CAMSHAFT REMOVAL

DISCHARGE FUEL SYSTEM PRESSURE

(Click here)

REMOVE UPPER RADIATOR SUPPORT SEAL

1. 

   Remove the 7 clips and radiator support seal.

REMOVE RADIATOR GRILLE

1. 

   Put protective tape around the radiator grille assembly.

   Table 1. Text in Illustration

   *1	Protective Tape

2. Remove the 3 screws.

3. Detach the 2 clips and 8 claws, and remove the radiator grille assembly.

4. w/ Wide View Front Monitor System:

   
   

   1. Disconnect the connector.

REMOVE FRONT BUMPER COVER

1. 

   Put protective tape around the front bumper cover.

   Table 2. Text in Illustration

   *1

   Protective Tape

   -

   -

2. 

   Using a T30 "TORX" socket, remove the 6 screws.

   Table 3. Text in Illustration

   *A

   LH Side

   *B

   RH Side

3. Remove the 3 clips, 4 screws and 4 bolts.

4. 

   Detach the 10 claws and remove the front bumper cover.

5. w/ TOYOTA Parking Assist-sensor System or w/ Fog Light:

   Disconnect the No. 4 engine room wire connector and remove the front bumper cover.

6. 

   w/ Headlight Cleaner System:

   Disconnect the headlight cleaner hose and remove the front bumper cover.

REMOVE TRANSMISSION OIL COOLER AIR DUCT

1. 

   Remove the 4 bolts and oil cooler air duct.

DISCONNECT RADIATOR SIDE DEFLECTOR LH

1. 

   Using a clip remover, remove the 4 clips and disconnect the side deflector.

REMOVE FRONT FENDER MAIN SEAL LH

1. 

   Using a clip remover, detach the 3 clips and remove the fender main seal.

REMOVE FRONT FENDER MAIN SEAL RH

REMOVE FRONT WIPER ARM LH

1. Remove the nut, wiper arm and blade.

REMOVE FRONT WIPER ARM RH

1. Remove the nut, wiper arm and blade.

REMOVE HOOD TO COWL TOP SEAL

1. 

   Using a clip remover, detach the 12 clips, 4 clamps and remove the hood to cowl top seal.

REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

1. 

   Remove the washer hose.

2. 

   Remove the 2 clips.

3. Detach the 17 claws and remove the cowl top ventilator louver sub-assembly.

REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

1. 

   Remove the 3 bolts and screw.

2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly LH.

REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

1. 

   Remove the 3 bolts and 2 screws.

2. Turn the clip indicated by the arrow in the illustration to remove the front fender splash shield sub-assembly RH.

REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

1. 

   Remove the 10 bolts and No. 1 engine under cover.

REMOVE NO. 2 ENGINE UNDER COVER

1. 

   Remove the 2 bolts and No. 2 engine under cover.

REMOVE FRONT FENDER APRON SEAL LH

1. 

   Using a clip remover, remove the 3 clips and fender apron seal.

REMOVE FRONT FENDER APRON SEAL FRONT RH

1. 

   Using a clip remover, remove the 3 clips and fender apron seal.

DRAIN ENGINE OIL

1. Remove the oil filler cap.

2. 

   Remove the 2 bolts and No. 2 engine under cover seal.

3. Remove the oil pan drain plug and gasket, and drain the engine oil into a container.

4. Install a new gasket and the oil pan drain plug.

   40 N*m

   408 kgf*cm

   30 ft.*lbf

DRAIN ENGINE COOLANT

1. Loosen the radiator drain cock plug.

   Tip:

   Collect the coolant in a container and dispose of it according to the regulations in your area.

2. Remove the radiator cap. Then drain the coolant from the radiator.

3. Loosen the 2 cylinder block drain cock plugs. Then drain the coolant from the engine.

4. 

   Tighten the 2 cylinder block drain cock plugs.

   13 N*m

   133 kgf*cm

   10 ft.*lbf

   Table 4. Text in Illustration

   *1	Radiator Reservoir	*2	Radiator Cap
   *3	Radiator Drain Cock Plug	*4	Cylinder Block Drain Cock Plug

5. Tighten the radiator drain cock plug by hand.

REMOVE V-BANK COVER SUB-ASSEMBLY

1. 

   Raise the front of the V-bank cover to detach the 3 pins. Then remove the 2 V-bank cover hooks from the bracket, and remove the V-bank cover.

   Table 5. Text in Illustration

   *1	Bracket
   *2	Hook
   *3	Pin
   *4	Grommet

REMOVE AIR CLEANER HOSE ASSEMBLY

1. 

   Disconnect the vacuum hose and No. 2 ventilation hose.

2. Loosen the 2 hose clamps.

3. Remove the air cleaner hose.

REMOVE AIR CLEANER ASSEMBLY

1. 

   Remove the 3 bolts and air cleaner.

REMOVE FAN SHROUD

1. 

   Loosen the 4 nuts holding the fluid coupling fan.

2. Remove the fan and generator V-belt (Click here).

3. 

   Disconnect the reservoir hose from the upper radiator tank.

4. Detach the claw to open the flexible hose clamp.

5. Remove the 2 bolts and disconnect the oil cooler tube from the fan shroud.

6. Remove the 2 bolts holding the fan shroud.

7. Remove the 4 nuts of the fluid coupling fan, and then remove the shroud together with the coupling fan.

   Note:

   Be careful not to damage the radiator core.

8. Remove the fan pulley.

REMOVE RADIATOR ASSEMBLY

1. 

   Disconnect the 2 oil cooler hoses.

2. 

   Remove the 4 bolts and radiator.

DISCONNECT ENGINE WIRE

1. Engine Room LH Side:

   
   
   1. 

      Remove the engine room relay block cover.

   2. Disconnect the 2 connectors and 2 clips from the engine room junction block.

   3. 

      Disconnect the injector connector.

   4. Disconnect the 4 ignition coil connectors.

   5. Disconnect the 2 VVT sensor connectors.

   6. Disconnect the 4 clamps.

   7. Remove the 2 bolts and ground wire.

   8. Disconnect the noise filter connector.

   9. 

      Disconnect the engine coolant temperature sensor connector.

   10. Disconnect the 2 camshaft timing oil control valve connectors.

   11. Disconnect the camshaft position sensor connector.

   12. Disconnect the 3 clamps.

   13. Disconnect the cooler compressor connector.

2. 

   Engine Room RH Side:

   
   

   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 throttle position sensor and throttle control motor connector.

   8. Disconnect the 5 clamps.

3. 

   Disconnect the 2 clamps and power steering oil pressure switch connector.

DISCONNECT WATER PIPE AND HOSE SUB-ASSEMBLY

1. 

   Disconnect the 3 hoses.

2. Remove the 2 bolts and disconnect the water pipe and hose from the cylinder head cover.

DISCONNECT COOLER COMPRESSOR ASSEMBLY

1. 

   Remove the 3 bolts, nut and stud bolt, and disconnect the cooler compressor.

   Tip:

   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.

DISCONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

1. 

   Remove the 2 bolts and disconnect the fuel tube.

   Table 6. Text in Illustration

   *A	LH Side
   *B	RH Side

REMOVE OIL FILTER ELEMENT

1. 

   Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

   Table 7. Text in Illustration

   *1	Pipe
   *2	Hose

2. 

   Remove the oil filter drain plug.

3. 

   Install the pipe to the oil filter cap.

   Table 8. Text in Illustration

   *1	Cap
   *2	Valve
   *3	Pipe
   *4	O-Ring
   *5	Hose

   Note:

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   Tip:

   Use a container to catch the draining oil.

4. 

   Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

5. 

   Using SST, remove the oil filter cap.

   09228-06501

   Table 9. Text in Illustration

   *1	Oil Filter Bracket Clip

   Note:

   Do not remove the oil filter bracket clip.

6. 

   Remove the oil filter element and O-ring from the oil filter cap.

   Table 10. Text in Illustration

   *1	Oil Filter Element
   *2	O-Ring

   Note:

   Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

1. 

   Disconnect the wire harness clamp.

2. Remove the dipstick.

3. Remove the bolt and dipstick guide.

4. Remove the O-ring from the dipstick guide.

REMOVE OIL PRESSURE SENDER GAUGE ASSEMBLY

1. 

   Disconnect the sender gauge connector.

2. 

   Remove the oil pressure sender gauge.

REMOVE NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

1. 

   Remove the 3 bolts.

2. Disconnect the 4 hoses and remove the water by-pass pipe.

REMOVE NO. 1 OIL COOLER BRACKET

1. 

   Remove the 2 nuts and bracket.

2. Disconnect the ground wire from the cylinder block.

REMOVE OIL FILTER BRACKET

1. 

   Connect a hose with an inside diameter of 15 mm (0.591 in.) to the pipe.

   Table 11. Text in Illustration

   *1	Pipe
   *2	Hose

2. 

   Remove the oil filter drain plug.

3. 

   Install the pipe to the oil filter cap.

   Table 12. Text in Illustration

   *1	Cap
   *2	Valve
   *3	Pipe
   *4	O-Ring
   *5	Hose

   Note:

   If the O-ring is removed with the drain plug, install the O-ring together with the pipe.

   Tip:

   Use a container to catch the draining oil.

4. 

   Check that oil is drained from the oil filter. Then disconnect the pipe and remove the O-ring as shown in the illustration.

5. 

   Using SST, remove the oil filter cap.

   09228-06501

   Table 13. Text in Illustration

   *1	Oil Filter Bracket Clip

   Note:

   Do not remove the oil filter bracket clip.

6. 

   Remove the oil filter element and O-ring from the oil filter cap.

   Table 14. Text in Illustration

   *1	Oil Filter Element
   *2	O-Ring

   Note:

   Be sure to remove the cap O-ring by hand, without using any tools, to prevent damage to the cap O-ring groove.

REMOVE INTAKE MANIFOLD

1. 

   Disconnect the ventilation hose from the ventilation pipe of the cylinder head cover LH and RH.

2. 

   Disconnect the 2 water by-pass hoses.

3. Disconnect the throttle body connector.

4. 

   Disconnect the No. 1 ventilation hose.

5. 

   Disconnect the purge VSV connector.

6. Disconnect the purge line hose from the purge VSV.

7. Disconnect the vacuum switching valve connector (for ACIS).

8. 

   Remove the No. 1 engine cover sub-assembly.

9. 

   Remove the No. 3 engine cover.

10. 

    Disconnect the 3 wire clamps from the 3 wire brackets.

11. 

    Remove the bolt and wire bracket from the intake manifold.

12. 

    Remove the 2 nuts, 8 bolts, intake manifold and 2 gaskets.

DISCONNECT VANE PUMP ASSEMBLY

1. 

   Remove the 2 bolts and disconnect the vane pump.

DISCONNECT OIL COOLER PIPE ASSEMBLY

1. 

   Remove the 2 bolts and disconnect the oil cooler pipe.

REMOVE GENERATOR ASSEMBLY

1. 

   Disconnect the generator connector.

2. Open the terminal cap.

3. Remove the nut and disconnect the generator wire.

4. Remove the bolt and disconnect the wire harness bracket from the generator.

5. 

   Remove the 3 bolts, nut and generator.

6. Remove the stud bolt.

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.

REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY

1. 

   Disconnect the 2 hoses.

2. Remove the 2 bolts and water by-pass pipe.

REMOVE FRONT WATER BY-PASS JOINT

1. 

   Disconnect the No. 2 water by-pass hose from the water by-pass joint.

2. Remove the 4 nuts, water by-pass joint and 2 gaskets.

REMOVE WATER INLET HOUSING

1. 

   Remove the 3 bolts, water inlet housing and gasket.

REMOVE WATER PUMP PULLEY

1. 

   Using SST, hold the water pump pulley.

   09960-10010

   09962-01000

   09963-01000

2. Remove the 4 bolts and water pump pulley.

REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY

1. 

   Remove the bolt and idler pulley.

REMOVE FLUID COUPLING BRACKET

1. 

   Remove the 4 bolts and fluid coupling bracket.

REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

1. 

   Remove the standard bolt, 6 mm hexagon wrench bolt and belt tensioner.

REMOVE IGNITION COIL ASSEMBLY

1. Remove the 8 bolts and 8 ignition coils.

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH

1. 

   Remove the 14 bolts, seal washer, cylinder head cover and gasket.

   Tip:

   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).

REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH

1. 

   Remove the bolt and noise filter.

2. 

   Remove the 14 bolts, seal washer, cylinder head cover and gasket.

   Tip:

   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).

REMOVE CRANKSHAFT PULLEY

1. 

   Using SST, loosen the crankshaft pulley set bolt until 2 or 3 threads are engaged.

   09213-70011

   09330-00021

   Table 16. Text in Illustration

   *a	Hold
   	Turn

2. 

   Using the pulley set bolt and SST, remove the crankshaft pulley.

   09950-50013

   09951-05010

   09952-05010

   09953-05010

   09954-05011

   Table 17. Text in Illustration

   *a	Hold
   	Turn

DISCONNECT WIRE HARNESS CLAMP BRACKET

1. 

   Remove the bolt and disconnect the bracket.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

1. 

   Remove the 28 bolts and nut shown in the illustration.

   Table 18. Text in Illustration

   	Bolt
   	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.

   Note:

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

   Tip:

   Tape the screwdriver tip before use.

3. 

   Remove the oil pump gasket from the cylinder block.

4. 

   Remove the O-ring from the oil pan.

REMOVE WATER INLET PIPE

1. 

   Remove the water inlet pipe.

2. Remove the 2 O-rings from the water inlet pipe.

SET NO. 1 CYLINDER TO TDC/COMPRESSION

1. Temporarily install the crankshaft pulley bolt.

2. 

   Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket and camshaft timing gears are as shown in the illustration.

   Tip:

   If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

   Table 19. Text in Illustration

   *1	Timing Mark	*2	Timing Mark Position
   *3	Knock Pin Position	*4	Key
   *a	Toward Ceiling	*b	Approximately 2°
   *c	Approximately 45°	*d	Approximately 16°
   *e	Approximately 18°	*f	Approximately 32°

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY LH

1. 

   Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

   Table 20. Text in Illustration

   *1	Plunger
   *2	Stopper Plate

2. 

   Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

   Table 21. Text in Illustration

   *1	Plunger
   *2	Stopper Plate

3. 

   Remove the 2 bolts, chain tensioner and gasket.

REMOVE NO. 1 CHAIN SUB-ASSEMBLY LH

1. 

   While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

   Table 22. Text in Illustration

   *1	Pin
   *2	Plunger
   *a	Push

2. 

   Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Table 23. Text in Illustration

   *a	Hold
   	Turn

   Note:
   

   • Be careful not to damage the cylinder head with the wrench.

   • Do not disassemble the camshaft timing gear.

3. 

   Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Table 24. Text in Illustration

   *a	Hold
   	Turn

   Note:

   Be careful not to damage the cylinder head with the wrench.

4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket LH.

5. Remove the No. 1 and No. 2 chains from the gears.

REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY RH

1. 

   Move the stopper plate clockwise to release the lock, and push the plunger deep into the tensioner.

   Table 25. Text in Illustration

   *1	Plunger
   *2	Stopper Plate

2. 

   Move the stopper plate counterclockwise to set the lock, and insert a hexagon wrench into the stopper plate hole.

   Table 26. Text in Illustration

   *1	Plunger
   *2	Stopper Plate

3. 

   Remove the 2 bolts and chain tensioner.

REMOVE NO. 1 CHAIN SUB-ASSEMBLY RH

1. 

   While raising up the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) into the hole to fix it in place.

   Table 27. Text in Illustration

   *1	Pin
   *2	Plunger
   *a	Push

2. 

   Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Table 28. Text in Illustration

   *a	Hold
   	Turn

   Note:
   

   • Be careful not to damage the cylinder head with the wrench.

   • Do not disassemble the camshaft timing gear.

3. 

   Hold the hexagonal portion of the camshaft with a wrench and loosen the bolt.

   Table 29. Text in Illustration

   *a	Hold
   	Turn

   Note:

   Be careful not to damage the cylinder head with the wrench.

4. Remove the 2 bolts. Then with the No. 1 and No. 2 chains still connected to the gears, remove the camshaft timing gear, camshaft timing exhaust gear and crankshaft timing sprocket RH.

5. Remove the No. 1 and No. 2 chains from the gears.