LEMON Manuals: Even more car manuals for everyone
Home >> Scion >> 2007 >> tC Spec, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical (2AZ-FE) >> Cylinder Head, Intake Manifold, Exhaust Manifold >> Removal

Cylinder Head, Intake Manifold, Exhaust Manifold: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE (See  REMOVAL  ) 
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
    CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
  3. REMOVE HOOD SUB-ASSEMBLY 
  4. REMOVE FRONT WHEEL RH 
  5. REMOVE ENGINE UNDER COVER RH 
  6. REMOVE ENGINE UNDER COVER LH 
  7. REMOVE FRONT FENDER APRON SEAL RH 
  8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY (See  REMOVAL  )
  9. REMOVE FRONT WIPER ARM HEAD CAP 
  10. REMOVE FRONT WIPER ARM LH 
  11. REMOVE FRONT WIPER ARM RH 
  12. REMOVE HOOD TO COWL TOP SEAL 
  13. REMOVE COWL TOP VENTILATOR LOUVER LH 
  14. REMOVE WIPER LINK ASSEMBLY 
  15. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY 
  16. REMOVE COWL BODY MOUNTING BRACKET LOWER LH 
  17. DRAIN ENGINE COOLANT (See  COOLANT  ) 
  18. DRAIN ENGINE OIL (See  REPLACEMENT  ) 
  19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (See  REMOVAL  ) 
  20. REMOVE THROTTLE BODY ASSEMBLY (See  REMOVAL  ) 
  21. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (See  REMOVAL  ) 
  22. REMOVE INTAKE MANIFOLD 
    1. Disconnect the 2 water by-pass hoses from the throttle body.
    2. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
      3. Fig 1: Locating Intake Manifold Bolts
      G04865442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR (See  INSPECTION  ) 
  24. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See  REMOVAL  ) 
  25. REMOVE OIL DIPSTICK 
  26. REMOVE OIL DIPSTICK GUIDE 
    1. Remove the bolt and guide.
    2. Remove the O-ring from the guide.
      Fig 2: Locating O-Ring And Bolt
      G04865443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 3: Locating Manifold Stay And Bolt
      G04865444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 4: Locating Manifold Stay And Bolt
      G04865445Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Disconnect the air fuel ratio sensor connector.
      Fig 5: Locating Air Fuel Ratio Sensor Connector
      G04865446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts, nut and heat insulator.
      Fig 6: Locating Heat Insulator, Bolts And Nut
      G04865447Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Remove the 5 nuts, manifold converter and gasket.
    Fig 7: Locating Manifold Converter And Nuts
    G04865448Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FAN AND GENERATOR V BELT (See  REMOVAL  )
  32. REMOVE GENERATOR ASSEMBLY (See  REMOVAL  ) 
  33. REMOVE VANE PUMP ASSEMBLY 
  34. REMOVE ENGINE MOUNTING INSULATOR RH (See  REMOVAL  )
  35. REMOVE IGNITION COIL ASSEMBLY (See  REMOVAL  ) 
  36. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See  REMOVAL  )
  37. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (See  REMOVAL  )
  38. REMOVE CRANKSHAFT POSITION SENSOR (See  REMOVAL  ) 
  39. REMOVE OIL PAN SUB-ASSEMBLY (See  REMOVAL  )
  40. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
    2. Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.

      If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.

      Fig 8: Identifying Timing Mark Of Camshaft Timing Gears
      G04865449Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE NO. 2 CAMSHAFT 
    1. Place paint marks on the chain and camshaft timing gears.
      Fig 9: Identifying Paint Marks On Chain And Camshaft Timing Gears
      G04865450Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt.
    3. Disconnect the wire harness protector clamp.
      Fig 10: Locating Wire Harness Protector Clamp
      G04865451Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 2 nuts, tensioner and gasket.
      Fig 11: Locating Tensioner And Bolt
      G04865452Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. While holding the camshaft with a wrench, loosen the camshaft timing set bolt.
      Fig 12: Loosening Camshaft Timing Bolt
      G04865453Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
    7. Remove the 5 bearing caps.
      Fig 13: Identifying Bearing Cap Bolts In Sequence
      G04865454Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
    9. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
    10. Remove the camshaft timing sprocket from the timing chain.
      Fig 14: Removing Camshaft Timing Sprocket Set Bolt
      G04865455Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE CAMSHAFT 
    1. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
    2. Remove the 5 bearing caps.
    3. Remove the camshaft and camshaft timing gear while holding the timing chain by hand.
      4. Fig 15: Identifying Bearing Cap Bolts In Sequence
      G04865456Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tie the timing chain with a string as shown in the illustration.
      NOTE: Be careful not to drop anything inside the timing chain cover.
      5. Fig 16: Identifying Timing Chain With String
      G04865457Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE CRANKSHAFT PULLEY (See  INSPECTION  )
  44. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (See  REMOVAL  )
  45. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
  46. REMOVE TIMING CHAIN GUIDE (See  REMOVAL  )
  47. REMOVE CHAIN TENSIONER SLIPPER (See  REMOVAL  )
  48. REMOVE CHAIN SUB-ASSEMBLY 
  49. REMOVE NO. 1 CHAIN VIBRATION DAMPER (See  REMOVAL  )
  50. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (See  ON-VEHICLE INSPECTION  ) 
  51. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
    2. Cover all the oil ports with vinyl tape except the advance side port shown in the illustration.
      Fig 17: Locating Advance Side Port
      G04865458Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Apply air pressure of 100 kPa (1.0 kgf/cm2 , 14 psi) to the oil path, then turn the camshaft timing gear to the advance direction (counterclockwise) by hand.
      CAUTION: Cover the paths with a shop rag to avoid oil splashes.

      HINT:

      Fig 18: Turning Camshaft Timing Gear To Advance Direction
      G04865459Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can hardly be applied because of air leakage from the port, there may be the case that the lock pin can hardly be released.

    4. Remove the flange bolt of the camshaft timing gear.
      NOTE:
      • Be sure not to remove the other 4 bolts.
      • When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.
      Fig 19: Identifying Camshaft Timing Gear And Bolt
      G04865460Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 2 CAMSHAFT BEARING 
    1. Remove the camshaft bearing.
      Fig 20: Identifying Camshaft Bearing
      G04865461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Disconnect the radiator hose inlet.
      Fig 21: Identifying Radiator Hose Inlet
      G04865462Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the radio setting condenser connector.
    3. Disconnect the engine oil pressure switch connector.
    4. Disconnect the engine coolant temperature sensor connector.
    5. Disconnect the camshaft position sensor connector.
    6. Remove the bolt and ground cable.
      Fig 22: Locating Camshaft Position Sensor Connector
      G04865463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.
      NOTE:
      • Be careful not to drop the plate washers into the cylinder head.
      • Head warpage or cracking could result from removing the bolts in the wrong order.
    54. Fig 23: Locating Cylinder Head Bolts Sequence
    G04865464Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE CYLINDER HEAD GASKET 
scientia non olet · About LEMON Manuals