Removal [12/2013 - ]: Procedure

WARNING: This page is about a different variant/trim than selected.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
Refer to PROCEDURE - Step 8
REMOVE MANIFOLD STAY
Refer to PROCEDURE - Step 6
REMOVE NO. 2 MANIFOLD STAY
Refer to PROCEDURE - Step 7
REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
Refer to PROCEDURE - Step 8
REMOVE EXHAUST MANIFOLD
Refer to PROCEDURE - Step 9
REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY
Refer to PROCEDURE - Step 4
REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)
Refer to PROCEDURE - Step 9
DISCONNECT NO. 2 VENTILATION HOSE
Refer to PROCEDURE - Step 10
DISCONNECT UNION TO VACUUM TUBE HOSE
Refer to PROCEDURE - Step 11
REMOVE FUEL DELIVERY PIPE
Refer to PROCEDURE - Step 10
REMOVE INTAKE MANIFOLD
Refer to PROCEDURE - Step 15

SET NO. 1 CYLINDER TO TDC/COMPRESSION

Temporarily install the crankshaft pulley bolt.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1	Crankshaft Pulley Key	-	-
*a	Approximately 7°	*b	Approximately 32°
*c	Timing Mark	-	-

Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.
Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.
HINT:

"A" is not a timing mark.
Remove the crankshaft pulley bolt.

REMOVE TIMING CHAIN GUIDE

Remove the bolt and timing chain guide.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Stopper Plate
*b	Plunger

Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CHAIN TENSIONER SLIPPER

Remove the bolt and chain tensioner slipper.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CHAIN SUB-ASSEMBLY
Refer to PROCEDURE - Step 30

REMOVE NO. 1 CHAIN VIBRATION DAMPER

Remove the 2 bolts and No. 1 chain vibration damper.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

Using a wrench to hold the hexagonal portion of the camshaft, remove the bolt and camshaft timing gear assembly.

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Hold
*b	Turn

NOTE:

Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
Do not disassemble the camshaft timing gear assembly.

REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

Using a wrench to hold the hexagonal portion of the No. 2 camshaft, remove the bolt and camshaft timing exhaust gear assembly.

*a	Hold
*b	Turn

NOTE:

Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.
Do not disassemble the camshaft timing exhaust gear assembly.

REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

Uniformly loosen and remove the 20 bolts in the order shown in the illustration.

Fig 1: Camshaft Housing Bolts Loosening Sequence
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

NOTE:

Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

HINT:

Tape the screwdriver tip before use.

REMOVE CAMSHAFT BEARING CAP

Remove the 11 bolts in the order shown in the illustration.

Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps.
HINT:

Arrange the removed parts in the correct order.

REMOVE OIL CONTROL VALVE FILTER
Refer to PROCEDURE - Step 41
REMOVE NO. 1 CAMSHAFT BEARING
Refer to PROCEDURE - Step 42
REMOVE CAMSHAFT
1. Remove the camshaft and No. 2 camshaft.
REMOVE NO. 2 CAMSHAFT BEARING
Refer to PROCEDURE - Step 43
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 16 valve stem caps from the cylinder head sub-assembly.
  HINT:
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the order shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.
  
  Fig 2: Cylinder Head Bolts Loosening Sequence
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  HINT:
  
  Be sure to keep the removed parts separate for each installation position.
  NOTE:
  - Be careful not to drop plate washers into the cylinder head sub-assembly.
  - Cylinder head warpage or cracking may result from removing bolts in the incorrect order.
2. Remove the cylinder head sub-assembly.
REMOVE CYLINDER HEAD GASKET
1. Remove the cylinder head gasket from the cylinder block sub-assembly.