Cylinder head removal

Remove engine under cover
Drain engine coolant
Remove air cleaner duct
Remove air cleaner, MAF meter and intake air connector pipe assembly (See page EM-57)
Remove drive belt (See page CH-8)
Remove No.2 front exhaust pipe (See page CH-8)
Remove exhaust manifold
1. Disconnect the 2 heated oxygen sensor connectors.
2. Using a 14 mm deep socket wrench, remove the 4 nuts, exhaust manifold and gasket. Remove the No.1 and No.2 exhaust manifolds.
Remove water bypass outlet and No.1 water bypass pipe (See page CO-7 )
Disconnect PS pump without disconnecting hoses
1. Disconnect these hoses:
  1. PS air hose from No.4 timing belt cover
  2. PS air hose from air intake chamber
2. Remove the 2 bolts, and disconnect the vane pump from the pump bracket.
  Put aside the vane pump, and suspend it.
Disconnect fuel return hose
1. Disconnect the fuel return hose from the fuel return pipe. Plug the hose end.
2. Disconnect the fuel return hose from the oil dipstick guide.
Remove engine wire bracket
1. Remove the bolt and bracket, disconnect the engine wire from the intake manifold stay.
Remove throttle body and intake air connector assembly (See page SF-19)
Remove air intake chamber stays
1. Remove the bolt, nut and No.1 stay.
2. Remove the bolt, nut and No.2 stay.
Remove oil dipstick and guide for engine (See page LU-9)
Remove oil dipstick and guide for transmission (See page EM-57)
Disconnect EGR Gas temperature sensor connector
1. Disconnect the connector from No.2 vacuum pipe.
2. Disconnect the sensor connector from the wiring connector.
Remove No.2 vacuum pipe and VSV assembly
Remove the 2 nuts, and disconnect the vacuum pipe from the air intake chamber and intake manifold.
Remove vacuum control valve set
1. Remove the 2 nuts, and disconnect the vacuum tank from the intake manifold.
2. Disconnect these connector and hoses, and remove the vacuum control valve set:
  1. VSV connector
  2. Vacuum hose (from air intake chamber) from port B of vacuum tank
  3. Vacuum hose (from actuator) from VSV
Remove DLC1 bracket and VSV assembly
1. Disconnect the connector and hoses:
  1. VSV connector
  2. Vacuum sensing hose from fuel pressure control
  3. Vacuum sensing hose from air intake chamber
2. Remove the bolt, the DLC1 bracket and VSV assembly.
Remove air intake chamber
1. Disconnect these hoses:
  - Vacuum hose from brake booster union
  - EVAP hose from No.2 vacuum pipe
2. Remove the bolt holding the engine wire protector to the air intake chamber.
3. Remove the 5 bolts, nut, air intake chamber and gasket.
Remove No.3 timing belt cover
1. Remove the oil filter cap.
2. Using a 5 mm hexagon wrench, remove the 6 bolts and timing belt cover.
Remove cylinder head rear cover
Using a 5 mm hexagon wrench, remove the 4 bolts and cylinder head rear cover.
Disconnect high-tension cords from cylinder head covers (See page IG-8)
Remove distributor and high-tension cords assembly (See page IG-14)
Remove spark plugs
Remove timing belt from camshaft timing pulleys (See page EM-13 )
1. Support the timing belt, so that the meshing of the crankshaft timing pulley and timing belt does not shaft.
2. Be careful not to drop anything inside the timing belt cover.
3. Do not allow the timing belt to come into contact with oil, water or dust.
Disconnect engine wire
1. Disconnect the wire clamp from the bracket.
2. Disconnect these connectors:
  1. Heated oxygen sensor (bank 1 sensor 1) connector
  2. Crankshaft position sensor connector
3. Remove the 2 bolts, and disconnect the 2 ground straps from the intake manifold.
4. Disconnect the wire clamp from the fuel return pipe.
5. Disconnect these connectors:
  1. ECT sensor connector
  2. ECT sender gauge connector
  3. 2 knock sensor connectors
  4. Oil pressure switch connector
  5. Oil level sensor connector
  6. A/C compressor connector
  7. 6 injector connectors
6. Remove the 3 nuts, and disconnect the engine wire protector from the intake manifold.
Remove water outlet with water bypass hose
1. Disconnect the water bypass hose from the clamp on the oil filter bracket.
2. Remove the 2 nuts, bolt and water outlet.
Remove intake manifold stay
Remove the 2 bolts and manifold stay.
Remove fuel pressure pulsation damper (See page SF-29)
Remove fuel inlet pipe
1. Remove the clamp bolt from the intake manifold.
2. Remove the union bolt, 2 gaskets and fuel inlet pipe.
Remove intake manifold and delivery pipe assembly
Remove the 6 bolts, 2 nuts, the intake manifold, delivery pipe assembly and gasket.
Remove No.3, No.1 and No.2 cylinder head covers
1. Remove the PCV valve.
2. Remove the 4 bolts, 4 nuts and No.3 cylinder head cover.
3. Remove the 4 bolts, No.1 cylinder head cover and gasket.
4. Remove the 4 bolts, No.2 cylinder head cover and gasket.
Remove camshaft timing pulleys
Hold the hexagon portion of the camshaft with a wrench, and remove the pulley the pulley mounting bolt and camshaft pulley.
Remove No.4 timing belt cover
Remove the 4 bolts and timing belt cover.
Remove camshafts
1. Uniformly loosen and remove the 4 No.1 bearing cap bolts.
2. Using a screwdriver, pry out the 2 No.1 camshaft bearing caps and oil seals.
  Be careful not to damage the cap. Tape the screwdriver tip.
3. Uniformly loosen and remove the 12 bearing cap bolts, in several passes, in the sequence shown, and remove the 6 bearing caps and camshaft.
4. Remove the intake and exhaust camshafts.
Remove cylinder head
1. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 14 cylinder head bolts, in several passes, in the sequence shown.
  Cylinder head warpage or cracking could result from removing in incorrect order
2. Remove the 14 plate washers.
3. Lift the cylinder head from the dowels on the cylinder block.
4. Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection.
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

This guide is based on the book edition Toyota (RM502U, 1997)

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