TOYOTA CELICA 1987 Service Repair Manual

ENGINE MECHANICAL - Cylinder Head
SST
Snap Ring
EM063
82
(f) $u;ily heat the cylinder head to approti; “90°C
0
*
(g) Using SST and hammer, drive in a new valve guide
bushing until the snap ring makes contact with the
cylinder head.
SST 09201-70010
Overall Length
II
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_-
2606.
-- ,
:,”
(h) Using a sharp 6 mm (0.23 in.) reamer, ream the valve
guide bushing to obtain standard specified clearance
(See page EM-471 between the.valve guide bushing
and new .valve.
11. INSPECT AND GRIND VALVES
(a) Grind the valve only enough to remove pits and car-
bon.
(b) Check that the valve are ground to the correct valve
face angle.
Valve face angle: 44.5”
(c) Check the valve head margin thickness.
Standard margin thickness: 1.3 mm (0.051 in.)
Minimum margin thickness: 0.5 mm (0.020 in.)
If the valve head margin thickness is less than minimum,
replace the valve.
(d) Check the valve overall length.
Standard overall length: 98.15 mm (3.8842 in.)
Minimum overall length: 97.75 mm (3.8484 in.1
If the valve overall length is less than minimum, replace
the valve.

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EM-50 ENGINE MECHANICAL - Cylinder Head
1 (e) Check the’surface of the valve stem tip for wear.
If the valve stem tip is worn, regrind it with grinder or re-
place the valve if necessary.
CAUTION: D6 not grind off more than minimum over-
all length (See page EM-49).
12.
INSPECT AND CLEAN VALVE SEATS
(a) Using a 45” carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
EM3026
(b) Check the valve seating position.
Apply a thin coat of prussian blue (or white lead) to
the valve face. Install the valve. Lightly press the
valve against the seat. Do not rotate the valve.
(c) Check the valve face and seat for the following:
0 If blue appears 360” around the face, the valve is
concentric. If not, replace the valve.
0 If blue appears 360” around the valve seat, the
guide and seat are concentric.
If not, resurface the seat.
0 Check that the seat contact is on the middle of the
valve face with the following width.
1.0 - 1.4 mm (0.039 - 0.055 in.1
If not, correct the valve seat as follows:
0 If seating is too high on the valve face use 30” and
45” cutters to correct the seat.
l If seating is too low on the valve face, use 60°. and
45” cutters to correct the seat.

ENGINE MECHANICAL -, Cylinder Head
EM-5J
Squareness -+- (d) Hand-lap the valve and valve seat with an abrasive
compound.
. .
13. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the squareness of the
valve springs.
Maximum. squareness: 1.5 mm (0.059 in.)
If squareness .is greater than maximum, replace the valve
spring.
(b) Using calipers, measure the free length of the valve
spring.
Free length : 41.64 mm (1.6394 in.)
If the free length is not within specification, replace the
valve spring.
(c) Using a spring tester, measure the tension of the
valve spring at the specified installed length.
Installed tension :
16.0 kg (35 lb, 157 N) at 35.0 mm (1.378 in.)
If the installed tension is not as specified, replace the valve
spring.
14. INSPECT CAMSHAFT AND BEARING CAPS
(a) Place the camshaft on V-blocks and, using a dial
gauge, measure the circle runout at the center jour-
nal.
Maximum circle runout: 0.03 mm (0.0012 in.)
If the circle runout is greater than maximum, replace the
camshaft.

EM-52
: ENGINE MECHANICAL - Cylinder Head
7614352 (b) Using a micrometer, measure the cam lobe height,
Standard cam lobe height:
Intake
7M-GE MA 38.38 mm (I 6102 in.1
.MS 38.18 mm (I 6024 in.1
7M-GTE 38.36 mm (1.6098 In.)
Exhaust
7M-GE MA 38.38 mm (I .6102 In.)
MS 38.36 mm (1.6098 in.1
7M-GTE 38.36 mm (1.6098 in.) .
Minimum cam lobe height:
Intake-
7M-GE MS 37.86 mm (1.4906 in.)
Others 38.00 mm (1.4981 in.)
Exhaust 38.00 mm (1.4981 in.1
If the cam lobe height is less than minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.
Standard diameter:
No.1
28.949 - 28.986 mm (I .0810 - 1.0616 in.1
No.2 - No.7
26.888 - 26.976 mm (1.0686 1 1.0620 in.)
If the journal diameter is less than specified, replace the
camshaft.
16. INSPECT CAMSHAFT OIL CLEARANCE
(a) Clean the bearing caps and camshaft journal.
(b) Place the camshaft in the cylinder head.
(4 Lay a strip of plastigage across each journal.
(d) Place the bearing caps with the top of the number on
the cap pointing toward the front and in numerical
order from the front side.
(e) Install and torque the cap bolts gradually in the
sequence shown in the figure.
Torque: 200 kg-cm (14 ft-lb, 20 Nmrn)
NOTE: Do not turn the camshaft while the plastigage is
in place.
(f) Remove the caps and measure the plastigage at its
widest point.

ENGINE MECHANICAL - Cylinder Head
L Et.4294
Standard oil clearance:
No.1 ... ..“..” .._.
0.036 - 0.072 mm (0.0014 - 0.0028 in,)
;
No.2 ii. No.7
0.025 - 0.093 mm (0.0010 - 0.0037 in.)
Maximum.oil clearance: 0.13 mm (0;0061 ‘hi.)
If dlearance is greater than maximum, replace the cylinder
head and/or camshaft.
(g) Clean out the pieces of plastigage from the bearing
caps and journals.
18. INSPECT-CAMSHAFT THRUST CLEARANCE
(a) Clean and install the camshaft and bearing caps.
(b) Using a dial gauge, measure <the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance’: 0.08 - 0.18 mm
(Q.9031 - 0.0976 in.)
Maximum thrust clearance: 0.30 mm IO.01 18 in.)
If clearance is greater than maximum, replace the
camshaft and/or cylinder head.
17. INSPECT VALVE LIFTER OIL CLEARANCE
.(a) Using a micrometer, measure the diameter of the
valve lifter.
Valve lifter diameter: 27.975 - 27.885 mm
(1.1014 - 1.1018 in.)
(b) Using a dial indicator, measure the inside diameter of
the cylinder head bore.
Lifter bore diameter: 28.000 - 28.021 mm
(1 .1024 - 1 .1032 in.)
(4 Subtract the valve lifter measuremeht from the
cylinder head bore.
Standard oil clearance: 0.015 - 0.048 mm
(0.0008 - 0.0018 in.)
Maximum oil clearance: 0.1 mm (0.004 in.)
If clearance is greater than maximum, replace the cylinder
head and/or valve lifter.
EM2948
EM3570
18. INSPECT INTAKE, EXHAUST MANIFOLD AND
INTAKE CHAMBER
Using a precision straight edge and feeler gauge;-check
the surfaces contacting the cylinder head, or intake
manifold for warpage.
Maximum warpage:
Intake manifold 0.10 mm (0.0039 in.)
Exhaust manifold IM-GE 0.75 mm (0.0295 in.)
7M-GTE 0.60 mm (OiOlQ7 in.)
Intake chamber 0.10 mm (0.0039 in.)
- .,, ,. 1. & ._i ^..s^..r*.., “,A

EM-54
ENGINE MECHANICAL - Cylinder Head
EM295
EMZS’
I
EM2954
I
EM295! 5
lnwEcTl0~ 0~ INTAKE AIR CONTROL
SYSTEM (‘/M-GE only)
. .
1.
CHECK AIR CONTROL VALVE OPERATION
With 400 mmHg (15.75 in.Hg, 53.3 kPa) of vacuum
applied to the actuator, check that the control valve
moves smoothly to the fully closed position.
If not adjust with the adjusting screw.
2. CHECK VACUUM TANK BY BLOWING AIR INTO
EACH PIPE
(a) Check that air flows from pipe B to A.
(b) Checkthat air does not flow from pipe A to B.
(c) Apply 500 mmHg (I 9.69 in.Hg, 66.7 kPa) of vacuum
to pipe B and check that there is no change in
vacuum after one minute.
If there is a change, replace the vacuum tank.
3. CHECK VACUUM CIRCUIT CONTINUITY IN THE VSV
BY BLOWING Alti INTO PIPE
(a) Connect the VSV terminals to the battery terminals
as illustrated.
(b) Blow into pipe E and check that air comes out of the
pipe G.
(c) Disconnect the battery.
(d) Blow into pipe E and check that air comes out of the
air filter.
If a problem is found, replace the VSV.

ENGINE MECHANICAL - Cylinder Head
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IN88 00 00 00 00 00
88 88 88 ,ge 88
No. 1 No. .2 No. 3 No. 4 No. 5 No. 6
EM06’
SSSEMBLY OF CYLINDER HEAD ..‘. ““..I.
See pages EM-37, 381
._
NOTE:
0 Thoroughly clean all parts to be assembled.
0 Before installing the parts, apply neti engine oil to all
sliding and rotating surfaces.
0 Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Insert the valves in the cylinder head valve guide
bushing. Make sure the valves are installed in the cor-
rect order.
(b) Using SST, install new oil seals on the valve guide
bushings.
SST 09201-41020
(c) Install spring seats, springs and spring retainers.
(d) Using SST, compress the valve retainers and place
two keepers around the valve stem.
SST 09202-70010
(e) Tap the stem lightly to assure proper fit.
2. INSTALL VALVE LIFTERS WITH SHIMS
Make sure the valve lifters with their shims are installed in
the correct order.
3. INSTALL CAMSHAFTS AND blL SEALS
(a) Apply engine oil to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.

EM-56
ENGINE MECHANICAL - Cylinder f-lead
I-
I: Intake
E: ljxhaust No.? - No. 7
Front Mark Intake
Exhaust (4 Coat all bearing journals with engine oil.
(d) Place the camshafts on the cylinder head as shown in
the figure,
NOTE: The eihaust camshaft has a distributor (‘IM-GE)
or cam position sensor (7M-GTE) drive gear.
(e) Apply seal packing to the areas indicated in the
figure.
Seal packing:
Part No.06826-00080 or equivalent
NOTE: Install the No.1 bearing cap immediately after
applying the. seal packing.
(f) Place bearing caps on each journal with the front
marks pointing toward the front.
(g) Tighten each bearing cap bolt a little at a time and in
the sequence shown in the figure.
(h) Using SST, drive in a new camshaft oil seal.
SST 09223-50010
NOTE: Be careful not to install the oil seal slantwise.

ENGINE MECHANICAL - Cylinder Head
EM-67
EM302
EM2921
(i) Tighten the No.3 and No.7 bearing cap bolts a little at
a time and in the sequence shown in the figure.
Torque:
20.0 kg-c* (14 ft-lb, 20 N-ml
(i) Torque each bearing cap bolt a little at a time and in
the sequence shown in the figure.
Torque : 200 kg-cm (14 ft-lb, 20 N-m)
(k) Check the camshaft thrust clearance.
4.
(w/ EGR)
INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts.
Torque :
140 kg-cm (IO ft-lb, 14 Nmrn)
(w/o EGR)
INSTALL EGR HOLE PLATE
Install a new gasket and EGR hole plate with the two bolts.
5. INSTALL HEATER UNION
(a) Install a new gasket, union, another gasket and union
bolt to the cylinder head.
(b) Torque the union bolt.
Torque:
600 kg-cm (43 ft-lb, 59 N-m)
6. INSTALL NO.2 ENGINE HANGER AND GROUND
STRAP
Torque:
400 kg-cm (29 ft-lb, 39 N-m)
7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) (w/ EGR)
0 Install the intake manifold and VSV with the two
nuts and seven bolts.
l Install the EGR valve with the two nuts.
l Torque the bolts and nuts.
Torque: 180 kg-cm (13 ft-lb, 18 Nnrn)

EM-58
ENGINE MECHANICAL - Cylinder Head
-.
(w/o EGR)
0 install.-the intake manifold four nuts and seven
bolts.
l Torque the bolts and nuts.
Torque :
180 kg-cm (13 ft-lb, 18 N.mI
8.
INSTALL DELIVERY PIPE WITH INJECTORS
(a)
Install the six insulators into the injector hole of the
cylinder head.
(b) Install the black rings on the upper portion of each of
the three spacers. Then install the spacers on the
delivery pipe mounting holes of the cylinder head.
(c) Place the injectors together with delivery pipe on the
cylinder head.
(d) Make sure that the injectors rotate smoothly.
(e) Install the three thinner spacers and bolts.
Torque the bolts.
Torque :
180 kg-cm (13 ft-lb, 18 N*m)
9.
INSTALL ALTERNATOR BRACKET
Torque :
400 kg-cm (29 ft-lb, 39 N.rnI
16. INSTALL NO.2 TIMING BELT COVER