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Removal [09/2014 - 11/2017]: Procedure

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  1. REMOVE BATTERY 

    Refer to REMOVAL [09/2014 - ]

  2. REMOVE FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to REMOVAL [09/2014 - 11/2017]

  3. REMOVE GENERATOR ASSEMBLY 

    Refer to REMOVAL [09/2014 - 11/2017]

  4. REMOVE NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 7

  5. REMOVE INJECTOR DRIVER 

    Refer to PROCEDURE - Step 8

  6. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 6

  7. REMOVE SPARK PLUG 

    Refer to PROCEDURE - Step 7

  8. REMOVE AIR CLEANER CASE SUB-ASSEMBLY 

    See step  24 [09/2014 - 10/2015], or see step  24 [10/2015 - 11/2017]

  9. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 10

  10. REMOVE NO. 1 OIL PIPE 

    Refer to PROCEDURE - Step 18

  11. REMOVE NO. 2 OIL PIPE 

    Refer to PROCEDURE - Step 19

  12. DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY 

    See step  41 [09/2014 - 10/2015], or see step  41 [10/2015 - 11/2017]

  13. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 
    1. Disengage the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly LH.
    2. Remove the cylinder head cover sub-assembly LH.

      Refer to PROCEDURE - Step 31

  14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Disengage the clamps and disconnect the connectors to disconnect the wire harness from the cylinder head cover sub-assembly.
    2. Remove the cylinder head cover sub-assembly.

      Refer to PROCEDURE - Step 30

  15. REMOVE SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 32

  16. REMOVE TIMING CHAIN COVER PLATE 
    1. Remove the 4 bolts, timing chain cover plate and gasket.
      GTY101397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. SET NO. 1 CYLINDER TO TDC / COMPRESSION 
    1. Turn the crankshaft pulley clockwise to set the No. 1 cylinder to TDC/Compression by aligning the notch with the "0" timing mark of the timing chain or belt cover sub-assembly.
      GTY508047Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Notch
    2. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.
      GTY498634Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a for Bank 2
      *b for Bank 1
      *c Timing Mark
      *d Paint Mark

      HINT: 

      If the marks are not aligned, turn the crankshaft pulley clockwise to align the marks.

    3. Place paint marks on the chain sub-assembly in alignment with the timing marks on each camshaft timing gear assembly and camshaft bearing cap.

      HINT: 

      Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gears at the locations of the timing marks of the camshaft timing gears.

  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly.

      HINT: 

      This prevents the valves and pistons from interfering with each other.

      GTY466348Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 0°
      *b 30°
    2. Align the hole in the stopper plate of the No. 1 chain tensioner assembly with the hole in the No. 1 chain tensioner body as shown in the illustration, and then insert a pin of 1.27 mm (0.0500 in.) diameter into the hole.
      GTY502502Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hole in the Stopper Plate
      *b Hole in the No. 1 Chain Tensioner Assembly
      *c Pin
    3. Turn the crankshaft clockwise until the timing notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly.
      GTY508046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Notch
    4. Remove the 2 bolts and No. 1 chain tensioner assembly.
      GTY459303Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain or belt cover sub-assembly.

  19. SEPARATE CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks.
      GTY470094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 30°
      WARNING:

      As the camshafts may turn suddenly, do not touch the camshafts or camshaft timing gears.

      NOTE:

      When turning the crankshaft, engine oil may spray out of the oil holes.

    2. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily.
      GTY469395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 to 10°
      NOTE:

      When turning the crankshaft, engine oil may spray out of the oil holes.

    3. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      GTY470339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      As the camshafts may turn suddenly, do not touch the camshafts or camshaft timing gear assemblies. Hold the chain sub-assembly and lift it upward to remove it from the sprocket.

  20. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 
    1. Remove the bolts and camshaft bearing caps in the order shown in the illustration.

      Immediately after removing the camshaft bearing caps, install service bolts and washers in the order shown in the illustration.

      Fig 1: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 1)
      GTY520390Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Service Bolt and Washers (Used to temporarily secure the camshaft housing sub-assembly RH)
      *b Part to be removed
      *c Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly RH

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing the service bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow the service bolts or washers to contact the camshaft.
      • Do not drop the service bolts or washers into the cylinder head sub-assembly RH.

      HINT: 

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
      • Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly RH: 91551-F0850 (9 bolts)
      • Part number for the service washers used to temporarily secure the camshaft housing sub-assembly RH: 90201-12028 (18 washers)
  21. REMOVE NO. 2 CAMSHAFT 
    1. Remove the bolt of the No. 2 chain tensioner assembly.
      GTY101215Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While lifting the No. 2 camshaft, remove the No. 2 chain tensioner assembly.
      GTY465991Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While lifting the No. 2 camshaft, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the engine to remove it.
      GTY103407Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE CAMSHAFT 
    1. Lift the rear of the camshaft so that it is at an angle.
    2. Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the camshaft and No. 2 chain sub-assembly towards the rear of the engine to remove them.
      GTY103409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain or belt cover sub-assembly.

    3. Suspend the chain sub-assembly with a string or equivalent.
      GTY101257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. SEPARATE CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. Turn the crankshaft counterclockwise until the timing notch is aligned with the "0" timing mark of the timing chain or belt cover sub-assembly.
      GTY508048Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Notch
    2. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      GTY463533Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      As the camshafts may turn suddenly, do not touch the camshafts or camshaft timing gear assemblies. Hold the chain sub-assembly and lift it upward to remove it from the sprocket.

  24. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 
    1. Remove the bolts and camshaft bearing caps in the order shown in the illustration.

      Immediately after removing the camshaft bearing caps, install service bolts and washers in the order shown in the illustration.

      Fig 2: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 2)
      GTY505209Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Service Bolt and Washers (Used to temporarily secure the camshaft housing sub-assembly LH)
      *b Part to be removed
      *c Install the service bolts and washers to temporarily secure the camshaft housing sub-assembly LH

      Torque: 10 N.m (102 kgf/cm, 7 ft.lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing the service bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow the service bolts or washers to contact the camshaft.
      • Do not drop the service bolts or washers into the cylinder head sub-assembly LH.

      HINT: 

      • Arrange the removed parts in such a way that they can be reinstalled to their original locations.
      • Part number for the service bolts used to temporarily secure the camshaft housing sub-assembly LH: 91551-F0850 (8 bolts)
      • Part number for the service washers used to temporarily secure the camshaft housing sub-assembly LH: 90201-12028 (16 washers)
  25. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Remove the bolt of the No. 3 chain tensioner assembly.
      GTY103956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. While lifting the No. 4 camshaft sub-assembly, remove the No. 3 chain tensioner assembly.
      GTY465989Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While lifting the No. 4 camshaft sub-assembly, pass it through the No. 2 chain sub-assembly and pull it out towards the front of the engine to remove it.
      GTY103405Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Lift the rear of the No. 3 camshaft sub-assembly so that it is at an angle.
    2. Remove the chain sub-assembly from the camshaft timing gear assembly and pull out the No. 3 camshaft sub-assembly and No. 2 chain sub-assembly towards the rear of the engine to remove them.
      GTY103410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain or belt cover sub-assembly.

    3. Suspend the chain sub-assembly with a string or equivalent.
      GTY103411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check the lock of the camshaft timing gear assembly.
      1. Secure the camshaft in a vise between aluminum plates, and confirm that the camshaft timing gear assembly is locked.
        NOTE:

        Be careful not to damage the camshaft.

    2. Release the lock pin.
      GTY506149Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Advanced Side Path
      *b Retard Side Path
      *c Open
      *d Close
      Rubber Piece
      Vinyl Tape
      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        HINT: 

        Plug 2 of the 4 paths with rubber pieces as shown in the illustration.

      2. Break through the tape on the advance side path and the retard side path on opposite sides of the camshaft as shown in the illustration.
      3. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the 2 open paths.
        GTY503508Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Advanced Side Path
        *b Retard Side Path
        WARNING:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. Check that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard side path.
        GTY504179Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *a Advance Side Path
        *b Retard Side Path
        *c Hold pressure
        *d Decompress

        HINT: 

        The lock pin is released and the camshaft timing gear assembly turns in the advance direction.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path.
        NOTE:

        Be sure to release the air pressure from the retard side path first. If the air pressure of the advance side path is released first, the camshaft timing gear assembly may abruptly shift in the advance direction and break the lock pin.

    3. Check for smooth rotation.
      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the camshaft timing gear assembly turns smoothly.
        NOTE:

        Do not use air pressure to perform the smooth operation check.

    4. Check the lock in the most retarded position.
      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.
  28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Remove the flange bolt and camshaft timing gear assembly.
      GTY456548Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Flange Bolt
      *2 Straight Pin
      *a Do not remove
      NOTE:
      • Do not remove the other 3 bolts.
      • If planning to reuse the camshaft timing gear assembly, be sure to release the straight pin lock before installing the camshaft timing gear assembly.
  29. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Check the lock of the camshaft timing exhaust gear assembly.
      1. Secure the camshaft in a vise, and confirm that the camshaft timing exhaust gear assembly is locked.
    2. Release the lock pin.
      GTY520550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Advanced Side Path
      *b Retard Side Path
      *c Open
      *d Close
      Rubber Piece
      Vinyl Tape
      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        HINT: 

        Plug 2 of the 4 paths with rubber pieces as shown in the illustration.

      2. Break through the tape on the advance side path and the retard side path on opposite sides of the camshaft as shown in the illustration.
      3. Apply approximately 200 kPa (2.0 kgf/cm2 , 29 psi) of air pressure to the 2 open paths.
        GTY467820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Advanced Side Path
        *2 Retard Side Path
        WARNING:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. Check that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.
        GTY464302Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        *1 Advance Side Path
        *2 Retard Side Path
        *a Hold pressure
        *b Decompress

        HINT: 

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.
        NOTE:

        Be sure to release the air pressure from the advance side path first.

        If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin.

    3. Check for smooth rotation.
      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position.

        Make sure that the camshaft timing exhaust gear assembly turns smoothly.

        NOTE:

        When the air pressure is released from the advance side path and then from the retard side path, the camshaft timing exhaust gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    4. Check the lock at the most advanced position.
      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.
  30. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY 
    1. Remove the flange bolt and camshaft timing exhaust gear assembly.
      GTY516322Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Flange Bolt
      *b Knock Pin
      *c Do not remove
      NOTE:
      • Be sure not to remove the other 4 bolts.
      • If planning to reuse the camshaft timing exhaust gear assembly, be sure to release the straight pin lock before installing the camshaft timing exhaust gear assembly.
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