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Removal [11/2016 - ]: Procedure

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  1. INSTALL ENGINE ASSEMBLY TO ENGINE STAND 

    Refer to REMOVAL [11/2016 - ] 

  2. REMOVE ENGINE HANGERS 

    See step  72

  3. REMOVE RADIATOR PIPE CLAMP 

    Refer to PROCEDURE - Step 1

  4. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 2

  5. REMOVE INJECTOR DRIVER 

    Refer to PROCEDURE - Step 6

  6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY 

    Refer to PROCEDURE - Step 9

  7. REMOVE THROTTLE BODY GASKET 

    Refer to PROCEDURE - Step 10

  8. DISCONNECT VENTILATION HOSE 

    Refer to PROCEDURE - Step 5

  9. REMOVE NO. 2 SURGE TANK STAY 

    Refer to PROCEDURE - Step 7

  10. REMOVE INTAKE AIR SURGE TANK ASSEMBLY 

    Refer to PROCEDURE - Step 8

  11. REMOVE AIR SURGE TANK TO INTAKE MANIFOLD GASKET 

    Refer to PROCEDURE - Step 9

  12. REMOVE NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 16

  13. DISCONNECT FUEL TUBE SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 7

  14. REMOVE NO. 2 ENGINE MOUNTING STAY RH 

    Refer to PROCEDURE - Step 24

  15. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 21

  16. REMOVE NO. 1 INTAKE MANIFOLD TO HEAD GASKET 

    Refer to PROCEDURE - Step 22

  17. REMOVE FUEL PUMP ASSEMBLY (for High Pressure) 

    Refer to REMOVAL [11/2016 - ]

  18. REMOVE IGNITION COIL ASSEMBLY 

    Refer to PROCEDURE - Step 10

  19. REMOVE WIRE HARNESS CLAMP BRACKET 

    Refer to PROCEDURE - Step 32

  20. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 17

  21. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 18

  22. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 7

  23. REMOVE CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 14

  24. REMOVE VVT SENSOR (for Intake Side of Bank 1) 

    Refer to PROCEDURE - Step 2

  25. REMOVE VVT SENSOR (for Exhaust Side of Bank 1) 

    Refer to PROCEDURE - Step 3

  26. REMOVE VVT SENSOR (for Intake Side of Bank 2) 

    Refer to PROCEDURE - Step 4

  27. REMOVE VVT SENSOR (for Exhaust Side of Bank 2) 

    Refer to PROCEDURE - Step 5

  28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 

    Refer to PROCEDURE - Step 26

  29. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH 

    Refer to PROCEDURE - Step 27

  30. REMOVE SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 28

  31. REMOVE TIMING CHAIN COVER PLATE 

    Refer to PROCEDURE - Step 38

  32. SET NO. 1 CYLINDER TO TDC (COMPRESSION) 
    1. Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY673470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    2. Check that the timing marks of the camshaft timing gear assemblies are aligned with the timing marks of the camshaft bearing caps as shown in the illustration.

      HINT: 

      If the marks are not aligned, turn the crankshaft again to align the marks.

      GTY638585Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *A for Bank 2
      *B for Bank 1
      *a Timing Mark
      *b Paint Mark
    3. Place paint marks on the timing marks and sprockets of each camshaft timing gear assembly and on the links of the chain sub-assembly.

      HINT: 

      Be sure to place the paint marks on 2 links of the chain sub-assembly and on the sprockets of the camshaft timing gear assemblies at the locations of the timing marks of the camshaft timing gear assemblies.

  33. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY 
    1. Turn the crankshaft approximately 30° counterclockwise so that there is some slack in the chain sub-assembly.

      HINT: 

      This prevents the valves and pistons from interfering with each other.

      GTY633273Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Align the hole in the lever of the No. 1 chain tensioner assembly with the hole in the tensioner body as shown in the illustration, and then insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole.
      GTY650461Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Lever Hole
      *b Tensioner Hole
      *c Pin
      NOTE:

      Check that the pin is locked.

    3. Turn the crankshaft clockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY673470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    4. Remove the 2 bolts and No. 1 chain tensioner assembly from the cylinder head sub-assembly.
      NOTE:

      Do not drop the No. 1 chain tensioner assembly or bolts into the timing chain cover assembly.

      GTY639670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 1) 
    1. Turn the crankshaft clockwise until it is in the position shown in the illustration so that there is some slack in the chain sub-assembly between the banks.
      WARNING:

      As the camshafts turn suddenly, do not touch the camshafts or camshaft timing gears.

      HINT: 

      When turning the crankshaft, engine oil may spray out of the oil holes.

      GTY654511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Turn the crankshaft clockwise until it is in the position shown in the illustration so that the chain sub-assembly can be removed easily.

      HINT: 

      When turning the crankshaft, engine oil may spray out of the oil holes.

      GTY679667Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a 5 to 10°
    3. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      WARNING:

      As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

      GTY660277Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. SEPARATE NO. 2 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt to separate the No. 2 chain tensioner assembly from the camshaft housing sub-assembly LH.
      GTY660276Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) 
    1. Hold the hexagonal portion of the camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft timing gear assembly.
      GTY620043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  37. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) 
    1. Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.
      NOTE:
      • Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
      GTY650363Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
  38. REMOVE CAMSHAFT BEARING CAP (for Bank 1) 
    1. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      GTY660263Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing replacement bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow replacement bolts or washers to contact the camshaft.
      • Do not drop replacement bolts or washers into the cylinder head sub-assembly.
        • Fig 1: Camshaft Bearing Caps (For Bank 1) Bolt Loosening Sequence
        GTY647568Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      • Arrange the removed parts so that they can be reinstalled in their original locations.
      • Part number for replacement bolts: 91551-F0850 (9 bolts)
      • Part number for replacement washers: 90201-12028 (18 washers)
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation
  39. REMOVE NO. 2 CAMSHAFT 
    1. While lifting up the camshaft timing exhaust gear assembly, remove the No. 2 chain tensioner assembly.
      GTY660260Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift up the rear of the No. 2 camshaft so that it is at an angle.
    3. Pull the No. 2 camshaft as shown in the illustration to remove it from the camshaft timing exhaust gear assembly.
      GTY660259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE CAMSHAFT 
    1. Lift up the rear of the camshaft so that it is at an angle.
    2. Pull the camshaft as shown in the illustration to remove it from the camshaft timing gear assembly.
      GTY660258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 1) 
    1. Remove the camshaft timing exhaust gear assembly.
      GTY660257Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1) 
    1. Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

      GTY683029Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Suspend the chain sub-assembly with a string or equivalent.
      GTY660268Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. DISCONNECT CHAIN SUB-ASSEMBLY (for Bank 2) 
    1. Turn the crankshaft counterclockwise to align the timing mark (cutout) on the crankshaft pulley with the "0" timing mark on the timing chain cover assembly.
      GTY673470Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Timing Mark (Cutout)
      *b "0" Timing Mark
    2. Remove the chain sub-assembly from the sprocket of the camshaft timing gear assembly and set it on the camshaft timing gear assembly.
      GTY660267Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      WARNING:

      As the camshaft may turn suddenly and pinch your fingers when the chain sub-assembly is removed, pinch the chain sub-assembly and lift it upward to remove it from the sprocket.

  44. SEPARATE NO. 3 CHAIN TENSIONER ASSEMBLY 
    1. Remove the bolt of the No. 3 chain tensioner assembly.
      GTY659186Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) 
    1. Hold the hexagonal portion of the No. 3 camshaft sub-assembly with a wrench and remove the camshaft timing gear bolt from the camshaft timing gear assembly.
      GTY612066Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  46. REMOVE CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) 
    1. Hold the hexagonal portion of the No. 4 camshaft sub-assembly with a wrench and remove the camshaft timing gear bolt from the camshaft timing exhaust gear assembly.
      GTY634696Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:
      • Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
      • If the camshaft timing gear bolt has been struck or dropped, replace it.
  47. REMOVE CAMSHAFT BEARING CAP (for Bank 2) 
    1. Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
      GTY659181Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the bolts and camshaft bearing caps in the order shown in the illustration. Immediately after removing a camshaft bearing cap, install replacement bolts and washers in the order shown in the illustration.

      Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) 

      NOTE:
      • Do not install the camshaft bearing caps when installing replacement bolts and washers.
      • Be sure to follow the numerical order when performing this procedure.
      • Do not allow replacement bolts or washers to contact the camshaft.
      • Do not drop replacement bolts or washers into the cylinder head LH.

      HINT: 

      • Arrange the removed parts so that they can be reinstalled in their original locations.
      • Part number for replacement bolts: 91551-F0850 (8 bolts)
      • Part number for replacement washers: 90201-12028 (16 washers)
      Fig 2: Loosening Sequence & Tightening Sequence Of Camshaft Bearing Cap Bolts (For Bank 2)
      GTY676893Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Replacement Bolt and Washer
      *b Part Removal
      *c Replacement Bolt and Washer Installation
  48. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY 
    1. While lifting up the camshaft timing exhaust gear assembly, remove the No. 3 chain tensioner assembly.
      GTY659178Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Lift up the rear of the No. 4 camshaft sub-assembly so that it is at an angle.
    3. Pull the No. 4 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing exhaust gear assembly.
      GTY659176Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY 
    1. Lift up the rear of the No. 3 camshaft sub-assembly so that it is at an angle.
    2. Pull the No. 3 camshaft sub-assembly as shown in the illustration to remove it from the camshaft timing gear assembly.
      GTY682783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 2) 
    1. Remove the camshaft timing exhaust gear assembly.
      GTY659189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2) 
    1. Remove the camshaft timing gear assembly and No. 2 chain sub-assembly.
      GTY682787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not drop the chain sub-assembly into the gap between the engine and timing chain cover assembly.

    2. Suspend the chain sub-assembly with a string or equivalent.
      GTY659192Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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