Page 3425 of 4770
EM0YL±01
S05282
S05281
S05300
TMC
Made
TMMK
Made
S05297
Clamp
Sensor
Connector
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±33
1205 Author: Date:
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP (See page EM±69)
3. REMOVE GENERATOR (See page CH±6)
4. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 nuts holding the front exhaust pipe to the
exhaust manifold.
(b) Remove the 3 (California) or 5 (Except California) bolts
and No.1 exhaust manifold heat insulator.
(c) Remove the 2 bolts and No.1 exhaust manifold stay.
(d) TMC Made:
Remove the 2 nuts and No.2 exhaust manifold stay.
(e) TMMK Made:
Remove the bolt, nut and No.2 exhaust manifold stay.
(f) Remove the wire clamp.
(g) California:
Disconnect the A/F sensor connector.
(h) Except California:
Disconnect the oxygen sensor (bank 1 sensor 1) connec-
tor.
(i) Remove the 6 nuts, the exhaust manifold, No.2 and No.3
exhaust manifold heat insulators assembly.
Page 3426 of 4770

S05548
Wire
Clamp
A01564(c)(d)
(e)
A07364
ConnectorClamp
EM±34
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1206 Author: Date:
(j) California:
Disconnect the A/F sensor connector for the wiring side
from the bracket on the LH engine hanger.
(k) Except California:
Disconnect the heated oxygen sensor (bank 1 sensor 1)
connector for the wiring side from the bracket on the LH
engine hanger.
5. REMOVE THROTTLE BODY (See page SF±32)
6. REMOVE IGNITION COILS, NO.2 INTAKE MANIFOLD
STAY AND HIGH±TENSION CORDS ASSEMBLY
(a) Disconnect the 2 ignition coil connectors.
(b) Disconnect the 4 high±tension cords from the 2 clamps
on the cylinder head cover.
(c) Disconnect the 4 high±tension cords from the spark
plugs.
(d) Disconnect the wire clamp from the manifold stay.
(e) TMC Made:
Remove the 2 nuts, 2 bolts, 2 ignition coils, manifold stay
and 4 high±tension cords assembly.
(f) TMMK Made:
Remove the nut, 3 bolts, 2 ignition coils, manifold stay and
4 high±tension cords assembly.
7. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
8. DISCONNECT NOISE FILTER CONNECTOR
9. REMOVE WATER OUTLET
(a) Disconnect the ECT sensor connector.
(b) Disconnect the ECT sender gauge connector.
(c) Disconnect the radiator hose from the water outlet.
(d) Disconnect the water bypass pipe hose from the water
outlet.
(e) Disconnect the heater water hose from the water outlet.
(f) Remove the 2 nuts, water outlet and gasket.
10. REMOVE INTAKE MANIFOLD STAY
Remove the bolt, nut and intake manifold stay.
11. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Disconnect the VSV connector for the EGR.
(b) Disconnect the hose clamp from the bracket on the intake
manifold.
(c) Remove the bolt, and disconnect the VSV for EGR from
the intake manifold.
Page 3427 of 4770

A07363
A07365
S05981
SST
S05990
(a)
(b)(c)
A07360
(e)(d)
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±35
1207 Author: Date:
(d) Loosen the union nut of the EGR pipe, and remove the
bolt, 2 nuts, the EGR valve, vacuum modulator, vacuum
hoses assembly and gasket.
12. DISCONNECT ENGINE WIRE FROM INTAKE MAN-
IFOLD
(a) Disconnect the engine wire clamp from the bracket on the
LH side of the intake manifold.
(b) Disconnect the 2 engine wire clamps from the 2 brackets
on the front side of the intake manifold.
13. DISCONNECT FUEL INLET HOSE FROM DELIVERY
PIPE
(a) Using SST, loosen the fuel pulsation damper.
SST 09612±24014 (09617±24011)
(b) Remove the fuel pulsation damper and 2 gaskets, and
disconnect the fuel inlet hose from the delivery pipe.
14. REMOVE INTAKE MANIFOLD
(a) Disconnect the MAP sensor vacuum hose from the gas
filter.
(b) Disconnect the brake booster vacuum hose from the in-
take manifold.
(c) Disconnect the PCV hose from the intake manifold.
(d) Remove the 2 bolts, and disconnect the 2 ground wires
from the intake manifold.
(e) Disconnect the knock sensor 1 connector.
Page 3428 of 4770

A07359
S06000
S05962
EM±36
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1208 Author: Date:
(f) Remove the 6 bolts, 2 nuts, intake manifold and gasket.
15. California:
REMOVE AIR HOSE FOR AIR ASSIST SYSTEM
Disconnect the air hose from the cylinder head port, and re-
move the air hose.
16. REMOVE DELIVERY PIPE AND INJECTORS
(a) Disconnect the 4 injector connectors.
(b) Remove the 2 bolts and delivery pipe together with the 4
injectors.
NOTICE:
Be careful not to drop the injectors when removing the de-
livery pipe.
(c) Remove the 4 insulators (except California) and 2
spacers from the cylinder head.
(d) Pull out the 4 injectors from the delivery pipe.
(e) California:
Remove the 2 O±rings, insulator and grommet from each
injector.
(f) Except California:
Remove the O±ring and grommet from each injector.
17. DISCONNECT TIMING BELT FROM CAMSHAFT TIM-
ING PULLEY (See page EM±17)
18. REMOVE CAMSHAFT TIMING PULLEY
(See page EM±17)
19. REMOVE NO.1 IDLER PULLEY AND TENSION
SPRING
Remove the bolt, pulley and tension spring.
20. REMOVE NO.3 TIMING BELT COVER
Remove the 3 bolts and timing and cover.
Page 3429 of 4770

A02593
S05933
P03355
10 ± 45°
Knock
Pin
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±37
1209 Author: Date:
NOTICE:
Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift.
Be careful not to drop anything inside the timing belt
cover.
Do not allow the belt to come into contact with oil, wa-
ter or dust.
21. REMOVE ENGINE HANGERS AND GENERATOR
BRACKET
(a) Remove the 3 bolts, the generator bracket and RH engine
hanger assembly.
(b) Remove the bolt and LH engine hanger.
22. REMOVE OIL PRESSURE SWITCH
23. REMOVE CYLINDER HEAD COVER
Remove the 4 nuts, grommets, head cover and gasket.
HINT:
Arrange the grommets in the correct order, so that they can be
reinstalled into their original positions. This minimizes any pos-
sibility of oil leakage due to reuse of the grommets in different
positions.
24. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept 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, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Remove the exhaust camshaft.
(1) Set the knock pin of the intake camshaft at 10 ± 45°
BTDC of camshaft angle.
HINT:
The above angle allows No.2 and No.4 cylinder cam lobes of
the exhaust camshaft to push their valve lifters evenly.
Page 3430 of 4770

P03445
Drive Gear
Service
Bolt
Sub±Gear
P03356
P03241
3
26 54
1
P03357
EM±38
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1210 Author: Date:
(2) Secure the exhaust camshaft sub±gear to drive
gear with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 ± 20 mm (0.63 ± 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub±gear has been eliminated by the above
operation.
(3) Remove the 2 bolts and rear bearing cap.
(4) Uniformly loosen and remove the 6 bolts on the
No.1, No.2 and No.4 bearing caps in several
passes, in the sequence shown.
NOTICE:
Do not remove the No.3 bearing cap bolts at this stage.
(5) Remove the No.1, No.2 and No.4 bearing caps.
(6) Alternately loosen and remove the 2 bolts on the
No.3 bearing cap.
HINT:
As the 2 No.3 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No.3 bearing cap bolts. Then reverse the or-
der of above steps from (6) to (1) and reset the knock pin
of the intake camshaft at 10 ± 45° BTDC, and repeat
steps from (2) to (6) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(7) Remove the No.3 bearing cap and exhaust cam-
shaft.
Page 3431 of 4770

P03358
8 0 ± 11 5°
Knock
Pin
P03359
P03360
1 2
3 45 6
P03361
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
EM±39
1211 Author: Date:
(b) Remove the intake camshaft.
(1) Set the knock pin of the intake camshaft at 80 ±
11 5° BTDC of camshaft angle.
HINT:
The above angle allows the No.1 and No.3 cylinder cam lobes
of intake camshaft to push their valve lifters evenly.
(2) Remove the 2 bolts, front bearing cap and oil seal.
(3) Uniformly loosen and remove the 6 bolts on the
No.1, No.3 and No.4 bearing caps in several
passes, in the sequence shown.
NOTICE:
Do not remove the No.2 bearing cap bolts at this stage.
(4) Remove the No.1, No.3 and No.4 bearing caps.
(5) Alternately loosen and remove the 2 bolts on the
No.2 bearing cap.
HINT:
As the 2 No.2 bearing cap bolts are loosened, make sure
that the camshaft is lifted out straight and level, after
breaking adhesion on the front bearing cap.
If the camshaft is not being lifted out straight and level, re-
tighten the 2 No.2 bearing cap bolts. Reverse the order
of above steps from (5) to (1) and reset the knock pin of
the intake camshaft at 80 ± 115° BTDC, and repeat steps
from (2) to (5) once again.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(6) Remove the No.2 bearing cap and camshaft.
Page 3432 of 4770

P05613
S01665
SST
Service
Bolt
S01666
EM7558
6 10
192 8 3
74 5
S05971
Pry EM±40
± ENGINE MECHANICAL (5S±FE)CYLINDER HEAD
1212 Author: Date:
25. DISASSEMBLE EXHAUST CAMSHAFT
(a) Mount the camshaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub±gear clockwise, and remove the
service bolt.
SST 09960±10010 (09962±01000, 09963±00500)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer, camshaft sub±gear and gear
spring.
26. REMOVE CYLINDER HEAD
(a) Disconnect the camshaft position sensor connector.
(b) Remove the 2 bolts holding the water bypass pipe to the
cylinder head.
(c) Uniformly loosen and remove the 10 cylinder head bolts
in several passes, in the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(d) Lift the cylinder head from the dowels on the cylinder
block, and place the cylinder head on wooden blocks on
a bench.
HINT:
If the cylinder head is off, pry between the cylinder head and cyl-
inder block with a screwdriver.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.