Removal

REMOVAL
1. DRAIN ENGINE COOLANT





2. DISCONNECT THESE CABLES:
a) Disconnect the accelerator cable from the throttle body.
b) A/T:
Disconnect the throttle cable from the throttle body.
c) w/ Cruise Control System:
Remove the actuator cover, and disconnect the cruise control cable from the actuator.





3. REMOVE AIR CLEANER CAP, MAF METER AND RESONATOR ASSEMBLY
a) Disconnect the 3 wire clamps for the engine wire.
b) Disconnect the MAF meter connectors.
c) Disconnect the air hose from the air cleaner cap.
d) Loosen the air cleaner hose clamp.
e) Loosen the 4 clips, and remove the air cleaner cap, MAF meter and resonator assembly.





4. REMOVE INTAKE AIR CONNECTOR
a) Except California Spec.: Disconnect the air hose for IAC.
b) Disconnect the vacuum hose for fuel pressure regulator.
c) Disconnect the wire clamp for engine wire.
d) Loosen the hose clamp, and remove the 2 bolts and intake air connector.





5. REMOVE OIL DIPSTICK GUIDE
a) Remove the bolt, dipstick guide and engine wire bracket.
b) Remove the O-ring from the dipstick guide.





6. w/PS:
REMOVE DRIVE BELT FOR PS PUMP
Loosen the lock bolt and adjusting bolt, and remove the drive belt.





7. w/PS:
REMOVE DRIVE BELT IDLER PULLEY FOR PS PUMP
Remove the 3 bolts and idler pulley.
8. w/PS:
REMOVE PS PUMP AND BRACKET





a) Using SST, remove the nut and PS pump pulley.
SST 09960-10010 (09962-01000, 09963-01000)
b) Disconnect the 2 air hoses from the throttle body and air intake chamber.





c) Remove the 2 bolts, and disconnect the PS pump.

HINT: Put aside the pump and suspend it.





d) Remove the 4 bolts and PS pump bracket.
9. REMOVE PCV HOSES





10. Except California Spec.:
REMOVE IGNITION COILS
a) Disconnect the 2 connectors from the ignition coils.
b) Remove the 4 bolts and 2 ignition coils from the bracket.

HINT: Arrange the ignition coils in correct order.

11. DISCONNECT ENGINE WIRE





a) Disconnect the A/C compressor connector.
b) Disconnect the oil pressure sensor connector and clamp.
c) Disconnect the ECT sender gauge connector.
d) Disconnect the 4 engine wire clamps and engine wire.
e) Disconnect the ECT sensor connector.
f) Except California spec. for 2RZ-FE:
1) Disconnect the EGR gas temperature sensor connector.
2) Disconnect the VSV connector for EGR.
3) Disconnect the 2 vacuum hose from the VSV for EGR and clamp.
g) Remove the bolt and ground strap from the cowl top panel.





h) Remove the engine wire from the air intake chamber.
i) Disconnect the 2 engine wire clamps and engine wire.





j) Disconnect the throttle position sensor connector.
k) Disconnect the IAC valve connector.





l) Disconnect the crankshaft position sensor connector.
m) Disconnect the knock sensor connector.





n) Disconnect the camshaft position sensor connector.





o) Disconnect the DLC1 from the bracket.
p) Disconnect the engine wire clamp.





12. Except California Spec. for 2RZ-FE:
REMOVE EGR PIPE
Remove the 4 nuts, bolt, EGR pipe and 2 gaskets.
13. REMOVE INTAKE CHAMBER STAY
Remove the 2 bolts and intake chamber stay.





14. REMOVE AIR INTAKE CHAMBER ASSEMBLY
a) Disconnect the EVAP hose from throttle body.
b) Disconnect the brake booster vacuum hose from union.
c) Disconnect the water bypass hose from water bypass pipe.
d) Disconnect the water bypass hose from cylinder head rear cover.
e) Remove the 3 bolts, 2 nuts, air intake chamber assembly and gasket.
15. DISCONNECT INJECTOR CONNECTORS





16. REMOVE FUEL INLET PIPE
Remove the 2 union bolts, 4 gaskets and fuel inlet pipe.





17. REMOVE FUEL RETURN PIPE
a) Disconnect the fuel return hose from fuel pressure regulator.
b) Disconnect the fuel return hose from fuel return pipe
c) Remove the 2 bolts and fuel return pipe.
18. REMOVE DELIVERY PIPE AND INJECTORS





a) Remove the 2 bolts and delivery pipe together with the 4 injectors.

NOTICE: Be careful not to drop the injectors when removing the delivery pipe.





b) Remove the 4 insulators from the 4 spacers.
c) Pull out the 4 injectors from the delivery pipe.
d) Remove the O-ring and grommet from each injector.
e) Using a screwdriver, pry out the 4 spacers.





19. REMOVE INTAKE MANIFOLD
Remove the 3 bolts, 2 nuts, intake manifold and gasket.
20. Except California Spec.:
REMOVE NO.1 EXHAUST PIPE (WITH TWC)
21. California Spec.:
REMOVE FRONT EXHAUST PIPE





22. REMOVE EXHAUST MANIFOLD
a) Except California spec. for 2RZ-FE:
Remove the 2 bolts, 2 nuts and heat insulator.
b) Remove the 6 nuts, exhaust manifold and gasket.





23. REMOVE WATER OUTLET
a) Disconnect the upper radiator hose.
b) Remove the 2 bolts, water outlet and gasket.





24. REMOVE CYLINDER HEAD REAR COVER
Remove the 3 bolts, cylinder head rear cover and gasket.





25. California Spec.:
REMOVE IGNITION COILS (WITH IGNITER)
a) Disconnect the 4 ignition coil connectors.
b) Remove the 4 bolts, and pull out the 4 ignition coils.
26. REMOVE SPARK PLUGS
27. REMOVE FRONT ENGINE HANGER





28. REMOVE ENGINE WIRE BRACKETS
Remove the 4 bolts, 4 wire brackets and ground strap.





29. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, 10 seal washers, cylinder head cover and gasket.
30. SET NO.1 CYLINDER TO TDC/COMPRESSION





a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover.





b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.





31. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
32. REMOVE SEMICIRCULAR PLUGS
33. REMOVE CAMSHAFT TIMING GEAR





a) Place the match marks on the camshaft timing gear and No.1 timing chain.





b) Hold the intake camshaft with a wrench and remove the bolt.
c) Remove the camshaft timing gear and chain from the in take camshaft and leave on the slipper and damper.
34. REMOVE CAMSHAFTS

NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, these steps should be carried out.

a) Remove the exhaust camshafts.





1) Bring the service bolt hole of the driven sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
2) Secure the exhaust camshaft sub-gear to the main gear with a service bolt.





Recommended service bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.





3) Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the sequence shown.





4) Remove the 5 bearing caps and camshaft.

HINT: If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the 2 bolts. Then alternately loosen and remove the bearing cap bolts with the camshaft gear pulled up.

NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.

b) Remove intake camshaft.





1) Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the sequence shown.





2) Remove the 5 bearing caps and camshaft.

HINT: If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the 2 bolts. Then alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.

35. DISASSEMBLE EXHAUST CAMSHAFT





a) Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





b) Using SST, turn the sub-gear clockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)





c) Using snap ring pliers, remove the snap ring.
d) Remove these parts the wave washer, the camshaft subgear and the camshaft gear spring.
36. REMOVE CYLINDER HEAD





a) Remove the 2 bolts in front of the head before the other head bolts are removed.





b) Uniformly loosen and remove the 10 cylinder head bolts in several passes, in the sequence shown.

NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order.





c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.