Removal [10/2017 - ]: Procedure

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REMOVE TIMING CHAIN COVER ASSEMBLY
Refer to REMOVAL [08/2015 - ]

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the pulley set bolt.

Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Crankshaft Pulley Set Key
*a	Center Mark

Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression). If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Timing Mark

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
Refer to PROCEDURE - Step 42
REMOVE CHAIN TENSIONER SLIPPER
Refer to PROCEDURE - Step 43
REMOVE CHAIN SUB-ASSEMBLY
Refer to PROCEDURE - Step 44

REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin
*b	Plunger
*c	Push

Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

NOTE:

Be careful not to damage the cylinder head with the wrench.
Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

NOTE:

Be careful not to damage the cylinder head with the wrench.
Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.

REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

Remove the bolt and No. 2 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CAMSHAFT BEARING CAP (for Bank 1)

Check that the camshafts are positioned as shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Knock Pin
*a	45°
*b	IN
*c	EX

Uniformly loosen and remove the 9 bolts in several steps and in the sequence shown in the illustration.

Fig 1: Camshaft Bearing Cap (For Bank 1) Loosening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Uniformly loosen and remove the 15 bolts in several steps and in the sequence shown in the illustration.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Uniformly loosen the bolts while keeping the camshaft level.

REMOVE FUEL PUMP LIFTER HOUSING

Remove the fuel pump lifter housing.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CAMSHAFT
1. Remove the camshaft from the camshaft housing sub-assembly RH.
REMOVE NO. 2 CAMSHAFT
1. Remove the No. 2 camshaft from the camshaft housing sub-assembly RH.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

Remove the camshaft housing RH by prying between the cylinder head and camshaft housing RH with a screwdriver.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Protective Tape

NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing RH.

HINT:

Tape the screwdriver tip before use.

REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Pin
*b	Plunger
*c	Push

Using a wrench to hold the hexagonal portion of each camshaft sub-assembly No. 3, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

NOTE:

Be careful not to damage the cylinder head with the wrench.
Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly LH with a new one.

Using a wrench to hold the hexagonal portion of each camshaft sub-assembly No. 4, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.

*a	Turn
*b	Hold

NOTE:

Be careful not to damage the cylinder head with the wrench.
Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly LH with a new one.

Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain sub-assembly.

REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

Remove the bolt and No. 3 chain tensioner assembly.

REMOVE CAMSHAFT BEARING CAP (for Bank 2)

Check that the camshafts are positioned as shown in the illustration.

*1	Knock Pin
*a	IN
*b	EX

Uniformly loosen and remove the 8 bolts in several steps and in the sequence shown in the illustration.

Fig 2: Camshaft Bearing Cap (For Bank 2) Loosening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Uniformly loosen and remove the 13 bolts in several steps and in the sequence shown in the illustration.

NOTE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 camshaft bearing caps.

REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.
REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver.

*a	Protective Tape

NOTE:

Be careful not to damage the contact surfaces of the cylinder head and camshaft housing sub-assembly LH.

HINT:

Tape the screwdriver tip before use.

REMOVE NO. 1 CHAIN VIBRATION DAMPER
Refer to PROCEDURE - Step 46
REMOVE NO. 2 CHAIN VIBRATION DAMPER
Refer to PROCEDURE - Step 47
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 24 No. 1 valve rocker arm sub-assemblies.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 24 valve lash adjuster assemblies.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 24 valve stem caps.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE REAR WATER BY-PASS JOINT
Refer to PROCEDURE - Step 22
REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY
Refer to PROCEDURE - Step 2
REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH
Refer to PROCEDURE - Step 3
REMOVE FUEL DELIVERY PIPE RH
Refer to PROCEDURE - Step 4
REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)
Refer to PROCEDURE - Step 5
REMOVE FUEL INJECTOR SEAL
Refer to PROCEDURE - Step 6
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 bolts and 8 plate washers.
  
  Fig 3: Cylinder Head Sub-Assembly Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to drop plate washers into the cylinder head sub-assembly.
  - Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep separate the removed parts for each installation position.
2. Remove the cylinder head sub-assembly.
REMOVE CYLINDER HEAD GASKET
1. Remove the cylinder head gasket from the cylinder block sub-assembly.
REMOVE CYLINDER HEAD LH
1. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.
  
  Fig 4: Cylinder Head LH Loosening Sequence (1 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 bolts and 8 plate washers.
  
  Fig 5: Cylinder Head LH Loosening Sequence (2 Of 2)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Be careful not to drop plate washers into the cylinder head LH.
  - Cylinder head warpage or cracking could result from removing bolts in an incorrect order.
  HINT:
  
  Be sure to keep separate the removed parts for each installation position.
3. Remove the cylinder head LH.
REMOVE NO. 2 CYLINDER HEAD GASKET
1. Remove the No. 2 cylinder head gasket from the cylinder block sub-assembly.
INSPECT CYLINDER HEAD SET BOLT
Refer to PROCEDURE - Step 4
INSPECT CYLINDER HEAD SUB-ASSEMBLY
Refer to PROCEDURE - Step 1