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remo

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EM-62
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD
EM1XP-01

REMOVAL
1. PREVENT GASOLINE FROM SPILLING OUT
2. DRAIN ENGINE COOLANT (See page CO-2)
3. DRAIN ENGINE OIL (See page LU-3)

4. REMOVE V-BANK COVER
Remove the 2 nuts and V-bank cover.

A23208

5. REMOVE AIR CLEANER
(a) Disconnect the ventilation hose No.2.

A23095

(b) Disconnect the vacuum hose.
(c) Disconnect the mass air flow meter connector.
(d) Remove the 2 wire harness clamps.

A23209

(e) Loosen the 2 hose clamps.
(f) Remove the 2 bolts and air cleaner
6. DISCONNECT FUEL PIPE (See page SF-1)
7. REMOVE FAN SHROUD
8. REMOVE RADIATOR (See page CO-17)

A23210
EM-63
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

9. LOOSEN FAN W/FLUID COUPLING
Loosen the 4 nuts of the fan w/ fluid coupling.

A23114

10. REMOVE DRIVE BELT
Release the belt tension by turning the belt tensioner counter-
clockwise. Remove the V-ribbed belt from the belt tensioner.
11. REMOVE FAN W/FLUID COUPLING
12. SEPARATE VANE PUMP (See page SR-47)
13. REMOVE GENERATOR (See page CH-7)
14. SEPARATE COOLER COMPRESSOR
(See page AC-54)
A22797 15. DISCONNECT HEATER WATER OUTLET AND INLET
HOSE

16. REMOVE INTAKE AIR SURGE TANK
(a) Disconnect the 2 water by-pass hoses.

A23085

(b) Disconnect the fuel vapor feed hose.

A23086
EM-64
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

A23087

(d) Disconnect the 2 VSV connectors.
(e) Disconnect the throttle body w/ motor connector.
(f) Separate the 3 wire harness clamps and hose clamp.

A23088

(g) Remove the 2 bolts and throttle body bracket.

A23089

(h) Remove the bolt and oil baffle plate.
(i) Remove the 4 bolts and 2 surge tank stays.

A23090
EM-65
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

(j) Remove the 2 nuts.
(k) Using a socket hexagon wrench 8, remove the 4 bolts, in-
take air surge tank and gasket.
17. REMOVE IGNITER (See page IG-6)

A23091

18. REMOVE CYLINDER HEAD COVER
(a) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder
head cover RH and gasket.
(b) Remove the 2 nuts, oil filter cap housing and gasket.

A22970

(c) Remove the 10 bolts, 3 seal washers, 2 nuts, cylinder
head cover LH and gasket.
19. REMOVE INTAKE MANIFOLD
(a) Disconnect the 6 fuel injector connectors.

A23092

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

A22882

(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.
21. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE

A22883
EM-66
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

22. REMOVE OIL CONTROL VALVE FILTER
RH Bank LH Bank
Remove the plug, filter and gasket from each cylinder head.
23. REMOVE VVT SENSOR
24. REMOVE RH AND LH FRONT EXHAUST PIPE
25. REMOVE RH AND LH EXHAUST MANIFOLD
(a) Remove the 6 bolts and 2 exhaust manifold stays.
(b) Remove the 12 nuts, RH and LH exhaust manifold and 2
gaskets.
A22969 26. REMOVE OIL PAN (See page EM-32)
27. REMOVE TIMING CHAIN COVER (See page EM-32)
28. REMOVE TIMING CHAIN (See page EM-32)
29. REMOVE CAMSHAFT
NOTICE:
As the thrust clearance of the camshaft is small, the cam-
shaft 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.

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

A22886

RH Bank (2) Using several steps, uniformly loosen and remove
the 16 bearing cap bolts in the sequence as shown
15 11
3 7 in the illustration.
(3) Remove the 8 bearing caps and 2 camshafts.
4 8 16 12
2 6 14
10

1 5 13 9
A22887

LH Bank (b) Remove the camshafts of the LH bank.
(1) Using several steps, uniformly loosen and remove
11 the 16 bearing cap bolts in the sequence as shown
15 7 3
in the illustration.
12 (2) Remove the 8 bearing caps and 2 camshafts.
16 8 4
10 14 6 2 30. REMOVE CAMSHAFT BEARING NO.1 AND NO.2

9 13 5 1
A22910
EM-67
ENGINE MECHANICAL (1GR-FE) - CYLINDER HEAD

LH Cylinder Head 31. REMOVE CYLINDER HEAD
(a) Using several steps, remove the 2 cylinder head bolts on
2 the LH cylinder head in the sequence as shown in the il-
lustration.

A22911

RH Cylinder Head (b) Using several steps, loosen the 8 cylinder head bolts on
3 5 7 2 each cylinder head with a 10 mm bi-hexagon wrench in
the sequence as shown in the illustration. Remove the 16
cylinder head bolts and plate washers.
NOTICE:
S Be careful not to drop the plate washers into the cylin-
der head.
1 8 6 4 S Cylinder head warpage or cracking could result from
removing the bolts in the incorrect order.

LH Cylinder Head

1 8 6 4

3 5 7 2
A22977

(c) Lift the cylinder head from the dowels on the cylinder
block, and place the 2 cylinder heads on wooden blocks
on a bench.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.
HINT:
If the cylinder head is difficult to lift off, pry between the cylinder
A22978 head and cylinder block with a screwdriver.
(d) Remove the RH and LH cylinder head gaskets.
32. REMOVE CYLINDER HEAD GASKET

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