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Cylinder Head, Intake Manifold, Exhaust Manifold: Removal

  1. PRECAUTION 

    (See PRECAUTION )

  2. REMOVE ENGINE ROOM SIDE LH COVER NO.2 (See  REMOVAL   ) 
  3. DISCHARGE FUEL SYSTEM PRESSURE 

    (See FUEL SYSTEM )

  4. REMOVE SERVICE PLUG GRIP  (See REMOVAL )
  5. DRAIN COOLANT (Engine side)  (See COOLANT )
  6. DRAIN COOLANT (Hybrid side)  (See COOLANT )
  7. DRAIN ENGINE OIL  (See OIL AND OIL FILTER )
  8. REMOVE FRONT WHEEL RH 
  9. REMOVE ENGINE UNDER COVER NO.1 (See  REMOVAL   ) 
  10. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH (See  REMOVAL   ) 
  11. REMOVE FRONT FENDER APRON SEAL RH (See  REMOVAL   ) 
  12. REMOVE ENGINE UNDER COVER NO.2 (See  REMOVAL   ) 
  13. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (See  REMOVAL   ) 
  14. REMOVE BATTERY (See  REMOVAL   ) 
  15. REMOVE BATTERY CARRIER SUB-ASSEMBLY (See  REMOVAL   ) 
  16. REMOVE AIR CLEANER CAP W/ INLET (See  REMOVAL   ) 
  17. REMOVE AIR CLEANER CASE W/ RESONATOR  (See REMOVAL )
  18. REMOVE W/ CONVERTER INVERTER ASSEMBLY 

    (See REMOVAL )

  19. REMOVE EMISSION CONTROL VALVE SET  (See REMOVAL )
  20. REMOVE INTAKE AIR SURGE TANK  (See REMOVAL )
  21. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1 (See  REMOVAL   ) 
  22. DISCONNECT HEATER INLET WATER HOSE 
    1. Lock the hose clamp as shown in the illustration (A).
    2. Disconnect the heater inlet water hose (B).
      Fig 1: Locating Heater Inlet Water Hose
      G05200408Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE INTAKE MANIFOLD 
    1. Remove the nut and disconnect the ground cable (A).
    2. Disconnect the 6 fuel injector connectors.
      Fig 2: Locating Fuel Injector Connectors
      G05200409Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.
  24. DISCONNECT RADIATOR HOSE INLET 
  25. REMOVE WATER OUTLET 
    1. Disconnect the ground cable connector (A).
      Fig 3: Identifying Ground Cable Connector
      G05200410Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine coolant temperature sensor connector (B).
    3. Remove the clamp (C).
    4. Remove the 2 bolts, 2 nuts and 2 washers.
    5. Lock the hose clamp as shown in the illustration (D) and remove the water outlet together with water bypass hose No. 1 (E).
      Fig 4: Locating Hose Clamp
      G05200411Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Remove the 2 gaskets from the 2 cylinder heads.
  26. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY (See  REMOVAL   ) 
  27. REMOVE RESERVOIR BRACKET (See  REMOVAL   ) 
  28. REMOVE AIR CLEANER BRACKET (See  REMOVAL   ) 
  29. REMOVE ENGINE MOVING CONTROL ROD (See  REMOVAL   ) 
  30. REMOVE ENGINE MOUNTING STAY NO.2 RH (See  REMOVAL   ) 
  31. REMOVE CRANKSHAFT PULLEY (See  REMOVAL   ) 
  32. REMOVE TIMING BELT NO.1 COVER (See  REMOVAL   ) 
  33. REMOVE TIMING BELT NO.2 COVER (See  REMOVAL   ) 
  34. REMOVE ENGINE MOUNTING BRACKET RH (See  REMOVAL   ) 
  35. REMOVE TIMING BELT GUIDE NO.2 
  36. REMOVE TIMING BELT (See  REMOVAL   ) 
  37. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2 (See  REMOVAL   ) 
  38. REMOVE CAMSHAFT TIMING PULLEY (See  REMOVAL   ) 
  39. REMOVE TIMING BELT NO.3 COVER (See  REMOVAL   ) 
  40. REMOVE EXHAUST PIPE ASSEMBLY FRONT (See  REMOVAL   ) 
  41. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3 (See  REMOVAL   ) 
  42. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 
    1. Remove the 3 bolts and exhaust manifold heat insulator No. 1.
  43. REMOVE MANIFOLD STAY 
    1. Remove the 2 bolts and manifold stay.
  44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH 
    1. Disconnect the heated oxygen sensor connector.
      Fig 5: Locating Heated Oxygen Sensor Connector
      G05200412Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
      Fig 6: Removing 6 Nuts In Sequence
      G05200413Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the exhaust manifold RH and the gasket from the cylinder head RH.
  45. REMOVE IGNITION COIL ASSEMBLY 
  46. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (See  ADJUSTMENT   ) 
  47. REMOVE CAMSHAFT (See  REMOVAL   ) 
  48. REMOVE NO.2 CAMSHAFT (See  REMOVAL   ) 
  49. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. Disconnect the VVT sensor connector.
    2. Disconnect the camshaft timing oil control valve connector.
    3. Remove the nut and disconnect the engine wire harness clamp.
      Fig 7: Locating Engine Wire Harness Clamp
      G05200414Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a socket hexagon wrench 8 mm, remove the hexagon bolt.
      Fig 8: Locating Hexagon Bolt
      G05129264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

      SST 09011-38121 

      NOTE:
      • Do not drop the washers into the cylinder head.
      • Head warpage or cracking could result from removing bolts in an incorrect order.
        Fig 9: Identifying Cylinder Head Bolts Loosening Sequence
        G05129265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE CYLINDER HEAD GASKET 
  51. REMOVE MANIFOLD CONVERTER INSULATOR NO.3 
    1. Remove the bolt, nut and manifold converter insulator No.3.
      Fig 10: Locating Bolt, Nut And Manifold Converter Insulator
      G05200417Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2 
    1. Remove the 2 bolts and manifold heat insulator No.2.
  53. SEPARATE COOLING FAN ECU 
    1. Remove the 2 bolts and separate the cooling fan ECU.

      HINT:

      • The cooling fan ECU should be separated to prevent it from being interfered with by the exhaust manifold.
      • Be sure to hang the disconnected ECU with the string to ensure safety.
        Fig 11: Locating Water Pump Bolts
        G05200418Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2 
    1. Disconnect the heated oxygen sensor connector.
    2. Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.
    3. Remove the exhaust manifold converter No.2 and the gasket from the cylinder head LH.
      Fig 12: Locating Heated Oxygen Sensor Connector
      G05200419Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE OIL LEVEL GAUGE GUIDE 
    1. Remove the bolt which is used to secure the oil level gauge guide from the cylinder head LH.
      Fig 13: Locating Oil Level Gauge Guide With Bolt
      G05200420Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Pull out the oil level gauge guide and the oil level gauge together from the cylinder block.
    3. Remove the O-ring from the oil level gauge guide.
  56. REMOVE WATER INLET PIPE  (See REMOVAL )
  57. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH (See  ADJUSTMENT   ) 
  58. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY (See  REMOVAL   ) 
  59. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY (See  REMOVAL   ) 
  60. REMOVE CYLINDER HEAD LH 
    1. Disconnect the VVT sensor connector (A).
    2. Disconnect the camshaft timing oil control valve connector (B).
    3. Remove the 2 nuts and disconnect the ground cable
    4. Remove the 2 bolts, wire harness clamp and intake air connector bracket No.2.
      Fig 14: Locating Nuts And Disconnecting Ground Cable
      G05200421Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a socket hexagon wrench 8 mm, remove the hexagon bolt.
      Fig 15: Connecting Ground Cable
      G05129546Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

      SST 09011-38121 

      NOTE:
      • Do not drop the washers into the cylinder head.
      • Head warpage or cracking could result from removing bolts in an incorrect order.
        Fig 16: Identifying Cylinder Head Bolts Loosening Sequence
        G05129446Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. REMOVE CYLINDER HEAD GASKET NO.2 
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