Cylinder Head, Intake Manifold, Exhaust Manifold: Removal

1. Discharge fuel system pressure (See FUEL SYSTEM ).

1. w/ engine under cover assembly

1. w/ engine under cover No. 2

1. Drain engine coolant (See COOLANT ).

1. Drain engine oil (See REPLACEMENT ).

1. Remove the FR wiper arm LH (See FRONT WIPER MOTOR ).

1. Remove the FR wiper arm LH (See FRONT WIPER MOTOR ).

1. Remove the cowl top ventilator louver sub-assembly (See FRONT WIPER MOTOR ).

1. Remove the windshield wiper link assembly (See FRONT WIPER MOTOR ).

1. Remove the cowl top panel sub-assembly (See REMOVAL ).

1. Remove the V-bank cover sub-assembly (See ADJUSTMENT  ).

1. Remove the air cleaner cap sub-assembly (See REMOVAL ).

1. Remove the air cleaner inlet No. 2 (See REMOVAL ).

1. Remove the air cleaner case (See REMOVAL ).

1. Remove the emission control valve set (See ADJUSTMENT  ).

1. Remove the intake air surge tank (See ADJUSTMENT  ).

1. Disconnect the fuel pipe sub-assembly No. 1 (See FUEL SYSTEM ).

1. Lock the hose clamp as shown in the illustration.
2. Disconnect the heater inlet water hose.

Fig 1: Disconnecting Heater Inlet Water Hose

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1. Remove the nut and disconnect the ground cable.
2. Disconnect the 6 fuel injector connectors.
   Fig 2: Disconnecting Fuel Injector Connectors

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3. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.

1. Disconnect the radiator hose inlet.
   Fig 3: Identifying Intake Manifold Bolts Removal Sequence

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Disconnect the engine coolant temperature sensor connector.
3. Remove the clamp.
4. Remove the 2 bolts, 2 nuts and 2 washers.
5. Lock the hose clamp as shown in the illustration and remove the water outlet together with water by-pass Hose No. 1.
6. Remove the 2 gaskets from the 2 cylinder heads.
Fig 4: Disconnecting Engine Coolant Temperature Sensor Connector
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1. Remove the front fender apron seal RH (See REMOVAL ).

1. Remove the V-(cooler compressor to crankshaft pulley) belt No. 1 (See REMOVAL  ).

1. Remove the vane pump V-belt (See REMOVAL  ).

1. Remove the engine moving control rod (See REMOVAL  ).

1. Remove the engine mounting stay No. 2 RH (See REMOVAL  ).

1. Remove the generator bracket No. 2 (See REMOVAL  ).

SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031) 

1. Remove the crankshaft pulley (See REMOVAL  ).

1. Remove the timing belt No. 2 cover (See REMOVAL  ).

1. Remove the engine mounting bracket RH (See REMOVAL  ).

1. Remove the timing belt (See REMOVAL  ).

SST 09960-10010 (09962-01000, 09963-01000), 09249-63010

1. Remove the camshaft timing pulley (See page REMOVAL  ).

1. Remove the timing belt No. 3 cover (See REMOVAL  ).

SST 09325-20010 

1. Remove the propeller shaft (See REMOVAL ).

1. Remove the exhaust pipe sub-assembly (See REMOVAL ).

1. Disconnect the heated oxygen sensor connector.
2. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
3. Remove the exhaust manifold RH and the gasket from the cylinder head RH.

1. Separate the exhaust pipe assembly front (See REMOVAL ).

Fig 5: Identifying Exhaust Manifold Bolts Loosening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the heated oxygen sensor connector.
2. Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.
3. Remove the exhaust manifold converter No. 2 and the gasket from the cylinder head LH.

Fig 6: Identifying Exhaust Manifold Converter No 2 Bolts Loosening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the bolt which is used to secure the oil level gage guide from the cylinder head LH.
2. Pull out the oil level gage guide and the oil level gage together from the cylinder block.
3. Remove the O-ring from the oil level gage guide.

Fig 7: Removing O-Ring From Oil Level Gage Guide

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1. Remove the cylinder head cover sub-assembly (See ADJUSTMENT  ).

1. Remove the cylinder head cover sub-assembly LH (See ADJUSTMENT  ).

1. Remove the camshaft (See REMOVAL  ).

1. Remove the No. 2 camshaft (See REMOVAL  ).

1. Remove the No. 3 camshaft sub-assembly (See REMOVAL  ).

1. Remove the No. 4 camshaft sub-assembly (See REMOVAL  ).

1. Disconnect the VVT sensor connector.
2. Disconnect the camshaft timing oil control valve connector.
3. Remove the nut and disconnect the engine wire harness clamp.
   Fig 8: Disconnecting Engine Wire Harness Clamp

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Using a socket hexagon wrench 8, remove the hexagon bolt.
   Fig 9: Identifying Hexagon Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

Fig 10: Identifying Cylinder Head Bolts Loosening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Disconnect the VVT sensor connector.
2. Disconnect the camshaft timing oil control valve connector.
3. Remove the bolts and disconnect the ground cable.
4. Remove the bolt and the wire harness clamp bracket.
5. Remove the bolt and separate the water inlet. (TMMWV MADE)
   Fig 11: Disconnecting Camshaft Timing Oil Control Valve Connector

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Using a socket hexagon wrench 8, remove the hexagon bolt.
   Fig 12: Identifying Hexagon Bolt

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

Fig 13: Identifying Cylinder Head Bolts Loosening Sequence

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002