Cylinder Head Assembly: Service and Repair

Fig. 25 Cylinder head & components. Camry models:

1. Disconnect battery ground cable.
2. Drain cooling system and oil from engine.
3. Remove cruise control actuator assembly.
4. Disconnect accelerator cable or cruise control cable from injection pump.
5. Remove air cleaner assembly from engine.
6. Mark then disconnect all electrical connectors and vacuum hoses from cylinder head.
7. Remove current sensor.
8. Raise and support vehicle.
9. Disconnect exhaust pipe from turbocharger turbine elbow.
10. Remove exhaust manifold mounting bracket bolt from exhaust manifold.
11. Lower vehicle.
12. Remove turbocharger. Refer to removal procedure under ``Turbocharger Service.''
13. Remove water outlet assembly.
14. Remove heater pipe.
15. Remove No. 1 water bypass hose and glow plugs.
16. Remove injection nozzle holders and level gauge guide support mounting bracket.
17. Remove No. 2 timing belt cover attaching bolts, then the cover.

Fig. 6 Aligning line mark on camshaft timing sprocket with top end of cylinder head. Camry models:

18. Position No. 1 cylinder at TDC of compression stroke by aligning the line mark on camshaft timing sprocket with top end of cylinder head, Fig. 6.

Fig. 7 Placing alignment marks on camshaft timing sprocket, injection pump pulley & timing belt. Camry models:

19. Remove camshaft timing sprocket as follows:
a. Place alignment marks on camshaft timing sprocket, injection pump pulley and timing belt, Fig. 7.
b. Using a suitable screwdriver, remove tension spring.
c. Loosen No. 1 idler pulley mount bolt.
d. Using tool No. 09278-54011 or equivalent, to hold timing sprocket, remove camshaft timing sprocket retaining bolt and washer.
e. Remove camshaft timing sprocket and timing belt.
f. Support timing belt so that belt meshing of injection pump timing pulley and timing belt does not shift. Do not allow oil, water or dust to come in contact with timing belt.
20. Remove No. 3 timing belt cover attaching bolts, then the cover.
21. Remove cylinder head cover attaching bolts, then the cover.
22. Remove No. 1 engine bracket.

Fig. 8 Cylinder head bolt removal sequence:

23. Loosen and remove cylinder head bolts in three steps and in sequence shown in Fig. 8.
24. Reverse procedure to install. Torque cylinder head bolts in three steps in sequence shown, Fig. 9, to 62 ft. lbs.