Note: The cylinder head removal procedures are given using the 3S-FE engine as an example. For the 4S-FE engine, the attachment removal procedure may be slightly different.
1. Disconnect the negative terminal from the battery.
2. Drain the coolant from the cylinder block and radiator.
3. Disconnect the cables and remove the throttle cable mounting bracket by unscrewing the two bolts.
Note: Before disconnecting the automatic transmission control cable (throttle valve control), mark with a marker (or measure with a caliper) its regulation (position of nuts).
4. Remove the generator.
a) Disconnect the wire harness clamp from the clamp on the generator.
b) Disconnect the generator connector.
c) Remove the rubber cap and unscrew the wire fastening nut, and disconnect the generator wire.
d) Loosen the lock bolt (models with air conditioning), adjusting bolt and hinge bolt.
d) Remove the generator drive belt.
e) Remove the adjustment lock bolt (models with air conditioning) or adjusting bolt (models without air conditioning) and the hinge bolt.
g) Remove the generator.
5. Remove the distributor.
a) Disconnect the two distributor connectors.
b) Disconnect the high-voltage wires by the rubber caps. Do not pull the wires.
Note: Pulling or bending wires may cause internal damage.
c) Unscrew the two bolts and remove the distributor.
5. Remove the exhaust manifold.
a) Remove the five bolts and the upper heat shield.
b) Unscrew the bolts, nuts and remove the exhaust manifold bracket and intake pipe.
c) Unscrew the six nuts, remove the exhaust manifold and gasket.
d) Unscrew the three bolts and remove the lower heat shield.
Removing and installing the cylinder head.
1 - engine wiring harness,
2 - insulator,
3 - nozzle,
4 - seal,
5 - O-ring seal,
6 - heat-insulating sleeve,
7 - fuel manifold,
8 - gasket,
9 - EGR electro-pneumatic valve (models with EGR system),
10 - vacuum tube,
11 - fuel supply hose,
12 - intake chamber assembly with manifold,
13 - EGR valve and vacuum modulator (models with EGR system),
14 - throttle cable bracket,
15 - throttle body,
16 - bracket No.2 of the intake manifold,
17 - left engine lifting hook,
18 - bracket No.1 of the intake manifold,
19 - fuel pressure pulsation damper,
20 - distributor,
21 - spark plug,
22 - coolant outlet pipe,
23 - coolant bypass pipe,
24 - upper heat shield,
25 - exhaust manifold,
26 - lower protective cover,
27 - exhaust manifold bracket.
6. Remove the coolant outlet pipe.
a) Disconnect the following connectors:
- (1) Coolant temperature gauge sensor connector.
- (2) Coolant temperature sensor connector.
- (3) Oil pressure sensor connector.
b) Disconnect the following hoses.
Note: Mark all hoses with paint before removal to ensure proper installation.
- (1) Upper radiator hose;
- (2) Coolant bypass hose;
- (3) Heater hose;
- (4) Coolant supply hose to idle speed control valve;
- (5) Two fuel vapor recovery system hoses (if installed).
c) Unscrew the two nuts, remove the coolant outlet pipe and gasket.
7. Remove the coolant bypass tube.
a) Disconnect the following hoses:
- (1) Idle Air Control Valve Coolant Bypass Hose from Coolant Bypass Tube.
- (2) Heater hose from coolant bypass pipe.
- (3) (Models with oil cooler) Two coolant bypass hoses from the oil cooler.
b) Unscrew two bolts and two nuts.
c) Disconnect the coolant bypass pipe from the coolant pump cover and remove it.
d) Remove the gasket and O-ring.
8. Remove the throttle body.
a) Disconnect the following connectors:
- (1) Throttle position sensor connector.
- (2) Idle speed control valve connector.
b) Disconnect the following hoses:
- (1) Crankcase ventilation hose from throttle body.
- (2) (Models with exhaust gas recirculation system) Two vacuum hoses from the throttle body.
- (3) (Models with fuel vapor recovery system) Vacuum hose from the throttle body.
- (4) Vacuum hose from the tube.
c) Unscrew four bolts or two bolts and two nuts.
d) Remove the throttle body and gasket.
9. Remove the left engine lifting hook and intake manifold bracket No.2 by unscrewing the bolt and nut.
10. (Models with EGR system) Remove the EGR valve and vacuum modulator.
a) Disconnect the following hoses:
Note: Mark all hoses with paint before removal to ensure proper installation.
- (1) Vacuum hose from channel "E" of the EGR solenoid valve.
- (2) Vacuum hose from channel "G" of the EGR solenoid valve.
b) Loosen the union nut of the EGR pipe OR, unscrew the two nuts, and remove the EGR valve, vacuum modulator, vacuum hoses and gasket.
11. Remove intake manifold bracket No.1 by unscrewing two bolts.
12. Disconnect the following connectors and cable:
- (1) Knock sensor connector;
- (2) (Models with EGR system) exhaust gas recirculation electropneumatic valve connector;
- (3) ground wire.
13. Remove the vacuum tube.
Note: Mark all hoses and tubes with paint before removal to ensure proper installation.
a) Disconnect the following hoses:
- (1) Vacuum hose from fuel pressure regulator.
- (2) vacuum hoses (from the gas filter).
- (3) Air hose of the air bypass control valve of the power steering pump (from the intake manifold).
- (4) Air hose of the idle speed increase valve when the air conditioner is turned on (from a vacuum tube).
(5) two vacuum hoses of the air bypass control valve of the power steering pump (from the air tube).
b) Unscrew the two bolts and remove the vacuum tube.
14. Disconnect the fuel supply hose from the fuel manifold, after releasing the pressure from the fuel tank.
a) Disconnect the engine wiring harness clamp from the bracket.
b) Using the special tool, loosen the fuel pressure pulsation damper.
c) Remove the fuel pressure pulsation damper and two gaskets and disconnect the fuel supply hose from the fuel rail.
15. Disconnect the fuel return hose from the fuel return line.
16. (Models with EGR system) Remove the EGR valve by unscrewing the bolt.
17. Remove the intake manifold.
a) Disconnect the following hoses, after marking them:
- (1) Crankcase ventilation hose (from the intake manifold),
- (2) Vacuum hose of the idle speed increase valve when the air conditioner is turned on (from the intake manifold),
- (3) Manifold Absolute Pressure Sensor Vacuum Hose from Gas Filter,
- (4) brake booster vacuum hose (from the intake manifold).
b) Disconnect the two engine wiring harness protection clamps from the upper timing belt cover mounting bolts in the sequence shown in the figure.
c) Disconnect the two engine wiring harness clamps from the intake manifold mounting bracket.
d) Unscrew six bolts, two nuts, and remove the intake manifold and gasket.
18. Remove the fuel manifold and injectors.
a) Disconnect the injector connectors.
b) Unscrew the two bolts and remove the fuel manifold together with the injectors.
Note: Be careful not to drop the injectors when removing the fuel rail.
c) Remove the insulators and spacers from the cylinder head.
d) Remove the injectors from the fuel manifold.
d) Remove the O-ring and sealing sleeve from each injector if you will be replacing them with new ones during installation.
19. Remove the timing belt from the camshaft toothed pulley.
a) Remove the upper timing belt cover by unscrewing 5 bolts and remove two gaskets.
b) Loosen the tension roller mounting bolt and push the roller to the left, being careful not to damage the belt surface, and tighten the bolt.
c) Remove the timing belt from the pulley.
d) Cover the hole with a rag (under the bottom cover), so that nothing gets in there.
20. Remove the camshaft toothed pulley using a special tool and unscrewing the bolt.
21. Remove the tension roller and spring by unscrewing the bolt.
22. Remove the rear timing belt cover by unscrewing the four bolts.
Note:
Hold the timing belt so that the crankshaft sprocket and belt do not move.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into contact with oil, water or dust.
23. Remove the generator bracket and the right engine lifting hook by unscrewing the three bolts.
24. Remove the oil pressure sensor.
25. Unscrew the four nuts, remove the spark plug tube seal, cylinder head cover and gasket.
Note: Arrange the spark plug tube seals in the order they were removed for proper installation to minimize the possibility of oil leakage.
26. Remove the high-voltage wire clamps, the crankcase ventilation valve and the hose from the cylinder head cover.
a) Loosen the bolt and remove the high-voltage wire clamps (1).
b) Remove the crankcase ventilation valve (2), hose (3) and seal (4).
c) Remove the crankcase ventilation hose (3).
27. Remove the intake and exhaust camshafts.
Note: Since the axial clearance of the camshaft is very small, to prevent jamming and/or damage to the shaft during its removal, it is necessary to hold the shaft in a horizontal position, to do this, it is necessary to follow the removal procedure described below.
a) Use a wrench to turn the camshaft 2-3 turns, first turn the crankshaft so that the pistons are in the middle position. Apply paint marks to the crankshaft pulley for subsequent installation.
b) Find the timing marks on the gears and mark them with a marker.
c) Install the camshafts in their original position and measure the thermal clearances in the valves so that they can be adjusted immediately during assembly,
A. Remove the exhaust camshaft.
a) Install the intake valve drive camshaft so that the opening for the process bolt of the intake valve camshaft gears is 10-45° before installation in TDC, as shown in the figure.
Note: In this position, the camshaft lobes of the exhaust valves of cylinders No.2 and No.4 act on the valve tappets.
b) Attach the exhaust camshaft auxiliary gear to the main gear with a process bolt.
Recommended process bolt: thread diameter 6 mm
- thread pitch - 1.0 mm
- bolt length - 16-20 mm
Note: When removing the camshaft, ensure that this operation neutralizes the torsional force of the auxiliary gear plate washer.
c) Unscrew the two bolts and remove the rear bearing cover.
d) Uniformly loosen and remove the 6 bearing cap bolts No.1, No.2 and No.4 in several passes, in the sequence shown in the figure.
Note: Do not remove bearing cap bolts #3 during this operation.
d) Remove bearing caps No.1, No.2 and No.4.
e) Loosen and remove the two bearing cap bolts No.3 one by one.
g) Remove bearing cap No.3 and the exhaust camshaft.
Note:
- If the camshaft does not lift straight and level, retighten the bearing cap mounting bolts #3 and perform the operations for installing the bearing caps and the dowel pin. Then perform the operations for removing the exhaust camshaft again.
- Do not use a special tool to remove the camshaft.
B. Remove the intake camshaft.
a) Set the intake camshaft alignment pin to 80-115° before TDC.
Note: In this position, the camshaft lobes of the intake valves of cylinders No.1 and No.3 act on the valve tappets.
b) Unscrew the two bolts, remove the front bearing cover and seal.
c) Uniformly loosen and remove the 6 bearing cap bolts No.1, No.3 and No.4 in several passes, in the sequence shown in the figure.
Note: Do not remove bearing cap bolts #2 during this operation.
d) Remove bearing caps No.1, No.3 and No.4.
d) Loosen and remove the two bearing cap bolts No.2 one by one.
e) Remove bearing cap No.2 and camshaft.
Note:
- If the camshaft does not lift straight and level, retighten the bearing cap bolts #2 and perform the operations for installing the bearing caps and dowel pin. Then perform the operations for removing the exhaust camshaft again.
- Do not use a special tool to remove the camshaft.
30. If necessary, disassemble the exhaust camshaft.
a) Place the camshaft in a vice as shown in the figure Note: Do not damage the camshaft as it is fragile.
b) Insert the tool (A) into the tool hole of the auxiliary camshaft drive gear.
c) Using a screwdriver, turn the auxiliary gear clockwise and remove the technological bolt (B).
Note: Be careful not to damage the camshaft.
d) Remove the retaining ring using pliers.
d) Remove:
- (1) Spring washer;
- (2) Auxiliary camshaft drive gear;
- (3) Camshaft gear spring ring.
31. Remove the cylinder head.
a) Uniformly loosen and remove the 10 cylinder head bolts in several passes, in the sequence shown in the figure.
Note: Incorrect order of loosening the bolts may result in deformation of the cylinder head or the appearance of cracks.
b) Remove the cylinder head from the guide pins on the cylinder block and place it on a workbench, placing wooden blocks and a rag underneath.
Note: If the cylinder head is difficult to remove, you can use a powerful screwdriver by inserting it into the gas joint as shown in the figure. However, be careful not to damage the surfaces of the head and block, as well as the cylinder head gasket.
