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Cylinder Head Gasket: Removal

  1. DISCHARGE FUEL SYSTEM PRESSURE  (See REMOVAL )
  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
  3. REMOVE FRONT WIPER ARM HEAD CAP  (See REMOVAL )
  4. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH  (See REMOVAL )
  5. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH  (See REMOVAL )
  6. REMOVE HOOD TO COWL TOP SEAL  (See REMOVAL )
  7. REMOVE COWL TOP VENTILATOR LOUVER RH  (See REMOVAL )
  8. REMOVE COWL TOP VENTILATOR LOUVER LH  (See REMOVAL )
  9. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY  (See REMOVAL )
  10. REMOVE OUTER COWL TOP PANEL  (See REMOVAL )
  11. REMOVE SUSPENSION TOWER DAMPER ASSEMBLY (w/ Front Strut Bar)  (See REMOVAL )
  12. REMOVE FRONT WHEEL RH 
  13. REMOVE ENGINE UNDER COVER LH 
  14. REMOVE ENGINE UNDER COVER RH 
  15. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY  (See REMOVAL )
  16. DRAIN ENGINE COOLANT  (See COOLANT )
  17. DRAIN ENGINE OIL  (See REPLACEMENT )
  18. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 2WD)  (See REMOVAL )
  19. REMOVE CENTER EXHAUST PIPE ASSEMBLY (for 4WD)  (See REMOVAL )
  20. REMOVE FRONT EXHAUST PIPE ASSEMBLY  (See REMOVAL )
  21. REMOVE V-RIBBED BELT  (See REMOVAL  )
  22. REMOVE GENERATOR ASSEMBLY  (See REMOVAL )
  23. SEPARATE RADIATOR RESERVE TANK ASSEMBLY  (See REMOVAL )
  24. REMOVE AIR CLEANER CAP SUB-ASSEMBLY WITH HOSE  (See REMOVAL )
  25. REMOVE THROTTLE BODY ASSEMBLY  (See REMOVAL )
  26. REMOVE IGNITION COIL ASSEMBLY  (See REMOVAL )
  27. REMOVE SPARK PLUG  (See REMOVAL )
  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY  (See REMOVAL )
  29. REMOVE ENGINE OIL LEVEL DIPSTICK 
  30. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 
    1. Remove the bolt and engine oil level dipstick guide.
      Fig 1: Locating Engine Oil Level Dipstick Guide Bolt
      G04974178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the O-ring from the engine oil level dipstick guide.
  31. DISCONNECT FUEL MAIN TUBE  (See REMOVAL )
  32. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY  (See REMOVAL )
  33. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY  (See REMOVAL )
  34. REMOVE INTAKE MANIFOLD  (See REMOVAL )
  35. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR  (See REMOVAL )
  36. REMOVE MANIFOLD STAY  (See REMOVAL )
  37. REMOVE NO. 2 MANIFOLD STAY  (See REMOVAL )
  38. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR  (See REMOVAL )
  39. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 
    1. Disconnect the air-fuel ratio sensor connector.
      Fig 2: Locating Air-Fuel Ratio Sensor Connector
      G04974184Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5 nuts, exhaust manifold converter sub-assembly and gasket.
    Fig 3: Locating Exhaust Manifold Converter Sub-Assembly Nuts
    G04974185Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH 
    1. Place a wooden block between a floor jack and the engine, then support the engine using the floor jack.
      Fig 4: Supporting Engine With Floor Jack
      G05387094Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 bolts and 2 nuts, then remove the engine mounting insulator sub-assembly RH.
      NOTE: Do not apply excessive force to the return tube when removing the engine mounting insulator sub-assembly RH.

      HINT:

      Keep clearance by lowering the engine using the floor jack when removing the front engine mounting insulator.

      Fig 5: Locating Front Engine Mounting Insulator Bolts And Nuts
      G06008280Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE IDLER PULLEY SUB-ASSEMBLY 
    1. Loosen the 2 bolts and remove the idler pulley sub-assembly with the 2 bolts.
    Fig 6: Locating Idler Pulley Sub-Assembly With Bolts
    G05387099Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE OIL PAN SUB-ASSEMBLY 
    1. Install the No. 1 and No. 2 engine hangers with new bolts.

      Torque: 38 N*m (387 kgf*cm, 28 ft.*lbf) 

      Part No  .

      TORQUE SPECIFICATION

      Item Part No.
      No. 1 engine hanger 12281-28010
      No. 2 engine hanger 12282-28010
      Bolt 91512-B1020 or 91552-81020
      Fig 7: Identifying No. 1 And No. 2 Engine Hangers With Bolts
      G05387100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Attach the sling device to the engine hangers and chain block.
    3. Remove the 12 bolts and 2 nuts.
      Fig 8: Locating Bolts And Nuts
      G06008283Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Insert the blade of an oil pan seal cutter between the crankcase, chain cover and oil pan, then cut through the applied sealer and remove the oil pan.
      NOTE: Be careful not to damage the contact surface of the crankcase, chain cover or oil pan.
      Fig 9: Inserting Blade Of Oil Pan Seal Cutter Between Crankcase
      G05387102Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. SET NO. 1 CYLINDER TO TDC/COMPRESSION 
    1. Turn the crankshaft pulley until the groove and the timing mark "0" on the timing chain cover are aligned.
    2. Check that each timing mark on the camshaft timing gear and sprocket is aligned with the timing marks located on the No. 1 and No. 2 bearing caps as shown in the illustration.

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

      Fig 10: Identifying Timing Mark On Camshaft Timing Gear And Sprocket
      G04973932Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE CRANKSHAFT PULLEY  (See REMOVAL )
  45. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Remove the 2 nuts, No. 1 chain tensioner assembly and gasket.
      NOTE: Do not turn the crankshaft without the No. 1 chain tensioner assembly.
  46. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Lift the engine upward.
      NOTE: Do not lift the engine more than necessary.
      Fig 11: Locating No. 1 Chain Tensioner Assembly Nuts
      G05387104Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolt, nut and V-ribbed belt tensioner assembly.
  47. REMOVE CRANKSHAFT POSITION SENSOR  (See REMOVAL )
  48. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY  (See REMOVAL )
    Fig 12: Locating V-Ribbed Belt Tensioner Assembly And Bolt With Nut
    G05128806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE 
    1. Remove the No. 1 crankshaft position sensor plate.
    Fig 13: Identifying No. 1 Crankshaft Position Sensor Plate
    G04973964Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE TIMING CHAIN GUIDE 
    1. Remove the bolt and timing chain guide.
    Fig 14: Locating Timing Chain Guide And Bolt
    G05387111Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE CHAIN TENSIONER SLIPPER 
    1. Remove the bolt and chain tensioner slipper.
    Fig 15: Identifying Chain Tensioner Slipper And Bolt
    G05387112Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE NO. 1 CHAIN VIBRATION DAMPER 
    1. Remove the 2 bolts and No. 1 chain vibration damper.
      Fig 16: Identifying No. 1 Chain Vibration Damper And Bolts
      G05387113Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE CHAIN SUB-ASSEMBLY 
  54. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET 
    1. Remove the crankshaft timing gear or sprocket from the crankshaft.
    Fig 17: Locating Crankshaft Timing Gear
    G05387114Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE NO. 2 CHAIN SUB-ASSEMBLY 
    1. Turn the crankshaft 90° counterclockwise to align the adjusting hole on the oil pump drive shaft sprocket with the groove on the oil pump.
      Fig 18: Aligning Adjusting Hole On Oil Pump Drive Shaft Sprocket With Groove On Oil Pump
      G04973970Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Insert a bar of 4 mm in diameter into the adjusting hole of the oil pump drive shaft sprocket to lock the gear in position, and then remove the nut.
      Fig 19: Identifying Adjusting Hole On Oil Pump Drive Shaft Gear To Lock Gear In Position
      G04973971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the bolt, chain tensioner plate and spring.
    4. Remove the oil pump drive sprocket, oil pump drive shaft sprocket and No. 2 chain.
  56. DISCONNECT NO. 1 RADIATOR HOSE  (See REMOVAL )
  57. DISCONNECT OUTLET HEATER WATER HOSE  (See REMOVAL )
  58. DISCONNECT INLET HEATER WATER HOSE  (See REMOVAL )
    Fig 20: Identifying Bolt, Chain Tensioner Plate And Spring
    G04973972Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. DISCONNECT ENGINE WIRE 
    1. Disconnect the radio setting condenser connector.
    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.
  60. REMOVE NO. 2 CAMSHAFT  (See DISASSEMBLY )
  61. REMOVE CAMSHAFT  (See DISASSEMBLY )
    Fig 21: Locating Camshaft Position Sensor Connector
    G04974042Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. REMOVE NO. 1 CAMSHAFT BEARING  (See DISASSEMBLY )
  63. REMOVE NO. 2 CAMSHAFT BEARING  (See DISASSEMBLY )
  64. REMOVE CYLINDER HEAD SUB-ASSEMBLY 
    1. In 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 22: Identifying Cylinder Head Bolts Removing Sequence
      G04974044Courtesy 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 between the cylinder head and cylinder block.
      Fig 23: Prying Between Cylinder Head And Cylinder Block
      G04974045Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. REMOVE CYLINDER HEAD GASKET 
Fig 24: Identifying Cylinder Head Gasket
G04974046Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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