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Removal [11/2017 - ]: Procedure

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  1. REMOVE TIMING CHAIN COVER ASSEMBLY 

    Refer to REMOVAL [11/2017 - ]

  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Temporarily install the crankshaft pulley set bolt.
    2. Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).
      GTY793759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Crankshaft Pulley Set Key
      *a Center Mark
    3. 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.
      GTY799083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark
  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 38

  4. REMOVE CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 39

  5. REMOVE CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 40

  6. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 2 chain tensioner assembly.
      GTY786454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. Using a wrench to hold the hexagonal portion of the camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.
      GTY786255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly RH with a new one.
    3. Using a wrench to hold the hexagonal portion of the No. 2 camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.
      GTY780785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly RH with a new one.
    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly RH together with the No. 2 chain sub-assembly.
  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt and No. 2 chain tensioner assembly.
      GTY836917Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 
    1. Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.
      GTY807430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Front View
      *c 45°
    2. Uniformly loosen and remove the 9 bolts in several steps and in the order shown in the illustration.
      Fig 1: Camshaft Bearing Caps Bolts Loosening Sequence (For Bank 1)
      GTY598990Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.
      Fig 2: Camshaft Bearing Caps Bolts Loosening Sequence (For Bank 1)
      GTY539430Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the camshaft and No. 2 camshaft remains level while uniformly loosening the bolts.

  9. REMOVE FUEL PUMP LIFTER HOUSING 
    1. Remove the fuel pump lifter housing.
      GTY800082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE CAMSHAFT 
    1. Remove the camshaft from the camshaft housing sub-assembly RH.
  11. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly RH.
  12. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly and camshaft housing sub-assembly RH with a screwdriver with its tip wrapped with protective tape.
      GTY795523Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

  13. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. While pushing down the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) diameter pin into the hole to secure the No. 3 chain tensioner assembly.
      GTY793650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.
      GTY799384Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.
    3. Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.
      GTY826965Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with wrench.
      • Do not loosen any other bolt. If any other bolt is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly LH with a new one.
    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly LH together with the No. 2 chain sub-assembly.
  14. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt and No. 3 chain tensioner assembly.
      GTY819039Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 
    1. Check that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly are positioned as shown in the illustration.
      GTY825611Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Front View
    2. Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.
      Fig 3: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 2)
      GTY588487Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 15 bolts in several steps and in the order shown in the illustration.
      Fig 4: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 2)
      GTY794613Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Make sure that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly remain level while uniformly loosening the bolts.

    4. Remove the 5 camshaft bearing caps.
  16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.
  17. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.
  18. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.
      GTY832074Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

  19. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 42

  20. REMOVE NO. 2 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 43

  21. 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 such a way that they can be reinstalled to their original locations.

  22. REMOVE VALVE LASH ADJUSTER ASSEMBLY 
    1. Remove the 24 valve lash adjuster assemblies.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  23. REMOVE VALVE STEM CAP 
    1. Remove the 24 valve stem caps.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  24. REMOVE REAR WATER BY-PASS JOINT 

    Refer to PROCEDURE - Step 18

  25. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 2

  26. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH 

    Refer to PROCEDURE - Step 3

  27. REMOVE FUEL DELIVERY PIPE RH 

    Refer to PROCEDURE - Step 4

  28. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection) 

    Refer to PROCEDURE - Step 5

  29. REMOVE FUEL INJECTOR SEAL 

    Refer to PROCEDURE - Step 6

  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.
      Fig 5: Cylinder Head Set Bolts Loosening Sequence
      GTY571792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to drop the cylinder head set plate washers into the cylinder head sub-assembly.
      • Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. Remove the cylinder head sub-assembly.
  31. REMOVE CYLINDER HEAD GASKET 
    1. Remove the cylinder head gasket from the cylinder block sub-assembly.
  32. REMOVE CYLINDER HEAD LH 
    1. Uniformly loosen and remove the 2 bolts in the several steps in the order shown in the illustration.
      Fig 6: Cylinder Head LH Bolts Loosening Sequence
      GTY606544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 10 mm bi-hexagon socket wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration. Remove the 8 cylinder head set bolts and 8 cylinder head set plate washers.
      Fig 7: Cylinder Head Set Bolts Loosening Sequence
      GTY599615Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to drop the cylinder head set plate washers into the cylinder head LH.
      • Warpage or cracking of the cylinder head LH may result from removing the cylinder head set bolts in the incorrect order.

      HINT: 

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    3. Remove the cylinder head LH.
  33. REMOVE NO. 2 CYLINDER HEAD GASKET 
    1. Remove the No. 2 cylinder head gasket from the cylinder block sub-assembly.
  34. INSPECT CYLINDER HEAD SET BOLT 

    Refer to PROCEDURE - Step 4

  35. INSPECT CYLINDER HEAD SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 1

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