Page 1225 of 2389
CYLINDER HEAD (3S±FE)
COMPONENTS
± ENGINE MECHANICALCylinder Head (3S±FE)EM±48
Page 1226 of 2389

REMOVAL OF CYLINDER HEAD
(See page EM±48)
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
2. DRAIN ENGINE COOLANT (See page CO±4)
3. (A/T)
DISCONNECT THROTTLE CABLE AND BRACKET FROM
THROTTLE BODY
4. DISCONNECT ACCELERATOR CABLE AND BRACKET
FROM THROTTLE BODY AND AIR INTAKE CHAMBER
5. REMOVE CRUISE CONTROL ACTUATOR
(See step 9 on page EM±108)
6. REMOVE AIR CLEANER HOSE
7. REMOVE ALTERNATOR (See page CH±6)
8. REMOVE OIL PRESSURE SWITCH, ENGINE HANGERS
AND ALTERNATOR UPPER BRACKET
9. RAISE VEHICLE
NOTICE: Be sure the vehicle is securely supported.
10. REMOVE RH FRONT WHEEL
11. REMOVE ENGINE RH UNDER COVER
12. REMOVE SUSPENSION LOWER CROSSMEMBER
(See step 20 on page EM±109)
13. DISCONNECT FRONT EXHAUST PIPE FROM
CATALYTIC CONVERTER
(See step 25 on page EM±110)
14. REMOVE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER ASSEMBLY
(a) Disconnect the oxygen sensor connector(s).
(b) Remove the six bolts and manifold upper heat insulator.
(c) Remove the two±bolts, two nuts and catalytic converter
stay.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±49
Page 1227 of 2389
17. REMOVE WATER OUTLET
(a) Disconnect the following connectors and hoses:
(1) Water temperature sender gauge connector
(2) Water temperature sensor connector
(3) Cold start injector time switch connector
(4) Radiator upper hose
(5) Water hoses
(6) Emission control vacuum hoses
(b) Remove the two bolts, water outlet and gasket.
18. REMOVE WATER BY±PASS PIPE
(a) Disconnect the water hoses.
(b) Remove the two bolts, two nuts, water by±pass pipe, gasket
and O±ring. 15. SEPARATE EXHAUST MANIFOLD AND CATALYTIC
CONVERTER
Remove the following parts:
(1) Five bolts
(2) Manifold lower heat insulator
(3) Eight bolts
(4) Two catalytic converter heat insulators
(5) Three bolts and two nuts
(6) Exhaust manifold
(7) Gasket
(8) Retainer
(9) Cushion
(10) Catalytic converter
16. REMOVE DISTRIBUTOR (Seepage IG±13) (d) Remove the six nuts, the exhaust manifold and catalytic
converter assembly.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±50
Page 1228 of 2389
22. REMOVE AIR TUBE
(a) Disconnect the following air hoses:
(1) Air intake chamber air hose
(2) Throttle body air hose
(3) (w/ PS)
PS pump air hoses
(b) Remove the two bolts and air tube.19. REMOVE EGR VALVE AND MODULATOR
(a) Remove the vacuum hoses.
(b) Loosen the union nut of the EGR pipe, and remove two
bolts, EGR modulator and gasket.
(c) Remove the bolt and EGR valve.
20. REMOVE THROTTLE BODY
(See steps 5 to 7 on page FI±107)
21. REMOVE COLD START INJECTOR PIPE
(See step 3 on page FI±78)
(b) Disconnect the vacuum sensing hose.
(c) Remove the six bolts, two nuts, intake manifold and
gasket. 23. REMOVE INTAKE MANIFOLD
(a) Remove the two bolts and manifold stay.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±51
Page 1229 of 2389

28. REMOVE NO. 3 TIMING BELT COVER
Remove the four bolts and belt cover.
HINT:
wSupport the belt so the meshing of the crankshaft timing
pulley and timing belt does not shift.
wBe careful not to drop anything inside the timing belt cover.
wDo not allow the belt to come into contact with oil, water or
dust. 24. REMOVE DELIVERY PIPE AND INJECTORS
(See steps 3 and 7 on page FI±89)
25. REMOVE SPARK PLUGS (See page IG±6)
26. REMOVE CAMSHAFT TIMING PULLEY
(See steps 2 to 14 on pages EM±23 and 25)
27. REMOVE NO. 1 IDLER PULLEY AND TENSION SPRING
(See step 18 on page FI±26)
30. REMOVE CAMSHAFTS
HINT: Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed.
If the camshaft is not kept level, the portion of the cylinder
head receiving the shaft thrust may crack or be damaged,
causing the camshaft to seize or break. To avoid this, the fol-
lowing steps should be carried out.
A. Remove exhaust camshaft
(a) Set the knock pin of the intake camshaft at 10 ± 450
BTDC of camshaft angle.
HINT: The above angle helps to lift the exhaust camshaft level
and evenly by pushing No. 2 and No. 4 cylinder cam lobes of
the exhaust camshaft to their valve lifters.29. REMOVE CYLINDER HEAD COVER
Remove the four nuts, grommets, head cover and gasket.
HINT: Arrange the grommets in correct order, so that they
can be reinstalled into their original positions. This minimizes
any possibility of oil leakage due to reuse of grommets.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±52
Page 1230 of 2389

Alternately loosen and remove No. 3 bearing cap bolts 9
and 10.
HINT:
wAs bearing cap bolts 9 and 10 are loosened, check that the
camshaft is being lifted out straight and level.
wIf the camshaft is not being lifted out straight and level, tighten
bearing cap bolts 9 and 10. Then reverse the order of above
steps from (f) to (a) and reset the knock pin of the intake cam-
shaft at 10 ± 45° BTDC, and repeat the steps from (b) and (g)
once again.
NOTICE: Do not pry on or attempt to force the camshaft
with a tool or other object.
(h) Remove the No. 3 bearing cap and exhaust camshaft.
B. Remove intake camshaft
(a) Set the knock pin of the intake camshaft at 80 ± 115°
BTDC of camshaft angle.
NOTE: The above angle allows No. 1 and No. 3 cylinder
cam lobes of the intake camshaft to push their valve lifters
evenly.(b) Secure the exhaust camshaft sub±gear to main gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch 1.0 mm
Bolt length 16 ± 20 mm (O.63 ± 0.79 in.)
HINT: When removing the camshaft, make certain that
the torsional spring force of the sub±gear has been elimi-
nated by the above operation.
(e) Uniformly loosen and remove bearing cap bolts 3 to 8
in several passes in the sequence shown.
HINT: Do not remove the No. 3 bearing cap bolts at this
stage.
(f) Remove the No. 1, No. 2 and No. 4 bearing cap.(c) Remove rear bearing cap bolts 1 and 2.
(d) Remove the rear bearing cap.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±53
Page 1231 of 2389

(f) Alternately loosen and remove No. 2 bearing cap bolts 9
and 10.
HINT:
wAs bearing cap bolts 9 and 10 are loosened, check that the
camshaft is being lifted out straight and level, after breaking
adhesion on the front bearing cap.
wIf the camshaft is not being lifted out straight and level, re-
tighten bearing cap bolts 9 and 10. Reverse the order of
above steps from (f) to (a) and reset the knock pin of the in-
take camshaft at 80 ± 115° BTDC, and repeat steps from (b)
to (f) once again.
NOTICE: Do not pry on or attempt to force the camshaft
with a tool or other object.
(g) Remove the No. 2 bearing cap and camshaft.
31. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the hexagonal wrench head portion of the camshaft
in a vise.
(b) Insert service bolt (A) into the service hole of the cam-
shaft sub±gear.
(c) Using a screwdriver, turn the sub±gear clockwise, and
remove the service bolt (B).
NOTICE: Be careful not to damage the camshaft.
(d) Uniformly loosen and remove bearing cap bolts 3 to 8
in several pass in the sequence shown.
HINT: Do not remove the No. 2 bearing cap bolts at this
stage.
(e) Remove the No. 1, No. 3 and No. 4 bearing caps. (b) Remove the front bearing cap bolts i and 2.
(e) Remove the front bearing cap and oil seal.
NOTICE: If the front bearing cap is not removable by
hand, do not try to remove by force but leave as it is
without bolts.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±54
Page 1232 of 2389
(e) Remove the following parts:
(1) Wave washer
(2) Camshaft sub±gear
(3) Camshaft gear spring
32. IF NECESSARY, REMOVE SPARK PLUG TUBES
Using a pipe wrench, remove the four spark tubes.
33. REMOVE CYLINDER HEAD
(a) Using SST, uniformly loosen and remove the ten cylinder
head bolts in several passes in the sequence shown.
SST 09043±88010
NOTICE: Head warpage or cracking could result from remov-
ing bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder block and
place the head on wooden blocks on a bench.
HINT: If the cylinder head is difficult to lift off, pry with a screw-
driver between the cylinder head and block saliences.
NOTICE: Be careful not to damage the cylinder head and cylin-
der block surfaces of cylinder head gasket side.
(d) Using snap ring pliers, remove the snap ring.
± ENGINE MECHANICALCylinder Head (3S±FE)EM±55