Removal

REMOVAL
1. REMOVE UPPER FRONT FENDERAPRON SEALAND UPPER RADIATOR SUPPORT SEAL
2. DRAIN ENGINE COOLANT
3. REMOVE RH FRONT WHEEL
4. REMOVE RH ENGINE UNDER COVER
5. 2ZZ-GE: REMOVE AIR SWITCHING VALVE
6. REMOVE DRIVE BELT AND GENERATOR
7. DISCONNECT PS PUMP FROM ENGINE
(a) Disconnect the PS oil pressure switch connector.
(b) Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.

HINT: Put aside the pump and suspend it to the cowl with a string.





8. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Set the jack to the engine.

HINT: Place a wooden block between the jack and engine.





(b) 1ZZ-FE: Remove the 4 bolts, 2 nuts and RH engine mounting insulator.
(c) 2ZZ-GE: Remove the 5 bolts, 2 nuts and RH engine mounting insulator.





9. 1ZZ-FE: REMOVE CYLINDER HEAD COVER
(a) Remove the 2 nuts, 2 clips and No.2 cylinder head cover.
(b) Remove the 4 ignition coils.
(c) Disconnect the 2 PCV hoses from the cylinder head.
(d) Remove the 9 bolts, 2 seal washers, 2 nuts, cylinder head cover and gasket.

10. 2ZZ-GE: REMOVE CYLINDER HEAD COVER
(a) Remove the 4 bolts and No.2 cylinder head cover.
(b) Remove the ignition coils.
(c) Disconnect the 2 PCV hoses from the cylinder head cover.





(d) Remove the 2 nuts, bolt and disconnect the No.3 ventilation hose from the No.1 ventilation pipe.
(e) Remove the No.1 ventilation pipe and gasket.





(f) Remove the 9 bolts, wire harness protector, cylinder head cover and gasket.
(g) Remove the O-ring from the cylinder head cover.

11. SET NO.1 CYLINDER TO TDC/COMPRESSION





(a) Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.





(b) Check that the point marks of the camshaft timing sprockets are in straight line on the timing chain cover surface as shown in the illustration.

If not, turn the crankshaft 1 revolution (360°) and align the marks as above.





12. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)

(b) Remove the crankshaft pulley from the crankshaft.





13. DISCONNECT CRANKSHAFT POSITION SENSOR FROM TIMING CHAIN COVER
Remove the 2 bolts and crankshaft position sensor.

14. REMOVE DRIVE BELT TENSIONER
Remove the bolt, nut and drive belt tensioner.

15. REMOVE RH ENGINE MOUNTING BRACKET
(a) 1ZZ-FE: Remove the 3 bolts and mounting bracket.
(b) 2ZZ-GE: Remove the 4 bolts and mounting bracket.

16. 2ZZ-GE: REMOVE FRONT EXHAUST PIPE
17. 2ZZ-GE: REMOVE EXHAUST MANIFOLD STAY
18. 2ZZ-GE: REMOVE EXHAUST MANIFOLD





19. REMOVE CHAIN TENSIONER
Remove the 2 nuts and chain tensioner.

20. REMOVE WATER PUMP





21. 1ZZ-FE: REMOVE TIMING CHAIN COVER
(a) Remove the 11 bolts and nut.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover by prying the portions between the cylinder head and cylinder block with a screw- driver.

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





22. 2ZZ-GE: REMOVE TIMING CHAIN COVER
(a) Remove the 12 bolts.
(b) Using a torx wrench socket (E8), remove the stud bolt.
(c) Remove the timing chain cover and 2 gaskets.

23. REMOVE CRANK ANGLE SENSOR PLATE
24. REMOVE CHAIN TENSIONER SLIPPER
Remove the bolt and slipper.





25. REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET
If the crankshaft timing sprocket cannot be removed by hand, use 2 screwdrivers.

NOTICE: Position shop rags as shown to prevent damage.

26. REMOVE CHAIN VIBRATION DAMPER
Remove the 2 bolts and damper.





27. REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET
Hold the hexagonal head wrench portion of the camshaft with a wrench, and remove the bolt, valve timing controller assembly and timing sprocket.

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