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Removal [08/2015 - ]: Procedure

  1. DISCHARGE FUEL SYSTEM PRESSURE 

    Refer to PROCEDURE - Step 1

  2. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY 

    (Refer to REMOVAL [08/2015 - ] )

  3. DRAIN ENGINE OIL 

    See step  1

  4. REMOVE AIR CLEANER ASSEMBLY 

    Refer to PROCEDURE - Step 24

  5. REMOVE RADIATOR ASSEMBLY 

    (Refer to REMOVAL [08/2015 - ] )

  6. DISCONNECT ENGINE WIRE 
    1. Engine Room LH Side:
      1. Remove the engine room relay block cover.
        GTY555511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Disconnect the 2 connectors and 2 clips from the engine room junction block.
      3. Disconnect the 4 air injection control driver connectors and wire harness clamp.
        GTY601310Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      4. Disconnect the injector connector.
        GTY584100Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      5. Disconnect the 4 ignition coil connectors.
      6. Disconnect the 2 VVT sensor connectors.
      7. Disconnect the 4 clamps.
      8. Remove the 2 bolts and ground wire.
      9. Disconnect the noise filter connector.
      10. Disconnect the engine coolant temperature sensor connector.
        GTY611528Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      11. Disconnect the 2 camshaft timing oil control valve connectors.
      12. Disconnect the camshaft position sensor connector.
      13. Disconnect the 3 clamps.
      14. Disconnect the cooler compressor connector.
    2. Engine Room RH Side:
      GTY611371Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Disconnect the 2 camshaft timing oil control valve connectors.
      2. Disconnect the 4 ignition coil connectors.
      3. Disconnect the injector connector.
      4. Disconnect the 2 VVT sensor connectors.
      5. Disconnect the noise filter connector.
      6. Remove the 2 bolts and ground wire.
      7. Disconnect the 2 air pump connectors.
      8. Disconnect the throttle position sensor and throttle control motor connector.
      9. Disconnect the 5 clamps.
    3. Disconnect the 2 clamps and power steering oil pressure switch connector.
      GTY611083Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. DISCONNECT AIR PUMP HOSE AND WIRE HARNESS 
    1. Disconnect the No. 2 air hose and No. 3 air hose.
      GTY586918Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 No. 2 Air Hose
      *2 No. 3 Air Hose
    2. Disconnect the 2 clamps.
  8. DISCONNECT NO. 2 WATER BY-PASS PIPE 
    1. Disconnect the 3 hoses.
      GTY611090Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 3 bolts and disconnect the No. 2 water by-pass pipe from the cylinder head cover.
  9. DISCONNECT COOLER COMPRESSOR ASSEMBLY 
    1. Remove the 3 bolts, nut and stud bolt, and disconnect the cooler compressor.
      GTY148637Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.

  10. DISCONNECT NO. 2 FUEL TUBE SUBASSEMBLY 
    1. Remove the 2 bolts and disconnect the fuel tube.
      GTY570550Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a LH Side
      *b RH Side
  11. REMOVE OIL FILTER ELEMENT 

    See step  4

  12. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE 

    Refer to PROCEDURE - Step 38

  13. REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY 

    See step  4

  14. REMOVE NO. 2 WATER BY-PASS PIPE SUBASSEMBLY (w/ Oil Cooler) 
    1. Remove the 3 bolts.
      GTY545961Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 4 hoses and remove the water by-pass pipe.
  15. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler) 

    See step  14

  16. REMOVE OIL FILTER BRACKET (w/ Oil Cooler) 

    See step  15

  17. REMOVE OIL FILTER BRACKET (w/o Oil Cooler) 
    1. Remove the 2 bolts, 2 nuts and oil filter bracket.
      GTY593366Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings.
      GTY604897Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE INTAKE MANIFOLD 

    Refer to PROCEDURE - Step 10

  19. DISCONNECT VANE PUMP ASSEMBLY 
    1. Remove the 2 bolts and disconnect the vane pump.
      GTY610877Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. DISCONNECT OIL COOLER TUBE 

    Refer to PROCEDURE - Step 53

  21. REMOVE GENERATOR ASSEMBLY 

    Refer to PROCEDURE - Step 13

  22. REMOVE NO. 1 WATER BY-PASS HOSE 
    1. Remove the No. 1 water by-pass hose by disconnecting the hose from the water inlet housing and front water by-pass joint.
      GTY610852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE WATER BY-PASS PIPE SUBASSEMBLY 
    1. Remove the bolt and disconnect the air tube.
      GTY610956Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Disconnect the 2 hoses.
      GTY611258Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 2 bolts and water by-pass pipe.
  24. REMOVE FRONT WATER BY-PASS JOINT 
    1. Disconnect the No. 2 water by-pass hose from the water by-pass joint.
      GTY611163Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 4 nuts, water by-pass joint and 2 gaskets.
  25. REMOVE NO. 2 ENGINE COVER 

    Refer to PROCEDURE - Step 6

  26. REMOVE NO. 1 ENGINE COVER 

    Refer to PROCEDURE - Step 8

  27. REMOVE AIR TUBE SUBASSEMBLY 
    1. Remove the bolt, disconnect the 2 hoses, and remove the air tube.
      GTY571520Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE WATER INLET HOUSING 
    1. Remove the 3 bolts, water inlet housing and gasket.
      GTY610973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE WATER PUMP PULLEY 
    1. Using SST, hold the water pump pulley.
      GTY611438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09960-10010 
        1. 09962-01000
        2. 09963-01000
    2. Remove the 4 bolts and water pump pulley.
  30. REMOVE NO. 1 IDLER PULLEY SUBASSEMBLY 
    1. Remove the bolt and idler pulley.
      GTY571521Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE FLUID COUPLING BRACKET 
    1. Remove the 4 bolts and fluid coupling bracket.
      GTY121915Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY 
    1. Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.
      GTY255060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE IGNITION COIL ASSEMBLY 
    1. Remove the 8 bolts and 8 ignition coils.
  34. REMOVE CYLINDER HEAD COVER SUBASSEMBLY LH 
    1. Remove the 14 bolts, seal washer, cylinder head cover and gasket.
      GTY121981Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    2. Remove the 5 gaskets from the camshaft bearing caps (No. 2, No. 3).
      GTY571580Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE CYLINDER HEAD COVER SUBASSEMBLY RH 
    1. Remove the bolt and noise filter.
      GTY480043Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 14 bolts, seal washer, cylinder head cover and gasket.
      GTY147820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT: 

      Make sure the removed parts are returned to the same places they were removed from.

    3. Remove the 5 gaskets from the camshaft bearing caps (No. 1, No. 3).
      GTY604869Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE SPARK PLUG TUBE GASKET 

    Refer to PROCEDURE - Step 22

  37. REMOVE CRANKSHAFT PULLEY 
    1. Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.
      GTY609738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09213-70011 
      • SST: 09330-00021 
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
    2. Using the pulley set bolt and SST, remove the crankshaft pulley.
      GTY541137Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-50013 
        1. 09951-05010
        2. 09952-05010
        3. 09953-05010
        4. 09954-05011
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
  38. DISCONNECT WIRE HARNESS CLAMP BRACKET 
    1. Remove the bolt and disconnect the bracket.
      GTY610828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE CRANKSHAFT TIMING GEAR KEY 
    1. Using a screwdriver, remove the timing gear key from the crankshaft.
      GTY587387Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE TIMING CHAIN COVER SUBASSEMBLY 
    1. Remove the 28 bolts and nut shown in the illustration.
      GTY573899Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Nut
    2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver as shown in the illustration.
      GTY121907Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

      HINT: 

      Tape the screwdriver tip before use.

    3. Remove the oil pump gasket from the cylinder block.
      GTY571506Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the O-ring from the oil pan.
      GTY268743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE WATER INLET PIPE 
    1. Remove the water inlet pipe.
      GTY571509Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 O-rings from the water inlet pipe.
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