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Cylinder Head: Removal

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  1. DISCHARGE FUEL SYSTEM PRESSURE (see appropriate step(s) under  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 RADIATOR SUPPORT OPENING COVER 
  4. REMOVE FRONT WHEEL RH 
  5. REMOVE NO. 1 ENGINE UNDER COVER 
  6. REMOVE FRONT FENDER APRON RH 
  7. REMOVE NO. 1 ENGINE COVER (see appropriate step(s) under  REMOVAL  ) 
  8. DRAIN ENGINE COOLANT (see appropriate step(s) under  COOLANT  ) 
  9. DRAIN ENGINE OIL (see appropriate step(s) under  REPLACEMENT  ) 
  10. REMOVE AIR CLEANER CAP (see appropriate step(s) under  REMOVAL  ) 
  11. REMOVE THROTTLE BODY (see appropriate step(s) under  REMOVAL  ) 
  12. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  13. REMOVE INTAKE MANIFOLD (see appropriate step(s) under  REMOVAL  ) 
  14. REMOVE INTAKE MANIFOLD INSULATOR (see appropriate step(s) under  REMOVAL  ) 
  15. REMOVE FRONT EXHAUST PIPE (see appropriate step(s) under  EXHAUST (2AZ-FE)  ) 
  16. REMOVE OIL DIPSTICK 
  17. REMOVE OIL DIPSTICK GUIDE 
    1. Remove the bolt and guide.
    2. Remove the O-ring from the guide.
      Fig 1: Identifying Oil Dipstick Guide
      G04484712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 2: Identifying Manifold Stay Bolt And Nut
      G04484713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE NO. 2 MANIFOLD STAY 
    1. Remove the bolt, nut and stay.
      Fig 3: Identifying No. 2 Manifold Stay Bolt And Nut
      G04484714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR 
    1. Remove the 4 bolts and heat insulator.
      Fig 4: Identifying Exhaust Manifold Heat Insulator
      G04484715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Disconnect the air-fuel ratio sensor connector.
      Fig 5: Identifying Air-Fuel Ratio Sensor Connector
      G04484716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 nuts, manifold converter and gasket.
      Fig 6: Identifying Manifold Coverter Nuts And Gasket
      G04484717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. DISCONNECT NO. 1 RADIATOR HOSE 
    1. Disconnect the No. 1 radiator hose.
      Fig 7: Identifying No. 1 Radiator Hose
      G04484718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. DISCONNECT ENGINE WIRE 
    1. Disconnect the radio setting condenser connector.
      Fig 8: Identifying Radio Setting Condenser Connector
      G04484719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the engine oil pressure switch connector.
    3. Disconnect the engine coolant temperature sensor connector.
    4. Disconnect the camshaft position sensor connector.
    5. Remove the bolt and ground cable.
  24. REMOVE FRONT SUSPENSION MEMBER REINFORCEMENT RH (see appropriate step(s) under  REMOVAL  ) 
  25. REMOVE FAN AND GENERATOR V BELT (see appropriate step(s) under  REMOVAL  ) 
  26. REMOVE GENERATOR ASSEMBLY (see  REMOVAL  ) 
  27. REMOVE ENGINE MOUNTING INSULATOR RH (see appropriate step(s) under  REMOVAL  ) 
  28. REMOVE IDLER PULLEY (see appropriate step(s) under  REMOVAL  ) 
  29. REMOVE IGNITION COIL ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  30. REMOVE SPARK PLUG (see appropriate step(s) under  ADJUSTMENT  ) 
  31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  33. REMOVE CRANKSHAFT POSITION SENSOR (see appropriate step(s) under  REMOVAL  ) 
  34. REMOVE OIL PAN SUB-ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  35. 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 gear and sprocket 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 9: Aligning Timing Mark With Camshaft Timing Gear And Sprocket
      G04484720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE NO. 2 CAMSHAFT 
    1. Place paint marks on the chain in alignment with the timing marks on the camshaft timing gear and camshaft timing sprocket.
      Fig 10: Placing Paint Marks On Chain In Alignment With Timing Marks On Camshaft Timing Gear
      G04484721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 nuts, tensioner and gasket.
      Fig 11: Identifying No. 2 Camshaft Nuts, Tensioner And Gasket
      G04484722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. While holding the camshaft with a wrench, loosen the camshaft timing set bolt.
      Fig 12: Loosening Camshaft Timing Set Bolt
      G04484723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
    5. Remove the 5 bearing caps.
      Fig 13: Identifying Bearing Cap Bolts In Sequence
      G04484724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
    7. Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
    8. Remove the camshaft timing sprocket from the timing chain.
      Fig 14: Removing Camshaft Timing Sprocket Set Bolt
      G04484725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. 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.
      Fig 15: Identifying Bearing Cap Bolts In Sequence
      G04484726Courtesy 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.
      Fig 16: Securing Timing Chain With String
      G04484727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE CRANKSHAFT PULLEY (see appropriate step(s) under  REMOVAL  ) 
  39. REMOVE ENGINE MOUNTING BRACKET RH (see appropriate step(s) under  REMOVAL  ) 
  40. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  41. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
  42. REMOVE TIMING CHAIN GUIDE (see appropriate step(s) under  REMOVAL  ) 
  43. REMOVE CHAIN TENSIONER SLIPPER (see appropriate step(s) under  REMOVAL  ) 
  44. REMOVE NO. 1 CHAIN VIBRATION DAMPER (see appropriate step(s) under  REMOVAL  ) 
  45. REMOVE CHAIN SUB-ASSEMBLY 
  46. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (see appropriate step(s) under  REMOVAL  ) 
  47. 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
      G04484728Courtesy 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:

      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 is difficult to apply because of air leakage from the port, there may be the case that the lock pin is difficult to release.

      Fig 18: Applying Air Pressure To Oil Path
      G04484729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    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 Flange Bolt Of Camshaft Timing Gear
        G04484730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. 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: Head warpage or cracking could result from removing the bolts in the wrong order.
      Fig 20: Identifying Cylinder Head Bolts
      G04484731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a screwdriver with its tip wrapped with tape, pry between the cylinder head and cylinder block, and remove the cylinder head.
      NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
      Fig 21: Removing Cylinder Head
      G04484732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE CYLINDER HEAD GASKET 
    Fig 22: Identifying Cylinder Head Gasket
    G04484733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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