Removal

1GR-FE ENGINE MECHANICAL: CYLINDER HEAD: REMOVAL

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE Removal
2. DRAIN ENGINE COOLANT Service and Repair
3. DRAIN ENGINE OIL Removal
4. REMOVE CHAIN SUB-ASSEMBLY

HINT: Removal

5. REMOVE NO. 1 COOL AIR INLET
(a) Remove the 2 bolts and cool air inlet with air cleaner hose.
6. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
(a) Remove the ATF level gauge.
(b) Remove the bolt and pull out the oil filler tube.
(c) Remove the O-ring from the oil filler tube.
7. REMOVE EXHAUST PIPE ASSEMBLY FRONT

HINT: Removal

8. REMOVE MANIFOLD STAY
(a) Remove the 3 bolts and manifold stay.
9. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
(a) Disconnect the A/F sensor connector.
(b) Remove the 6 nuts, exhaust manifold and gasket.
10. REMOVE NO. 2 EXHAUST FRONT PIPE ASSEMBLY Removal
11. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the 3 bolts and No. 2 manifold stay.
12. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
(a) Disconnect the A/F sensor connector.
(b) Remove the 6 nuts, exhaust manifold and gasket.
13. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY Removal
14. DISCONNECT NO. 2 FUEL PIPE SUB-ASSEMBLY Removal
15. REMOVE INTAKE MANIFOLD
(a) Disconnect the 6 fuel injector connectors.

(b) Remove the 10 bolts, intake manifold and 2 gaskets.
16. REMOVE WATER BY-PASS JOINT RR
(a) Disconnect the engine coolant temperature sensor connector.
(b) Disconnect the heater hose.

(c) Remove the 2 bolts, 4 nuts, water by-pass joint RR and 2 gaskets.
(d) Remove the O-ring from the water outlet pipe.
17. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

(a) While raising the No. 2 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

(b) Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and No. 2 timing chain.

NOTICE:
- Be careful not to damage the cylinder head and valve lifter with the wrench.
- Do not disassemble the camshaft timing gear assembly.

18. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

(a) Remove the bolt and No. 2 chain tensioner.
19. REMOVE CAMSHAFTS (for Bank 1)

NOTE: As 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 which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Rotate the camshafts counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration.

(b) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
(c) Remove the 8 bearing caps and 2 camshafts.
20. REMOVE NO. 2 CAMSHAFT BEARING
21. REMOVE NO. 1 CHAIN VIBRATION DAMPER
(a) Remove the 2 bolts and No. 1 chain vibration damper.
22. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

(a) While pushing down the No. 3 chain tensioner, insert a pin of dia1.0 mm (0.039 in.) into the hole to fix it.

(a) Remove the bolt and No. 3 chain tensioner.
24. REMOVE CAMSHAFTS (for Bank 2)

NOTE: As 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 which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

(a) Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
(b) Remove the 8 bearing caps and 2 camshafts.
25. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Remove the 2 bolts and separate the 2 ground cables.

(b) Using several steps, loosen the 8 cylinder head bolts on the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- 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.

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

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

26. REMOVE CYLINDER HEAD GASKET
27. REMOVE CYLINDER HEAD LH
(a) Remove the bolt and separate the ground cable.

(b) Using several steps, remove the 2 cylinder head bolts on the cylinder head in the sequence as shown in the illustration.

(c) Using several steps, loosen the 8 cylinder head bolts on the cylinder head uniformly with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- Cylinder head warpage or cracking could result from removing bolts in incorrect order.

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

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

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

28. REMOVE NO. 2 CYLINDER HEAD GASKET