TOYOTA CELICA 1987 Service Repair Manual

ENGINE MECHANICAL - Cylinder Head
EM-&j
REMOVAL OF CYLINDER HEAD
1. (See pages EM-37, 38)
REMOVE AiiERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.
2.
3.
4. (7M-GTE)
REMOVE PS RESERVOIR TANK
Remove the two bolts, nut and, reservoir tank with bracket.
(‘IM-GTE),
REMOVE CAM POSITION SENSOR
REMOVE AIR INTAKE CHAMBER WITH CONNECTOR
(a) Remove the PCV pipe.
(b) Disconnect following connectors:
. (7M-GE)
Cold start injector connector
l Throttle position sensor connector
l ISC valve connector
(c) Disconnect following hoses: aI
l BVSV hose from throttle body
l EGR hoses from throttle.boby
l Vacuum transmitting p.ipe hose from intake cham-
ber
0 Pressure regulator hose
;, I
l VSV (for fuel pressure up) &es
. (7 M-GE)
Diaphragm hose
(d) Disconnect following hoses:
-
0 (7M-GTE)
Auxiliary air pipe hose from vacuum transmitting
pipe hose
l No.1 water by-pass hose from ISC valve
. (7M-GE)
No.3 water by-pass hose from throttle body ,
0 (-/M-GTE)
No.3 water by-pass hose from water by-pass pipe
(e) (w/ EGR)
Remove the EGR pipe mounting bolts.
(f) Remove the manifold stay mounting bolts.

.
EM-40 ENGINE MECHANICAL -# Cylinder Head
5. (g) UM-GE)
Remove the throttle body bracket(s).
. .
(7M-GTE)
Remove the ISC pipe.
(h) (7M-GTE)
Remove the air intake connector mounting bolt.
6) (7M-GE)
Remove the air intake connector bracket mounting
bolts.
cj) Remove the cold start injector tube.
(k) Remove the EGR vacuum modulator from the’
bracket.
!I) Disconnect the engine wire from the clamps of intake
chamber.
(m) Remove the two nuts, five bolts, vacuum transmitting
pipes and intake chamber with connector and gasket.
(t-r) (7M-GTE)
Disconnect the cold start injector connector.
(7M-GTE)
REMOVE IGNITION COIL WITH BRACKET
(See steps 5 and 6 on pages EM-1 2, 13)

.
ENGINE MECHANICAL - Cylinder Head
-. 6. REMOVE ENGINE WIRE
(a) Disconnect following wires:
. fw/ TWC)
Oxygen sensor connector
l Oil pressure sender gauge connector
l Water temp. sensor connector
l Water temp. sender gauge connector
_-
l Cold start injector time switch connector
l Distributor connector
.,
l Injector connectors
l Three VSV connectors
l Knock sensor connectors
l Ground strap from intake manifold
(b) Remove the engine wire from the each clamps.
7.
REMOVE PULSATION DAMPER, VSV AND NO.1 FUEL
PIPE
6.
REMOVE NO.2 FUEL PIPE
(a) Disconnect the fuel hose from the No.2 fuel pipe.
(b) Remove the bolt,’ union bolt, No.2 fuel pipe and
gaskets.
9. (7M-GTE)
REMOVE AUXILIARY AIR PIPE
10. (7M-GE)
REMOVE HIGH-TENSION CORDS AND DISTRIBUTOR
11. (7M-GE)
REMOVE OIL DIPSTICK
12. (7M-GTE)
REMOVE TURBOCHARGER
(See steps 5 to 7 and 9 to 15 on pages TC-IO-to 12):

EM-42 ENGlNE MECHANICAL .-’ Cvlinder Head
r
13. REMOVE EXHAUST MANIFOLD
(a) (7M-GTE)
Remove the five nuts and heat insulators.
(b) (7M-GTE)
Remove the three bolts and exhaust manifold stay.
(c) Remove the seven nuts, exhaust manifold and
gasket.
14. REMOVE WATER OUTLET HOUSING
(a)
(b)
(cd (7M-GE)
Remove the union bolts,. union with No.4 water by-
pass hose and gaskets.
Disconnect the No.6 water by-pass hose from the
water by-pass pipe.
Remove the bolt, two nuts, water outlet housing and
gasket.

ENGINE MECHANICAL -- Cylinder Head
I

15. REMOVE CYLINDER HEAD COVERS
(a) (LHD)
Remove the accelerator link.
(b) (MA)
Remove the heater hose clamp.
(c) Remove the No.1 and No.2 cylinder head covers.
(d) Using SST, remove the No.3 cylinder head cover.
SST 09923-00010
16. REMOVE SPARK PLUGS
(See page 16-7)
17. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS
(See steps 4 and 6 to 9 on pages’ EM-28 to 30)
18. REMOVE CYLINDER HEAD $g!!$
_I -
(a) Using SST, uniformly loosen and remove thecylinder
head bolts in several passes, in the sequence shown.
SST 09043-38100
CAUTION: Head warpage or cracking could result
from removing in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block.
(c) 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 projec-
tion.
CAUTION :
l Be careful not to damage the cylinder head and
block surface on the cylinder and head gasket side.
l Be careful not to damage the VSV.

EM2921
DISASSEMBLY OF CYLiNDER HEAD
(See pages EM-3.7,. 36)
1. REMOVE NO.2 TItiING BELT COVER
2. REMOVE ALTEPNATOR BRACKET
3. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the three bolts, and then remove the delivery
pipe with the injectors.
NOTE: When removing the delivery pipe, be careful not
to drop the injectors.
(b) Remove the six insulators and three spacers from the
cylinder head.
4. REMOVE INTAKE MANIFOLD
(w/ EGR)
Remove the four nuts, seven bolts, EGR valve, VSV, intake
manifold and gasket.
(w/o EGR)
Remove the four nuts, seven bolts, VSV, intake manifold
and gasket.
5. REMOVE NO.2 ENGINE HANGER AND GROUND
STRAP
6.
REMOVE HEATER UNION
7.
(wl EGR)
REMOVE EGR COOLER
6. REMOVE BEARING CAPS AND CAMSHAFTS
(a) Uniformly loosen and remove the bearing cap bolts in
several passes, in the sequence shown.
(b) Remove the camshaft bearing caps, oil seal and
camshaft.

ENGINE MECHANICAL - CylinderHead
:
EM:‘45;
‘N gij ggJ & gijJ &g ‘i$.
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 9. REMOVE VALVE LIFTERS WITH SHIMS ,...
Arra,nge the valve lifters and shims in order.
10. REMOVE VALVES
(a) Using SST, press the valve spring and remove the
two keepers.
SST 09202-70010
(b) Remove the-spring retainer, valve spring, seat and
valve.
(c) ‘Pry out the oil seal.
NOTE: Arrange the valves, seats, valve springs and
retainers in order.
INSPECTION, CLEANING AND REPAIR OF
CYLl.NDER HEAD COMPONENTS
1. CLEAN TOP OF; &ONS AND TOP OF CYLINDER
.BLOCk
.1.
(a) Turn the crankshaft and bring each piston to top
dead center. Using a gasket scraper, remove all the
‘carbon from the piston tops.
(b) Using a gasket scraper, remove all gasket material
from the top of the block. Blow carbon and oil from
the bolt holes.
WARNING: Protect your eyes when using high
pressure air.
2.
REMOVE GASKET MATERIAL
Using a gasket scraper, remove all gasket material from
the head and manifold surfaces.
CAUTION: Be careful not to scratch the surfaces.

EM-46 ENGINE MECHANICAL -, Cylinder Head
L
3.
EM002I
4.
/
EM2932
EM293
EM293
EM293
5.
6. CLEAN COMBUSTION CHAMBER
Using a wire.-brush, remove all the carbon from the com-
bustion chambers.
CAUTION: Be dareful not to scratch the head gasket
contact surface.
CLEAN VALVE GUIDE BUSHINGS
Using a valve guide brush and solvent, clean all the valve
guide bushings.
CLEAN CYLINDER HEAD
Using a soft brush and solvent, thoroughly clean the head.
INSPECT CYLINDER HEAD FOR FLATINESS
Using a precision straight edge and feeler gauge, measure
the surface contacting the cylinder block and manifold for
warpage.
Maximum warpage: 0.10 mm (0.0039 in.1
If warpage is greater than maximum, replace the cylinder
head.

i ’
‘
ENGINE MECHANICAL - Cylinder Head
EM-47
INSPECT CYLINDER HEAD FOR CRACKS
Using a dye penetrant, check the combustion chamber,
intake and-exhaust ports, head surface and the top of the
head for cracks.
if cracked, replace the head. 8.
9. CLEAN VALVES
(a) Use a gasket scraper to chip any carbon from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of
the valve guide.
Guide inside diameter:
6.010 - 6.030 mm
(0.2366 - 0.2374 in.)
EM2586 EM2931
(b) Using a micrometer, measure the diameter of the
valve stem.
Stem diameter:
Intake 5.970 - 5.985 mm
(0.2350 - 0.2356 in.) _
Exhaust 5.965 - 5.980 mm
(0.2348 - 0.2354 in.)
(c) Subtract the valve stem diameter measurement from
the valve guide bushing inside diameter measure-
ment.
Standard stem oil clearance:
Intake 0.025 - 0.060 mm
(0.0010 - 0.0024 in.)
Exhaust 0.030 - 0.065 mm
(0.0012 - 0.0026 in.)
Maximum stem oil clearance:
Intake 0.08 mm (0.0031 in.)
Exhaust 0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve
and guide busing.

EM-48 ENGINE MECHANICAL h Cylinder Head
Both intake and exhaust
Bushing bore mm (in.)
11.000 - 11.027
(0.433 1 - 0.4341 I Bushing size
.’ Use STD
Over 11.027
(0.434 1) Use O/S 0.05 10. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS
(a) insert an old valve wrapped with tape into the valve
guide bushing and break off the.valve guide bushing
by hitting it with a hammer.
CAUTION: Be careful.not to damage the lifter hole.
(b) Gradu
9O”C(’ .
ally heat the cylinder head to approx.
194OF).
(c) Using SST and hammer, drive out valve guide bush-
ing.
SST 09201-70010
(d) Using a caliper gauge, measure the valve guide bore
of the cylinder head.
(e) Select a new valve guide bushing.
If the valve guide bushing bore of the cylinder head is
more than 11.027 mm (0.4341 in.), machine the bore to
the following dimensions.
Rebored valve guide bushing bore dimension:
11.050 - 11.077 mm (0.4350 - 0.4381 in.1