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Removal [11/2015 - ]: Procedure

  1. REMOVE EGR COOLER ASSEMBLY 

    (Refer to REMOVAL [11/2015 - ] )

  2. REMOVE NO. 1 IGNITION COIL 

    Refer to PROCEDURE - Step 1

  3. SEPARATE ENGINE WIRE 
    1. Disconnect the 4 injector connectors.
      GTY334393Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the wire harness clamp.
      GTY342937Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 3 bolts and separate the engine wire.
  4. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY 
    1. Disconnect the No. 1 ventilation hose and No. 2 ventilation hose.
      GTY334389Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 9 bolts, 2 seal washers, 2 nuts and cylinder head cover sub-assembly.
      GTY708726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the gasket from the cylinder head cover sub-assembly.
  5. SET NO. 1 CYLINDER TO TDC / COMPRESSION 

    See step  2

  6. REMOVE SCREW PLUG 

    Refer to PROCEDURE - Step 12

  7. REMOVE NO. 2 CAMSHAFT 
    1. Loosen the bolts on the camshaft timing gear or sprocket while holding the hexagonal portion of the No. 2 camshaft.
      GTY341329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
    2. Insert a screwdriver from the plug hole and turn the stopper plate of the No. 1 chain tensioner assembly clockwise to release the lock, and keep it as it is.
      GTY336123Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Plunger
      *2 Stopper Plate
      *a Unlock

      HINT: 

      • The plunger of the No. 1 chain tensioner assembly is locked.
      • If the stopper plate is locked firmly, slightly turn the hexagonal portion of the camshaft to the right and left.
    3. Slightly turn the hexagonal portion of the No. 2 camshaft clockwise so that the plunger of the No. 1 chain tensioner assembly is pushed by the chain sub-assembly.
      GTY336701Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Plunger
    4. Insert a screwdriver from the plug hole and turn the stopper plate of the No. 1 chain tensioner assembly counterclockwise to the lock, and keep it as it is. Insert the hexagon wrench into the stopper plate hole.
      GTY695643Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Hexagon Wrench
      *2 Plunger
      *3 Stopper Plate
      *a Lock

      HINT: 

      Hold the hexagon wrench with tape so that the hexagon wrench does not come off.

      GTY687926Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown in the illustration. Then remove the No. 1 camshaft bearing cap and 4 No. 2 camshaft bearing caps.
      Fig 1: Camshaft Bearing Cap Bolts Loosening Sequence
      GTY688584Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the No. 2 camshaft level.

    6. Remove the bolt with the No. 2 camshaft lifted up.
      GTY324051Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Remove the No. 2 camshaft and camshaft timing gear or sprocket.
  8. REMOVE CAMSHAFT 
    1. Loosen the bolts on the camshaft timing gear assembly while holding the hexagonal portion of the camshaft.
      GTY328603Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Hold
    2. Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown in the illustration. Then remove the 4 No. 2 camshaft bearing caps.
      Fig 2: Camshaft Bearing Cap Bolts Loosening Sequence
      GTY730769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Uniformly loosen the bolts while keeping the camshaft level.

    3. Hold the chain sub-assembly with one hand, and remove the camshaft.
      GTY332097Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Tie the chain sub-assembly with a string or similar as shown in the illustration.
      GTY334386Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to drop anything inside the timing chain cover.

  9. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Check the camshaft timing gear assembly lock.
      1. Clamp the camshaft in a vise, and make sure that the camshaft timing gear assembly does not rotate.
        GTY339783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the lock pin.
      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
        GTY328266Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Retard Side Path
        *b Advance Side Path
        *c Open
        *d Close
        Rubber Piece
        Vinyl Tape

        HINT: 

        4 oil paths are provided in the groove. Plug 2 paths with rubber pieces.

      2. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.
      3. Apply approximately 150 kPa (1.5 kgf/cm2, 22 psi) of air pressure to the 2 paths (the advance side path and the retard side path).
        GTY334300Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Advance Side Path
        *b Retard Side Path

        HINT: 

        Cover the paths with a piece of cloth when applying pressure to keep oil from spraying.

      4. Make sure that the camshaft timing sprocket turns in the retard direction when reducing the air pressure applied to the advance side path.
        GTY340854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
        TEXT IN ILLUSTRATION

        *a Advance Side Path
        *b Retard Side Path
        *c Decompress
        *d Hold Pressure

        HINT: 

        The lock pin is released and the camshaft timing sprocket turns in the retard direction.

      5. When the camshaft timing sprocket moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.
        NOTE:

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing sprocket may abruptly shift in the advance direction and break the lock pin or other parts.

  10. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY 
    1. Remove the bolt and camshaft timing gear assembly.
      GTY702704Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Do Not Remove
      NOTE:
      • Be sure not to remove the other 4 bolts.
      • When reusing the camshaft timing gear assembly, release the lock pin first, then install the camshaft timing gear assembly.
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