Cylinder Head Assembly: Service and Repair

1. Disconnect battery ground cable.
2. Remove right seat and engine service cover.
3. Drain cooling system and engine oil.
4. Remove power steering pump.
5. Remove front exhaust pipe and bracket assembly.
6. Disconnect accelerator cable from throttle body.
7. Remove air cleaner assembly from engine.
8. Mark then disconnect all EFI electrical connectors, electrical wiring and vacuum hoses from cylinder head.
9. Disconnect radiator and heater hoses.
10. Remove throttle body from air intake chamber.
11. Remove EGR valve, then disconnect cold start in injector line, water bypass hose and pressure regulator hose.
12. Remove air intake chamber and air valve assembly from engine.
13. Remove exhaust manifold bracket, heater pipe bracket, fuel inlet line union bolt and fuel outlet hose.
14. Remove spark plugs.
15. Remove cylinder head cover attaching bolts, then the cover.

Fig. 29 Rocker arm shaft bolt removal sequence. 3Y-EC & 4Y-EC engines:

16. Remove rocker arm shaft assembly by gradually loosening shaft bolts in three steps in sequence shown in Fig. 29.
17. Remove pushrods from engine.

Fig. 30 Cylinder head bolt removal sequence. 3Y-EC & 4Y-EC engines:

18. Loosen cylinder head bolts gradually in three steps in sequence shown in Fig. 30.
19. Remove cylinder head from engine.

Fig. 31 Cylinder head bolt tightening sequence. 3Y-EC & 4Y-EC sequence.:

Fig. 32 Rocker arm shaft bolt tightening sequence. 3Y-EC & 4Y-EC engines:

20. Reverse procedure to install. Torque cylinder head bolts in three steps in sequence shown in Fig. 31 to 65 ft. lbs. for 14 mm bolts and 14 ft. lbs. for 12 mm bolts. Torque rocker arm shaft assembly bolts in three steps in sequence shown in Fig. 32 to 17 ft. lbs.