Removal and installation the cylinder head: 1 - valve of the variable geometry intake manifold system; 2 - gasket; 3 - intake manifold; 4 - right rear hook for lifting the engine; 5 - fuel manifold and injectors assembly; 6 - variable geometry intake manifold system unit; 7 - insulator; 8 - cylinder head cover; 9 - camshaft bearing cap; 10 - camshaft oil seal; 11 - cylinder head; 12 - intake manifold bracket; 13 - cylinder head gasket; 14 - air tube; 15 - gasket; 16 - heat-insulating sleeve; 17 - sealing washer; 18 - gasket; 19 - gasket; 20 - intake camshaft; 21 - exhaust camshaft; 22 - oil pressure sensor; 23 - O-ring seal; 24 - gasket; 25 - Generator bracket No.1; 26 - Generator bracket #2; 27 - exhaust manifold bracket; 28 - intake chamber; 29 - throttle body; 30 - Bracket No.1 of the intake chamber; 31 - Bracket No.2 of the intake chamber; 32 - gasket; 33 - cold start injector; 34 - gasket; 35 - pusher; 36 - adjusting washer; 37 - crackers; 38 - valve spring plate; 39 - valve spring; 40 - retaining ring; 41 - valve guide; 42 - valve; 43 - O-ring seal; 44 - left hook for lifting the engine; 45 - Coolant bypass pipe; 46 - gasket; 47 - Right front hook for lifting the engine; 48 - distributor; 49 - Coolant outlet pipe; 50 - gasket; 51 - Exhaust manifold heat shield; 52 - exhaust manifold; 53 - exhaust manifold bracket; 54 - spring seat.
Removal the cylinder head
1. Disconnect the negative terminal from the battery.
2. Drain the coolant from the cylinder block and radiator.
3. Remove the generator.
- a) Loosen the tension roller bolt and adjusting bolt and remove the drive belt.
- b) Disconnect the generator connector.
- c) Unscrew the two bolts, disconnect the engine wiring harness from the brackets.
- d) Remove two bolts and generator bracket No.2.
- d) Unscrew the nut and disconnect the generator wire.
- e) Unscrew the two bolts and the generator.
4. Remove the right front engine lifting hook and generator bracket No.1 by unscrewing the three bolts.
5. Remove the exhaust manifold.
- a) Disconnect the exhaust pipe.
- b) Unscrew the five bolts and remove the exhaust manifold heat shield.
- c) Unscrew the three bolts, nut and remove the right manifold bracket.
- d) Unscrew the two bolts and remove the left manifold bracket.
- d) Unscrew the six nuts, remove the exhaust manifold and two gaskets.
6. Remove the coolant outlet pipe.
- a) Disconnect the following connectors:
- coolant temperature gauge sensor connector,
- coolant temperature sensor.
- cold start injector timer connector.
- b) Disconnect the following hoses:
- (1) Upper radiator hose,
- (2) coolant bypass hose from the bypass tube,
- (3) Idle Air Control Valve Coolant Bypass Hose,
- (4) heater hose.
- c) Unscrew the two bolts, remove the coolant outlet pipe and gasket.
7. Remove the oil pressure sensor.
8. Remove the coolant bypass tube.
- a) Disconnect the following hoses:
- (1) Idle Air Control Valve Coolant Bypass Hose,
- (2) coolant bypass hose from the cylinder block,
- (3) two coolant bypass hoses from the oil cooler,
- (4) heater hose.
- b) Unscrew the two bolts and two nuts, remove the coolant bypass pipe, gasket and O-ring.
9. Remove the throttle body.
10. Remove the air tube.
- a) Disconnect the following hoses:
Note: Mark all hoses with paint before removal for proper installation.
- (1) vacuum hose from fuel pressure regulator,
- (2) two vacuum hoses of the power steering pump,
- (3) two vacuum hoses from the intake chamber,
- (4) vacuum hose from vacuum tube (from the fuel pressure regulator solenoid valve).
- b) unscrew the two bolts and remove the air tube.
11. Remove the intake manifold bracket by unscrewing the two bolts.
12. Remove the intake manifold geometry control system assembly.
- a) Disconnect the following connectors:
- fuel pressure regulator solenoid valve connector;
- solenoid valve connector.
- b) Disconnect the following hoses:
- (1) vacuum hose (from the fuel pressure regulator solenoid valve) from the intake manifold,
- (2) vacuum hose (from the solenoid valve) from the drive,
- (3) vacuum hose (from the vacuum tank) from the intake manifold,
- c) Unscrew the three bolts and remove the intake manifold geometry change system unit.
13. Remove the cold start injector.
14. Remove the intake chamber.
- a) Unscrew the four bolts and remove bracket No.2.
- b) Unscrew six bolts and two nuts, remove the intake chamber and gasket.
[See the source on the internet resource www.TOYOTAMAN.ru]
- c) Unscrew the two bolts and remove bracket No.1.
15. Remove the distributor.
16. Remove the left engine lifting hook by unscrewing the two bolts.
17. Remove the VGA valve by unscrewing the two bolts and two nuts and remove the gasket.
18. Remove the intake manifold.
- a) Loosen the bolt and disconnect the ground wire.
- b) Disconnect the knock sensor connector.
- c) Unscrew four bolts, three nuts, remove the intake manifold and gasket.
19. Remove the right rear engine lifting hook by unscrewing the bolt.
20 Disconnect the engine wiring harness from the cylinder head cover.
- a) Disconnect the four injector connectors.
- b) Remove the two bolts and disconnect the engine wiring harness from the cylinder head cover.
21. Remove the fuel manifold and injectors.
Note: Do not lose the heat-insulating bushings and insulators.
22. Remove the cylinder head cover. Remove the ten screws, washers, cylinder head cover and two gaskets.
23. Remove the camshaft toothed pulleys. (See section "Timing belt (3S-GE engine) points 6-9").
24. Remove the tension roller. (see point 14).
25. Remove the timing belt cover by unscrewing the five bolts.
Note:
- Support the timing belt so that the engagement of the crankshaft sprocket and the timing belt does not change.
- Be careful not to drop foreign objects inside the timing belt cover
- Do not allow oil, water or dust to come into contact with the timing belt.
26. Loosen and remove the ten bearing cap bolts evenly in several passes. Remove the camshaft bearing caps, seals, and then the camshafts themselves.
Note: Pre-measure valve clearances to facilitate adjustment after assembly.
27. Remove the cylinder head.
- a) Uniformly loosen and remove the ten 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 its cracking.
- 6) Remove the cylinder head from the guide pins on the cylinder block and place it on a workbench with 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.
Checking the variable intake manifold geometry system
1. Check the intake manifold geometry control valve.
- a) Using a precision ruler and a flat feeler gauge, check the intake manifold surface for flatness.
- Maximum flatness - 0.20 mm
- b) Apply a pressure of 53.3 kPa to the valve and check that the valve moves slowly to the closed position.
- c) Check that the valve opens quickly under vacuum.
2. Check the vacuum tank.
- a) Check that air when supplied to port "A" comes out in one direction from port "B" and does not come out of port "A" when air is supplied to port "B".
- b) Apply a vacuum of 66.7 kPa to port "A" and check that there is no change in pressure after one minute.