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

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  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY 

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

  2. SET NO. 1 CYLINDER TO TDC / COMPRESSION 

    Refer to PROCEDURE - Step 44

  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 

    Refer to PROCEDURE - Step 45

  4. REMOVE CHAIN TENSIONER SLIPPER 

    Refer to PROCEDURE - Step 46

  5. REMOVE CHAIN SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 47

  6. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1) 
    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.
      GTY509794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.
      GTY469839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09922-10010 
      NOTE:
      • Be careful not to damage the cylinder head sub-assembly RH with SST.
      • 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 RH with a new one.
    3. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly RH together with the No. 2 chain sub-assembly.
    4. Remove the No. 2 chain sub-assembly.
  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt and No. 2 chain tensioner assembly.
      GTY136423Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 
    1. Check that the camshafts are positioned as shown in the illustration.
      GTY511463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Exhaust
      *c Intake
      *d 45°
    2. Uniformly loosen and remove the 9 bolts in several steps in the order shown in the illustration.
      Fig 1: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 1)
      GTY467878Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 14 bolts in several steps in the order shown in the illustration.
      Fig 2: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 1)
      GTY465082Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 6 camshaft bearing caps.

      HINT: 

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

  9. REMOVE CAMSHAFT 
    1. Remove the camshaft from the camshaft housing sub-assembly RH.
  10. REMOVE NO. 2 CAMSHAFT 
    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly RH.
  11. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH 
    1. Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly RH and camshaft housing sub-assembly RH with a screwdriver.
      GTY508147Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  12. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. 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.
      GTY518690Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Pin
      *b Plunger
      *c Push
    2. Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.
      GTY468560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      • SST: 09922-10010 
      NOTE:
      • Be careful not to damage the cylinder head sub-assembly LH with SST.
      • 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.
    3. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly LH together with the No. 2 chain sub-assembly.
    4. Remove the No. 2 chain sub-assembly.
  13. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt and No. 3 chain tensioner assembly.
      GTY145648Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 
    1. Check that the camshafts are positioned as shown in the illustration.
      GTY511053Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Knock Pin
      *b Intake
      *c Exhaust
    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)
      GTY460997Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Uniformly loosen and remove the 13 bolts in several steps in the order shown in the illustration.
      Fig 4: Camshaft Bearing Cap Bolts Loosening Sequence (For Bank 2)
      GTY458569Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 5 camshaft bearing caps.

      HINT: 

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

  15. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.
  16. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.
  17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH 
    1. Remove the camshaft housing sub-assembly LH by prying between the cylinder head sub-assembly LH and camshaft housing sub-assembly LH with a screwdriver.
      GTY509827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Protective Tape
      NOTE:

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

      HINT: 

      Tape the screwdriver tip before use.

  18. REMOVE NO. 1 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 49

  19. REMOVE NO. 2 CHAIN VIBRATION DAMPER 

    Refer to PROCEDURE - Step 50

  20. 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.

  21. 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.

  22. 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.

  23. REMOVE REAR WATER BY-PASS JOINT 

    Refer to PROCEDURE - Step 29

  24. REMOVE FUEL INJECTOR SEAL 

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

  25. REMOVE CYLINDER HEAD SUB-ASSEMBLY RH 
    1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration.

      Remove the 8 cylinder head set bolts and plate washers.

      Fig 5: Cylinder Head Set Bolts RH Loosening Sequence
      GTY456787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to drop the plate washers into the cylinder head sub-assembly RH.
      • cylinder head sub-assembly RH warpage or cracking could result from removing the cylinder head set bolts in an 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 RH.
  26. REMOVE CYLINDER HEAD GASKET 
    1. Remove the cylinder head gasket.
      NOTE:
      • Clean the bolt holes of the cylinder block sub-assembly and check for damage.
      • If the bolt holes are damaged, repair them with a tap.
  27. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH 
    1. Uniformly loosen and remove the 2 bolts in the order shown in the illustration.
      Fig 6: Cylinder Head Sub-Assembly LH Bolts Loosening Sequence
      GTY465498Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 cylinder head set bolts in the order shown in the illustration.

      Remove the 8 cylinder head set bolts and plate washers.

      Fig 7: Cylinder Head Set Bolts LH Loosening Sequence
      GTY469393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Be careful not to drop the plate washers into the cylinder head sub-assembly LH.
      • Warpage or cracking of the cylinder head sub-assembly LH could result from removing the cylinder head set bolts in an 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 sub-assembly LH.
  28. REMOVE NO. 2 CYLINDER HEAD GASKET 
    1. Remove the No. 2 cylinder head gasket.
      NOTE:
      • Clean the bolt holes of the cylinder block sub-assembly and check for damage.
      • If the bolt holes are damaged, repair them with a tap.
  29. INSPECT CYLINDER HEAD SUB-ASSEMBLY FOR FLATNESS 

    Refer to PROCEDURE - Step 1

  30. INSPECT CYLINDER HEAD SUB-ASSEMBLY FOR CRACKS 

    Refer to PROCEDURE - Step 2

  31. INSPECT CYLINDER HEAD SET BOLT 
    1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.
      GTY509258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Measurement Length

      Standard Length

      141.3 to 142.7 mm (5.56 to 5.62 in.)

      Maximum Length

      143.7 mm (5.66 in.)

      HINT: 

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. Using a vernier caliper, measure the diameter of the threads at the measurement point.
      GTY511485Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Approximately 100 mm (3.94 in.)
      *b Measurement Point

      Standard Diameter

      10.80 to 11.00 mm (0.425 to 0.433 in.)

      Minimum Diameter

      10.70 mm (0.421 in.)

      NOTE:
      • If the diameter is less than the minimum, replace the cylinder head set bolt. Failure to do so may lead to engine damage.
      • If there is any thread deformation, replace the cylinder head set bolt with a new one.
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