Engines 4A-F/FE
- Unscrew the water pump pulley nuts, loosen the V-belt adjusting bolt and remove the V-belt (Pic. 5). Unscrew the water pump pulley.
- Remove four spark plugs. To do this you need a long spark plug wrench.
- Disconnect the crankcase ventilation hose from the vent valve.
- Unscrew the three cylinder head cover nuts and remove the cover with the nut sealing washers and gasket.
- Rotate the crankshaft pulley until the mark aligns with the mark "0" on the timing belt cover. Check if there is any play in the valve tappets of the first cylinder. If there is no play, turn the engine one more revolution. In Fig. Figure 7 shows how the crankshaft pulley must be installed to keep the engine at TDC.
- Unscrew the coolant drain pipe (2 bolts).
- Unscrew the 2 bolts and remove the exhaust manifold support.
- Remove the 4 bolts and upper exhaust manifold heat shield.
- Unscrew the 3 bolts and 2 nuts of the exhaust manifold and remove the exhaust manifold with gaskets. Remove the 3 bolts and lower exhaust manifold heat shield.
- Remove the ignition distributor along with the ignition wires.
- Remove the cooling system inlet housing. To do this, disconnect 2 water hoses, unscrew 2 nuts and a bolt (Pic. 37) and remove the housing.
Pic. 37. Removing the cooling system inlet housing (for engine 4A-F/FE)
- On carburetor engines (4A-F) remove the fuel pump (Pic. 38).
Pic. 38. Removing the fuel pump (on engine 4E-F)
- Disconnect the crankcase ventilation hose, disconnect the water hose from the intake manifold and remove the 2 intake manifold support bolts.
- Unscrew 6 bolts and 2 nuts, remove the cable bracket and remove the intake manifold with gasket.
- Unscrew the upper and lower toothed belt covers and remove the gaskets. A total of 3 bolts should be removed on each side.
- When installing the old timing belt, mark it with an arrow for the direction of movement and location marks relative to the camshaft gear and crankshaft pulley, as can be seen in Fig. 10, but in this case the mark is applied only on the camshaft gear.
- Loosen the toothed belt tensioner bolt at the front, push the tensioner all the way to the left, as shown in Fig. 11, and tighten in this position. The timing belt is now free and can be removed. At the same time, remove the belt under tension so that it cannot jump off the crankshaft gear. Do not allow foreign objects to get into the gas distribution mechanism and do not stain the belt.
- Loosen the camshaft gear bolt. The shaft should be held as shown in Fig. 12 so that it does not turn.
- Measure the axial play of both camshafts. To do this, install a dial indicator at the end of the camshaft, as shown in Fig. 14, and use two screwdrivers to move the camshaft in both directions. Take readings from the dial indicator. The intake camshaft play should be in the range from 0.030 to 0.085 mm; The exhaust camshaft play should be in the range from 0.035 to 0.090 mm.
- Remove both camshafts in accordance with the instructions in Chapter 2.2.
- Using a Torx wrench, loosen the cylinder head bolts in the sequence shown in Fig. 19. Loosening the bolts in a different sequence may cause the cylinder head to become misaligned. Raise the cylinder head. If the head is firmly seated, insert a screwdriver in the direction indicated in Fig. 20 place between the protrusion of the motor block and the head, without damaging the surface. The head sits on pins.
Engine 3S-FE
- Disconnect the battery and drain the coolant.
- Release the generator mounting bracket, tilt the generator and remove the drive belt. Remove the generator.
- Unscrew the engine lifting brackets and remove the generator upper mount.
- If there is a catalyst, remove the exhaust manifold and the catalyst or exhaust manifold. Remove all heat shields to allow access to bolts and nuts.
- After removing the spark plug tips, remove the spark plugs using a long spark plug wrench.
- Unscrew the 4 cylinder head cover nuts and remove the cover with sealing washers and cover gasket.
- Remove the throttle body of the fuel injection device, disconnect the air hose and air pipe.
- Unscrew the intake manifold support, disconnect the vacuum hose and unscrew the manifold. Remove the manifold with gasket.
- Rotate the crankshaft until the mark on the crankshaft belt pulley coincides with the mark "0" on the scale on the front of the engine (see fig. 7). Check that the valves of the first cylinder have clearances. If they shift, turn the crankshaft one more revolution. To avoid errors, observe the camshaft gear. There is a hole on the wheel that should align with the mark on the camshaft bearing cap, as shown in Fig. 26.
- Remove the cooling system drain housing (2 bolts).
- Remove the ignition distributor with ignition wires.
- Unscrew the cooling system bleeder pipe. First disconnect the water hoses. After this, unscrew the 2 bolts and 2 nuts, remove the tube and gasket, as well as the O-ring.
Pic. 39a. Removing the cooling system outlet pipe
Pic. 39b. Removing the top timing belt cover on a 3S-FE engine
- If equipped, remove the exhaust gas return valve and control valve. They are located in the location shown in Fig. 31. To remove, disconnect the vacuum hoses, unscrew the union nut and unscrew the two bolts. Remove the control valve with gasket. The exhaust gas return valve is secured with one bolt.
- Remove the injection pipes and injectors.
- Unscrew the 5 bolts and remove the top timing belt cover. Remove the gasket.
- When installing the old belt, mark the direction of movement of the belt with an arrow and a mark on the belt relative to the camshaft wheel, as shown in Fig. 27.
- Loosen the timing belt tensioner bolt, press the tensioner all the way to the left, as shown in Fig. 11, and tighten in this position. The timing belt is now free and can be removed. At the same time, ensure the tension of the belt so that it cannot jump off the crankshaft gear.
- Remove the camshaft wheel bolt. Since the shaft rotates, it must be held. Typically, a device is used for this, which is shown in Fig. 30, which is inserted into two holes in the wheel, but you can also insert a long rod into one of the holes, turn the wheel until the rod rests on the cylinder head and then unscrew the bolt. Remove the washer and gear.
- Remove the 4 bolts and cover from the front of the cylinder head. The cover is shown in Fig. 40.
Pic. 40. Before removing the camshaft, remove the cover from the front side of the cylinder head
- Before removing the camshafts, their axial play should be measured. These works have already been described above. After this, remove the camshafts.
- Using a Torx wrench, loosen the cylinder head bolts in the sequence shown in Fig. 19. Loosening the bolts in a different sequence may cause the cylinder heads to become misaligned. Raise the cylinder head. If the head is stuck, insert a screwdriver as shown in Fig. 20, between the protrusion on the motor block and the head, without damaging the surface. The head sits on pins.