Disassembling the cylinder head (5E-FE) 1 - air duct; 2 - intake manifold; 3 - gasket; 4 - throttle body; 5 - bracket of the upper part of the intake manifold; 6 - distributor assembly with high-voltage wires; 7 - vacuum hose; 8 - Engine lift bracket No.2; 9 - cylinder head cover; 10 - gasket; 11 - intake camshaft; 12 - bearing cover No.4 of the camshaft; 13 - bearing cover No.3 of the camshaft; 14 - adjusting washer; 15 - pusher; 16 - crackers; 17 - spring plate; 18 - valve spring; 19 - oil seal; 20 - support washer; 21 - valve; 22 - segment plug; 23 - thermostat housing; 24 - coolant bypass hose; 25 - exhaust manifold heat shield; 26 - exhaust manifold. 27 - timing belt cover No.3; 28—cylinder head gasket; 29 - Engine lift bracket N91; 30 - insulator; 31 - cylinder head; 32 - spacer sleeve; 33 - gasket; 34 - fuel manifold assembly with injectors; 35 - valve guide bushing; 36 - fuel supply hose; 37 - exhaust camshaft; 38 - oil seal; 39 - bearing cover No.1 of the camshaft; 40 - camshaft gear leaf spring; 41 - auxiliary gear camshaft; 42 - retaining ring; 43 - spring washer; 44 - Intake camshaft plug; 45 - bearing cover No.2 of the camshaft; 46 - gasket; 47 - intake manifold bracket; 48 - oil filler cap; 49 - crankcase ventilation hose; 50 - gasket; 51 - air bypass valve to exhaust; 52- Air Bypass Valve (ACV); 53 - O-ring seal; 54 - vacuum modulator of the exhaust gas recirculation system; 55 - exhaust gas recirculation system tube assembly; 56 - EGR valve; 57 - gasket.
Removal the cylinder head
1. Drain the coolant.
2. Remove the distributor together with the high-voltage wires.
- a) Disconnect the high-voltage wires by the rubber caps.
Note: Do not pull the wires. Pulling or bending the wires may cause internal breaks.
- b) Unscrew the bolt securing the wire holders.
- c) Disconnect the two connectors.
- d) Unscrew the two clamping bolts and remove the distributor.
- d) Remove the distributor housing O-ring.
3. Remove the spark plugs.
4. Disconnect the vacuum hoses.
- a) (Models with automatic transmission) Disconnect the following hoses:
- Vacuum hose from the throttle actuator (1).
- Vacuum hose from EGR valve (2)
- Three vacuum hoses from the EGR vacuum modulator (3).
- b) Disconnect the vacuum hose from the fuel vapor canister.
5. Remove the EGR pipe, vacuum modulator and EGR valve.
- a) Loosen the union nut of the pipe and unscrew the bolt, two nuts and remove the EGR pipe.
- b) Remove the EGR vacuum modulator and its bracket by unscrewing the bolt.
- c) Unscrew the two nuts and remove the EGR valve and gasket.
6. Remove the thermostat housing.
- a) Disconnect the following connectors:
- Coolant Temperature Sensor - Switch Connector (to the drive of the electric fan of the cooling system) (1).
- Coolant temperature sensor connector (2).
- Coolant temperature gauge sensor connector (3).
- (Models with automatic transmission) Coolant temperature switch sensor connector.
- b) Disconnect the following hoses:
- Cooling system inlet hose (1).
- Heater outlet hose (2).
- Coolant bypass hose (3)
- Two vacuum hoses of the thermo-controlled pneumatic valve (4)
- c) Unscrew the bolt, two nuts and remove the EGR valve and gasket.
7. Remove the exhaust manifold.
- a) Unscrew the three bolts and remove the heat shield.
- b) Remove the exhaust manifold and gasket by unscrewing the six nuts.
The article was copied from the portal www.TOYOTAMAN.ru
8. Remove the air bypass valve to the outlet.
- a) Disconnect the valve connector.
- b) Disconnect the air duct.
- c) Disconnect the two bolts, the ground wire and the air bypass valve to the outlet.
- d) Remove the O-ring from the valve.
9. Remove the throttle body.
10 Remove the fuel manifold and injectors.
11 Remove the air tube by unscrewing the two bolts.
12. Remove the intake manifold.
- a) Unscrew the two bolts, nut and remove the manifold bracket.
- b) Unscrew three bolts, three nuts and remove the intake manifold.
13. Remove the cylinder head cover
- a) Remove the oil filler cap.
- b) Unscrew the five cover nuts and remove the sealing washers.
- c) Remove the cylinder head cover and gasket.
14. Remove timing belt cover No.2 and gasket by unscrewing four bolts.
15. Remove the generator drive belt by loosening the axle bolt nut and adjusting bolt.
16. Remove timing belt cover No.3 from timing belt cover No.1.
17. Remove the timing belt from the crankshaft toothed pulley
Note: When reusing the timing belt, make marks on the timing belt and camshaft sprocket.
- a) Loosen the tension roller mounting bolt and push the tension roller to the left as far as possible, and then temporarily tighten it.
Note: Do not damage the timing belt.
- b) Remove the timing belt from the camshaft toothed pulley.
18. Remove the intermediate pulley by unscrewing the bolt.
Note.
- Secure the timing belt so that it does not move.
- Be careful not to drop anything inside.
- Keep the belt away from oil, water and dust.
19. Holding the camshaft with one wrench, loosen the pulley mounting bolt with another wrench and remove the camshaft toothed pulley.
20. 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 removal, it is necessary to hold the shaft in a horizontal position, to do this, follow the removal procedure below.
- a) Install the intake camshaft so that the hole for the intake camshaft gear bolt is on top (as shown in the picture).
Note: In this position, the cam lobes of the intake camshafts of cylinders #2 and #4 act on the valve lifters, which will help lift the exhaust camshaft smoothly and evenly.
- b) Unscrew the four bolts and remove bearing caps No.1 and No.2.
- c) Remove the intake camshaft plug and seal.
- d) Attach the auxiliary gear of the intake camshaft to the main gear with a technological bolt.
- Recommended process bolt:
- diameter - 6 mm
- thread pitch - 1.0 mm
- bolt length - 16-20 mm
Note: When removing the camshaft, make sure that this operation neutralizes the torsional force of the auxiliary gear leaf spring.
- d) Uniformly loosen and remove the eight bearing cap bolts in several passes in the sequence shown in the figure.
- e) Remove the four bearing caps and the exhaust camshaft.
Note: If the camshaft does not come off straight and level, re-fasten bearing cap No.3 with two bolts, then alternately loosen the bearing cap bolts while pulling the camshaft out by the gear.
Note: Do not attempt to remove the camshaft using a tool.
- g) Uniformly loosen and remove the eight intake camshaft bearing cap bolts in several passes as shown in the figure.
- c) Remove the four bearing caps and the intake camshaft.
Note:
- If the camshaft does not come off straight and level, re-fasten bearing cap #3 with two bolts, then alternately loosen the bearing cap bolts while pulling the camshaft out by the gear.
- Do not attempt to remove the camshaft using a tool.
21. Remove the intake camshaft.
- a) Place the hexagonal section of the camshaft in a vice.
Note: Do not damage the camshaft.
- b) Insert the service bolt (A) into the hole of the auxiliary camshaft drive gear.
- c) Using a screwdriver, turn the auxiliary gear clockwise and remove the technological bolt (B).
Note: Do not damage the camshaft.
- d) Remove the retaining ring using pliers.
- d) Remove: spring washer (1), auxiliary camshaft drive gear (2), leaf spring (3).
22. Remove the cylinder head.
- a) Using an 8 mm Allen key, loosen and remove the ten cylinder head bolts evenly in several passes in the sequence shown in the illustration.
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 with wooden blocks underneath.
Note: If the cylinder head is difficult to remove, you can use a powerful screwdriver, 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.
