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Home >> Lexus >> 2007 >> LX 470 >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2UZ-FE) >> Cylinder Head >> Removal

Cylinder Head: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag activation.
  3. DRAIN ENGINE OIL 
    1. Remove the oil pan drain plug and drain the engine oil.
    2. Clean the oil pan drain plug and install a new gasket and the drain plug.

      Torque: 39 N*m (398 kgf*cm, 29 ft.*lbf) 

  4. REMOVE TIMING BELT 
    1. Remove the TIMING BELT  .
  5. DISCONNECT NO. 1 FUEL HOSE (See  REMOVAL  ) 
  6. DISCONNECT NO. 2 FUEL HOSE (See  REMOVAL  ) 
  7. REMOVE FRONT EXHAUST PIPE LH (See  REMOVAL  ) 
  8. REMOVE FRONT EXHAUST PIPE RH (See  REMOVAL  ) 
  9. REMOVE INTAKE MANIFOLD ASSEMBLY (See  REMOVAL  ) 
  10. REMOVE AIR SWITCHING VALVE ASSEMBLY (See  DISASSEMBLY  ) 
  11. REMOVE AIR PUMP ASSEMBLY (See  REMOVAL  ) 
  12. REMOVE CAMSHAFT POSITION SENSOR (See  REMOVAL  ) 
  13. REMOVE VVT SENSOR (for Bank 1) (See  REMOVAL  ) 
  14. REMOVE VVT SENSOR (for Bank 2) (See  REMOVAL  ) 
  15. REMOVE KNOCK SENSOR (See  REMOVAL  ) 
  16. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 1) (See  REMOVAL  ) 
  17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Bank 2) (See  REMOVAL  ) 
  18. REMOVE STARTER ASSEMBLY (See  REMOVAL  ) 
  19. REMOVE WATER INLET HOUSING 
    1. Disconnect the water by-pass hose from the water inlet housing.
    2. Remove the 2 bolts and inlet housing.
  20. REMOVE FRONT WATER BY-PASS JOINT 
    1. Disconnect the ECT sensor connector and by-pass hose.
      Fig 1: Identifying Inlet Housing Bolts
      G04061785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  21. DISCONNECT HEATER HOSE 
    Fig 2: Identifying Water By-Pass Joint Nuts
    G04061786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE WATER BY-PASS PIPE SUB ASSEMBLY 
    1. Remove the bolt.
    2. Pull out the water by-pass pipe.
    3. Remove the O-ring from the water by-pass pipe.
    Fig 3: Removing O-Ring From Water By-Pass Pipe
    G04061787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE REAR WATER BY-PASS JOINT 
    1. Remove the 4 nuts and water by-pass joint.
    2. Remove the 2 gaskets from the water by-pass joint.
    Fig 4: Identifying Water By-Pass Joint Nuts
    G04061788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE OIL DIPSTICK GUIDE WITH DIPSTICK 
    1. Remove the bolt and dipstick guide with dipstick.
    2. Remove the O-ring.
  25. REMOVE IGNITION COIL 
    1. Remove the 8 bolts and 8 ignition coils.
  26. REMOVE SPARK PLUG 
  27. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Remove the 9 bolts, 9 seal washers and cylinder head cover.
    Fig 5: Identifying Cylinder Head Cover Bolts - LH
    G04061789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH 
    1. Remove the 9 bolts, 9 seal washers and cylinder head cover.
    Fig 6: Identifying Cylinder Head Cover Bolts - RH
    G04061790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. WORK FOR PISTON AND VALVE DAMAGE PREVENTION 
    1. Turn the crankshaft timing pulley counterclockwise by 45° and match the timing mark with the illustrated position.
      Fig 7: Identifying Crankshaft Timing Marks
      G04061791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    HINT:

    When the No. 1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other even when the valve is fully open.

    NOTE: Be sure to match the cut part by turning it counterclockwise.
  30. REMOVE CAMSHAFT TIMING PULLEY LH 
    1. Hold the camshaft timing pulley with SST, loosen the 4 bolts of the timing pulley.

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

    2. Remove the timing pulley.
      Fig 8: Loosening Bolts Of Timing Pulley - LH
      G04061792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE CAMSHAFT TIMING PULLEY RH 
    1. Hold the camshaft timing pulley with SST, loosen the 4 bolts of the timing pulley.

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

    2. Remove the timing pulley.
    Fig 9: Loosening Bolts Of Timing Pulley - RH
    G04061793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE REAR NO. 2 TIMING BELT PLATE LH 
    1. Remove the 2 bolts and No. 2 timing belt plate.
  33. REMOVE REAR TIMING BELT PLATE LH 
    1. Remove the bolt and timing belt plate.
  34. REMOVE REAR NO. 2 TIMING BELT PLATE RH 
    1. Remove the 2 bolts and No. 2 timing belt plate.
  35. REMOVE REAR TIMING BELT PLATE RH 
    1. Remove the bolt, stud bolt and timing belt plate.
  36. REMOVE CAMSHAFT (for Bank 1) 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Bring the service bolt hole of the sub-gear upward by turning the hexagon head portion of the No. 4 camshaft with a wrench.
    2. Secure the sub-gear to the main gear with a service bolt.

      Recommended service bolt 

      SERVICE BOLT

      Thread Diameter Thread Pinch Bolt Length
      6 mm 1.0 mm 16 to 20 mm (0.63 to 0.79 in.)
      Fig 10: Securing Sub-Gear To Main Gear With Service Bolt
      G04061794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

    3. Set a wrench to the hexagon head portion of the No. 4 camshaft. Turn the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.
      Fig 11: Aligning Timing Marks (2 Dot Marks Each) On Camshaft Drive And Driven Main Gears
      G04061795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
    5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and the No. 3 and No. 4 camshafts.
      Fig 12: Identifying Removal Sequence Of Bearing Cap Bolts
      G04061796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not forcibly pry the camshaft with a tool.
      • Do not damage the reception part of the thrust on the cylinder head side.
  37. REMOVE CAMSHAFT (for Bank 2) 
    NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
    1. Bring the service bolt hole of the sub-gear upward by turning the hexagon head portion of the No. 2 camshaft with a wrench.
    2. Secure the sub-gear to the main gear with a service bolt.

      Recommended service bolt 

      SERVICE BOLT

      Thread diameter Thread pinch Bolt length
      6 mm 1.0 mm 16 to 20 mm (0.63 to 0.79 in.)
      Fig 13: Securing Sub-Gear To Main Gear With Service Bolt
      G04061797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

    3. Set a wrench to the hexagon head portion of the No. 2 camshaft. Turn the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10°, as shown in the illustration.
      Fig 14: Turning Timing Mark (1 Dot Mark) On Camshaft Main Gear Is Moved Approximately 10°
      G04061798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
    5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and the No. 1 and No. 2 camshafts.
      Fig 15: Identifying Removal Sequence Of Bearing Cap Bolts
      G04061799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not forcibly pry the camshaft with a tool.
      • Do not damage the reception part of the thrust on the cylinder head side.
  38. REMOVE NO. 1 ENGINE HANGER 
    1. Remove the 2 bolts and engine hanger.
    Fig 16: Identifying No. 1 Engine Hanger Bolts
    G04061800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE NO. 2 ENGINE HANGER 
    1. Remove the 2 bolts and engine hanger.
    Fig 17: Identifying No. 2 Engine Hanger Bolts
    G04061801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE CYLINDER HEAD LH 
    1. Uniformly loosen the 10 cylinder head bolts on the cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.
      Fig 18: Identifying Loosening Sequence Of Cylinder Head Bolts
      G04061802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    2. Lift the cylinder head from the ring pins on the cylinder block, and place the cylinder head on wooden blocks on a bench.
    3. Remove the cylinder head together with the exhaust manifold.
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
        Fig 19: Removing Cylinder Head Together With Exhaust Manifold
        G04061803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • When removing the cylinder head, tilt the cylinder head but make sure the valve lifter does not drop.

    HINT:

    If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

  41. REMOVE CYLINDER HEAD GASKET LH 
  42. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and heat insulator.
    Fig 20: Identifying Heat Insulator Bolts
    G04061804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH 
    1. Remove the 8 nuts, exhaust manifold and gasket.
    Fig 21: Identifying Exhaust Manifold Nuts
    G04061805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CYLINDER HEAD RH 
    1. Uniformly loosen the 10 cylinder head bolts on the cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.
      Fig 22: Identifying Loosening Sequence Of Cylinder Head Bolts
      G04061806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
      • Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
    2. Lift the cylinder head from the ring pins on the cylinder block, and place the cylinder head on wooden blocks on a bench.
    3. Remove the cylinder head together with the exhaust manifold.
      NOTE:
      • Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
        Fig 23: Removing Cylinder Head Together With Exhaust Manifold
        G04061807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

    HINT:

    If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

  45. REMOVE CYLINDER HEAD GASKET RH 
  46. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and heat insulator.
    Fig 24: Identifying Heat Insulator Bolts
    G04061808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Remove the 8 nuts, exhaust manifold and gasket.
    Fig 25: Identifying Exhaust Manifold Nuts
    G04061809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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