Cylinder Head Assembly: Service and Repair
Fig. 26 Cylinder head & components. Corolla models:
1. Disconnect battery ground cable.
2. Drain coolant and oil from engine.
3. Remove engine under cover.
4. Disconnect exhaust pipe from exhaust manifold.
5. Disconnect air inlet hose.
6. Disconnect accelerator and throttle cables from injection pump.
7. Remove water inlet assembly.
8. Disconnect heater hoses from heater.
9. Remove EGR valve.
10. Mark then disconnect all electrical connectors and vacuum hoses from cylinder head.
11. Disconnect water bypass hose from cylinder head union.
12. Disconnect and plug fuel hose from fuel line.
13. Remove fuel injection line.
14. Remove fuel return line and current sensor.
15. Remove glow plugs and injection nozzles.
16. Remove No. 2 timing belt cover attaching bolts, then the cover.
17. Remove timing belt from camshaft timing sprocket as follows:
a. Turn crankshaft clockwise and position No. 1 cylinder at TDC of compression stroke.
Fig. 7 Placing alignment marks on camshaft timing sprocket, injection pump pulley & timing belt. Camry models:
b. Place alignment marks on the camshaft timing sprocket, injection pump and timing belt, Fig. 7.
c. Using a screwdriver, remove tension spring.
d. Loosen No. 1 idler pulley mount bolt.
e. Remove timing belt from camshaft timing sprocket.
18. Using tool No. 09278-54011 or equivalent, to hold sprocket, remove sprocket retaining bolt then the sprocket.
19. Support timing belt so that the meshing of the injection pump timing pulley and timing belt does not shift. Do not allow water, oil or dust to come in contact with the timing belt.
20. Remove cylinder head cover attaching bolts, then the cylinder head cover.
21. Remove oil level gauge guide clamp.
Fig. 8 Cylinder head bolt removal sequence:
22. Loosen and remove cylinder head bolts in three steps and in sequence shown in Fig. 8.
Fig. 9 Cylinder head bolt tightening sequence:
23. Reverse procedure to install. Torque cylinder head bolts in three steps in sequence shown in Fig. 9 to 62 ft. lbs.