Removal [08/2015 - ]: Procedure

Refer to REMOVAL [08/2015 - ]

Refer to REMOVAL [08/2015 - ]

Refer to PROCEDURE - Step 1

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 2

Refer to PROCEDURE - Step 3

1. Detach the clamp and disconnect the No. 3 ventilation hose from the engine wire.

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2. Disconnect the air fuel ratio sensor connector.
3. Remove the bolt and disconnect the engine wire from the cylinder head cover sub-assembly.

1. Slide the 4 clips and disconnect the No. 1, No. 2, No. 3 and No. 4 turbo water by-pass hoses.

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   *1	No. 1 Turbo Water By-pass Hose
   *2	No. 2 Turbo Water By-pass Hose
   *3	No. 3 Turbo Water By-pass Hose
   *4	No. 4 Turbo Water By-pass Hose
   *5	No. 1 Turbo Water Pipe

2. Remove the 3 bolts and No. 1 turbo water pipe.

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1. Slide the clip and disconnect the No. 3 ventilation hose from the cylinder head cover sub-assembly.

1. Remove the 19 bolts and cylinder head cover sub-assembly from the camshaft housing sub-assembly.

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Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the cylinder head cover gasket and No. 2 cylinder head cover gasket from the cylinder head cover sub-assembly.

1. Remove the camshaft bearing cap oil hole gasket from the No. 1 camshaft bearing cap.

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   *1	Camshaft Bearing Cap Oil Hole Gasket
   *2	Gasket

2. Remove the gasket from the No. 2 camshaft bearing cap.

Refer to REMOVAL [08/2015 - ]

Refer to PROCEDURE - Step 3

1. Turn the crankshaft until the timing mark (groove) of the crankshaft pulley assembly and the timing mark "0" of the timing chain cover assembly are aligned.

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   *a	Paint Mark
   *b	Timing Mark (Groove)
   *c	Timing Mark "0"

2. Check that each timing mark of the camshaft timing gear assembly and camshaft timing exhaust gear assembly are located as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.
3. Place paint marks on the chain sub-assembly in alignment with the timing marks on the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

Refer to PROCEDURE - Step 20

1. Turn the crankshaft approximately 15° clockwise.

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   *a	Approximately 15°

2. Turn the crankshaft approximately 15° counterclockwise.

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   *a	Approximately 15°

3. Align the holes of the stopper plate and No. 1 chain tensioner assembly, and insert a pin into the stopper plate hole to lock the No. 1 chain tensioner assembly.

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   *a	Stopper Plate
   *b	Pin

4. Turn the crankshaft approximately 15° clockwise.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Approximately 15°

5. Remove the bolt and nut, and then remove the No. 1 chain tensioner assembly and gasket from the cylinder block sub-assembly.

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   	Bolt
   	Nut

   NOTE:

   Make sure not to drop the gasket inside the timing chain cover assembly.

6. Turn the crankshaft approximately 15° counterclockwise.

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   *a	Approximately 15°

Refer to PROCEDURE - Step 23

1. Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft.

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   *a	Hold
   	Turn

   NOTE:

   Be careful not to damage the camshaft housing sub-assembly or spark plug tube with the wrench.

1. Using several steps, remove the 11 camshaft bearing cap bolts in the sequence shown in the illustration.
   Fig 1: Camshaft Bearing Cap Bolt Loosening Sequence (1 Of 2)

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2. Using several steps, remove the 10 camshaft bearing cap bolts in the sequence shown in the illustration.
   Fig 2: Camshaft Bearing Cap Bolt Loosening Sequence (2 Of 2)

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   NOTE:

   Make sure to loosen the camshaft bearing cap bolts evenly while holding the camshaft horizontally.

3. Remove the No. 1, No. 2, No. 3 and No. 4 camshaft bearing caps from the camshaft housing sub-assembly.

   HINT: 

   Arrange the removed parts in the correct order.

1. Raise the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.

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1. Remove the camshaft timing gear assembly.

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   NOTE:

   Do not disassemble the camshaft timing gear assembly.

1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

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2. Suspend the chain sub-assembly with a string or equivalent as shown in the illustration.

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   NOTE:

   Be careful not to drop the chain sub-assembly inside the timing chain cover assembly.

1. Using SST, grip the hexagonal portion, and then secure the SST and No. 2 camshaft in a vise as shown in the illustration.
   • SST: 09212-31010 
   NOTE:

   • Do not damage the No. 2 camshaft.
   • Never grip areas other than the hexagonal portion, as this may cause damage.

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   *a	Hexagonal Portion

2. Remove the bolt and camshaft timing exhaust gear assembly from the No. 2 camshaft.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   • Be careful not to damage the No. 2 camshaft and camshaft timing exhaust gear assembly.
   • Do not disassemble the camshaft timing exhaust gear assembly.

Refer to PROCEDURE - Step 34

Refer to PROCEDURE - Step 37

Refer to PROCEDURE - Step 38

Refer to PROCEDURE - Step 6