Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Drain coolant and oil from engine.
3. Drain coolant from intercooler assembly.
4. Remove suspension under brace.
5. Disconnect accelerator cable from throttle body assembly.
6. Remove reservoir tank and air cleaner assembly.
7. Remove alternator.
8. Raise and support vehicle.
9. Remove right hand front wheel.
10. Remove engine under covers.
11. Remove suspension lower crossmember.
12. Remove front exhaust pipe.
13. Remove catalytic converter.
14. Remove alternator brackets.
15. Remove turbocharger and exhaust manifold assemblies.
16. Remove distributor.
17. Remove No. 2 air pipe.
18. Remove left hand engine hanger.
19. Remove oil pressure switch and water outlet.
20. Remove water bypass pipe.
21. Remove throttle body.
22. Disconnect cold start injector connector. Remove EGR valve, vacuum modulator and EGR control VSV.
23. Remove vacuum pipe and intake manifold stays.
24. Remove No. 1 air pipe.
25. Remove fuel pressure VSV.
26. Remove T-VIS, VSV, vacuum tank and turbocharger pressure VSV.
27. Remove intake manifold and air control valve.
28. Remove power steering oil reservoir tank without disconnecting lines.
29. Remove spark plugs.
30. Remove No. 2 timing belt cover.
31. Remove timing belt as follows:
a. Place No. 1 cylinder to TDC of compression stroke by turning crankshaft pulley (sprocket) and aligning pulley groove with No. 1 timing belt cover marking ``0''.
b. Check that the alignment marks on the camshaft timing pulleys and No. 3 timing belt cover are aligned. If not, turn the crankshaft one revolution (360°).
c. With timing marks properly aligned, remove timing belt.
32. Remove PCV pipe and cylinder head cover.
33. Remove camshaft timing pulleys (sprockets).
34. Remove No. 1 idler pulley (sprocket) and tension spring.
35. Remove No. 3 timing belt cover.
36. Remove intake and exhaust camshafts as follows:

Fig. 47 Intake & exhaust camshaft bearing cap bolt loosening sequence. 3S-GTE engine:

a. Uniformly loosen and remove the twenty bearing cap bolts in several passes, in sequence shown, in Fig. 47.
b. Remove the ten bearing cap, two oil seals and two camshaft assemblies. Arrange the intake and exhaust camshaft and components in order removed.
37. Remove right hand rear engine hanger.
38. Remove cylinder head as follows:

Fig. 48 Cylinder head bolt loosening sequence. 3S-GTE engine:

a. Using tool 09043-38100 or equivalent, uniformly loosen and remove the ten cylinder head attaching bolts in several passes, in sequence shown in Fig. 48. Cylinder head warpage or cracking could result from loosening the bolts in incorrect order.
b. Lift the cylinder head from the dowels on the cylinder block and place it on a suitable workbench.
39. If cylinder head is difficult to remove, pry cylinder head off using a suitable screwdriver. When doing so, do not damage cylinder head or block surfaces.
40. Reverse procedure to install, noting the following:
a. The cylinder head bolts are tighten in steps.
b. If any of the bolts break or deform, replace them.
c. Apply a light coat of clean engine oil onto bolt threads and under the heads of the bolts.

Fig. 49 Cylinder head bolt tightening sequence. 3S-GTE engine:

d. Using tool 09043-38100 or equivalent, install a uniformly tighten cylinder head bolts in several passes, in sequence shown in Fig. 49.
e. Torque bolts to specification. If any of the bolts do not meet the required torque specification, replace the bolt.
f. Mark the front of the cylinder head bolt head with paint.
g. Tighten the ten cylinder head bolts an additional 90° in sequence shown.
h. Ensure paint mark applied, is now at a 90° angle from the front.
i. During installation of the intake and exhaust camshafts, place the camshaft onto the cylinder with the No. 1 camshaft lobe facing outward. Apply seal packing to the No. 1 bearing cap.

Fig. 50 Bearing cap location & identification. 3S-GTE engine:

Fig. 51 Intake & exhaust camshaft bearing cap bolt tightening sequence. 3S-GTE engine:

j. Install the bearing caps in their correct locations, as shown in Fig. 50. Each bearing cap has a number and front mark. Apply a light coat of clean engine oil onto the threads and under the heads of the bearing cap attaching bolts. Install and uniformly tighten the twenty bearing cap bolts in several passes, in sequence shown in Fig. 51. Torque bolts to 14 ft. lbs.