)
25:41 Replace valve rocker arms; Add silicone sealant on clean edge surface to seal against camshaft housing; Replace camshaft housing
26:03 Replace timing chain with timing marks lined up on camshaft timing gear, camshaft timing sprocket, and crankshaft position sensor plate
26:51 Turn crank multiple revolutions to ensure timing marks are still lined up; Add silicone sealant to clean edge surface of timing cover; Replace timing chain tensioner and all other components in reverse order
27:20 Start car; There may be a rattle from timing chain tensioner that will disappear quickly
Specialty tools: Torx E8 socket (don't get a cheap one), 10mm bi-hexagon head bolt male wrench (don't use triple-square) Standard tools: Penetrating oil e.g. PB Blaster to prevent breaking bolts or studs; Vice grips if you break a bolt or stud; 3/8" drive ratchet; 1/2" drive ratchet; 10mm, 12mm, 14mm standard sockets; 10mm, 12mm, 14mm, 17mm , 19mm, 21mm deep sockets
0:50 Disconnect auxillary battery and hybrid battery safety plug ("service plug grip" in repair manual)
1:13 Remove plastic engine cover
1:19 Remove wiper blades (3x 14mm nuts) and upper cowl panel
1:46 Remove wiper motor assembly (4x 10mm bolts, 1 wire connector) and lower cowl panel (10x 10mm bolts)
2:30 Unplug MAF sensor (1 wire connector); remove intake air cleaner assembly, air cleaner hose assembly, air cleaner cap sub-assembly, air cleaner hose assembly, air cleaner case (3x 10mm bolts)
3:29 Unplug ignition coils (4 wire connectors), variable valve timing solenoid (1 wire connector)
4:08 Remove ground wires (3x 10mm bolts)
4:46 Be mindful of damaging A/C compressor connector
5:07 Unplug A/C compressor, knock sensor, water pump, throttle body; Remove coolant lines and vacuum lines from throttle body; Remove intake manifold (2x 10mm bolts on EGR valve; 3x 12mm bolts, 2x 12mm nuts on cylinder head sub-assembly)
5:29 Double sneeze
5:36 Excuses
6:34 Remove intake manifold and throttle body as one unit
6:52 Remove cylinder head cover (12x 10mm bolts, 1x long 10mm bolt w/ non-replaceable seal washer)
7:30 Raise car; Remove splash shield
8:00 Drain engine oil and engine coolant
8:15 Unplug oxygen sensor, oil pressure sensor, crank position sensor
8:25 Excuses
8:30 Remove timing cover bolts (9x 14mm), crank pulley AFTER setting cylinder 1 to Top-Dead-Center/Compression (1x 19mm bolt), water pump (3x short 12mm bolts, 2x long 12mm bolts, non-reusable gasket)
9:13 Remove exhaust manifold (2x 14mm bolts, 1 bracket)
10:23 Remove EGR coolant hoses
10:41 Excuses
10:47 Remove radiator pipe from transmission (2x 12mm bolts); Remove radiator hose from engine block
11:15 Remove coolant reservoir (2x 10mm bolts); Remove A/C coolant line bracket (2x 10mm)
11:27 Remove motor mount (4x 17mm bolt, 1x 17mm nut, 1x 14mm nut)
12:36 How to set cylinder no. 1 to Top-Dead-Center/Compression
13:49 Remove timing chain tensioner (2x 10mm bolts, 1x non-reusable gasket); Remove water pump
14:55 Remove timing cover
15:28 Remove chain tensioner slipper and chain vibration damper; Remove timing chain
16:37 Remove EGR (4x 12mm bolts, 4x Torx E8 studs); Remove camshaft housing (15x 12mm bolts)
17:36 Remove radiator hose, remove fuel line
18:10 Remove valve rocker arms; Be mindful of losing valve stem covers
18:32 Remove head bolts (10x non-reusable 10mm bi-hexagon bolts); Be mindful of breaking bolts loose over multiple passes and from outside inwards to avoid warping, stripping, or other damage; Do not reuse head bolts as they are torqued upon installation and stretched
19:41 Remove cylinder head
20:35 Inspect pistons, engine block, and cylinder head for warpage; Resurface engine block and cylinder head; Clean camshaft housing and timing cover; Consider bringing engine head to an auto machine shop to resurface and inspect valve seals since you're already saving so much money replacing the head gasket yourself
22:10 Timing sprocket details
22:58 Apply replacement head gasket; Replace cylinder head
24:36 Add new head bolts (10x 10mm bi-hexagon bolts torqued 49Nm/36ftlb torque on first pass, 90 degree turn on second pass, 45 degree turn on third and final pass; Torque bolts from inside outwards on each pass for even torque)
25:41 Replace valve rocker arms; Add silicone sealant on clean edge surface to seal against camshaft housing; Replace camshaft housing
26:03 Replace timing chain with timing marks lined up on camshaft timing gear, camshaft timing sprocket, and crankshaft position sensor plate
26:51 Turn crank multiple revolutions to ensure timing marks are still lined up; Add silicone sealant to clean edge surface of timing cover; Replace timing chain tensioner and all other components in reverse order
27:20 Start car; There may be a rattle from timing chain tensioner that will disappear quickly
Specialty tools: Torx E8 socket (don't get a cheap one), 10mm bi-hexagon head bolt male wrench (don't use triple-square) Standard tools: Penetrating oil e.g. PB Blaster to prevent breaking bolts or studs; Vice grips if you break a bolt or stud; 3/8" drive ratchet; 1/2" drive ratchet; 10mm, 12mm, 14mm standard sockets; 10mm, 12mm, 14mm, 17mm , 19mm, 21mm deep sockets
