Removal

2TR-FE ENGINE MECHANICAL: CYLINDER HEAD:

REMOVAL

1. REMOVE HOOD SUB-ASSEMBLY
2. DISCHARGE FUEL SYSTEM PRESSURE (Technician Safety Information)
3. REMOVE NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type)
(a) Remove the 4 bolts, then remove the No. 1 engine under cover.
4. REMOVE NO. 2 ENGINE UNDER COVER SUB-ASSEMBLY (for Pre Runner and 4WD Type, Regular Cab)
(a) Remove the 4 bolts, then remove the No. 2 engine under cover.
5. DRAIN ENGINE OIL (Removal)

6. DRAIN ENGINE COOLANT (Service and Repair)

7. REMOVE BATTERY
8. REMOVE BATTERY TRAY
9. REMOVE RADIATOR SUPPORT TO FRAME SEAL LH (Removal)

10. REMOVE FAN SHROUD (Removal)

11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (Removal)

12. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
13. REMOVE AIR CLEANER CASE
(a) Remove the 3 bolts, then remove the air cleaner case.
14. SEPARATE VANE PUMP ASSEMBLY (Removal)

15. REMOVE NO. 2 RADIATOR HOSE
16. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning) (Removal)

17. REMOVE RADIATOR HOSE INLET
18. SEPARATE WATER HOSE SUB-ASSEMBLY (Removal)

19. DISCONNECT FUEL HOSE (Removal)

20. DISCONNECT NO. 2 FUEL HOSE (Removal)

21. SEPARATE FUEL VAPOR FEED HOSE ASSEMBLY (Removal)

22. DISCONNECT NO. 1 AIR INJECTION HOSE (Removal)

23. DISCONNECT ENGINE WIRE (Removal)

24. REMOVE EXHAUST PIPE ASSEMBLY TAIL (Removal)

25. REMOVE EXHAUST PIPE ASSEMBLY FRONT (Removal)

26. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY





27. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (Service and Repair)

28. REMOVE ENGINE ASSEMBLY (Installation)

29. REMOVE CLUTCH COVER ASSEMBLY (for Manual Transmission)





30. REMOVE CLUTCH DISC ASSEMBLY (for Manual Transmission)





31. REMOVE FLYWHEEL SUB-ASSEMBLY (for Automatic Transmission) (Removal)

32. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Manual Transmission) (Removal)

33. REMOVE REAR END PLATE
(a) Remove the 2 bolts, then remove the rear end plate.
34. REMOVE INTAKE AIR CONNECTOR (Removal)

35. REMOVE GENERATOR ASSEMBLY (Service and Repair)

36. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (Removal)

37. REMOVE INTAKE PIPE INSULATOR (Removal)

38. REMOVE AIR SWITCHING VALVE ASSEMBLY (Removal)





39. REMOVE EXHAUST MANIFOLD
(a) Remove the 8 nuts, then remove the exhaust manifold.
40. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (Removal)

41. REMOVE NO. 1 IDLER PULLEY SUB-ASSEMBLY (Removal)

42. REMOVE IDLE PULLEY ASSEMBLY WITH BRACKET (w/ Air Conditioning System) (Removal)

43. REMOVE CRANKSHAFT POSITION SENSOR (Removal)

44. REMOVE CAMSHAFT POSITION SENSOR (Removal)

45. REMOVE NO. 1 INTAKE MANIFOLD HEAD GASKET (Removal)

46. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (Removal)

47. REMOVE CRANKSHAFT PULLEY (Removal)

48. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
49. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY (Removal)

50. REMOVE OIL STRAINER SUB-ASSEMBLY (Removal)

51. REMOVE OIL PAN SUB-ASSEMBLY (Removal)

52. REMOVE TIMING CHAIN COVER (Removal)

53. REMOVE TIMING CHAIN GUIDE (Removal)

54. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY (Removal)

55. REMOVE CHAIN TENSIONER SLIPPER (Removal)

56. REMOVE NO. 1 CHAIN VIBRATION DAMPER (Removal)

57. REMOVE CHAIN SUB-ASSEMBLY
58. REMOVE CAMSHAFT (Removal)





59. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
(a) Remove the 16 valve rocker arms.





60. REMOVE VALVE LASH ADJUSTER ASSEMBLY
(a) Remove the valve lash adjuster.
61. REMOVE CYLINDER HEAD SUB-ASSEMBLY





(a) Disconnect the water hose shown in the illustration.
(b) Disconnect the engine coolant temperature sensor connector.
(c) Remove the bolts, then separate the wire harnesses.
(d) Remove the bolt, then separate the wire harness bracket.





(e) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

- Be careful not to drop the washers into the cylinder head.
- Head warpage or cracking could result from removing the bolts in the wrong order.

62. REMOVE CYLINDER HEAD GASKET