Tercel 1995-1996

Cylinder Head

Print

Removal & Installation



3E-E Engine

Specific to:

Toyota Tercel 1995

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Remove the right side under engine splash shield. Relieve the fuel pressure on fuel injected engines.
  4.  
  5. Drain the engine coolant from the radiator.
  6.  
  7. Remove the power steering pump and bracket (if equipped).
  8.  
  9. If equipped with A/C, but not power steering, remove the idler pulley/bracket.
  10.  
  11. Disconnect the radiator hoses. Disconnect the accelerator and throttle valve cable linkage.
  12.  
  13. Remove the timing belt and camshaft timing pulley.
  14.  
  15. Disconnect the heater inlet hose. Disconnect and plug the fuel lines. On the fuel injected engine remove the pulsation damper and disconnect the fuel inlet and return hoses.
  16.  
  17. Disconnect the power brake booster vacuum line from the intake manifold.
  18.  
  19. Disconnect the water inlet hose. Disconnect the intake manifold water hose from the intake manifold.
  20.  
  21. Tag (for identification) all vacuum lines, hoses and wires or harnesses to the intake manifold and cylinder head and disconnect them.
  22.  
  23. Remove the evaporative valve and cold enrichment valve if so equipped.
  24.  
  25. Disconnect the water bypass hoses from the carburetor if so equipped.
  26.  
  27. Disconnect the exhaust pipe from the exhaust manifold.
  28.  
  29. Remove the intake manifold stay bracket and ground strap. Remove the engine wire harness bracket clamp from the intake manifold.
  30.  
  31. Remove the cylinder head cover.
  32.  
  33. Loosen and remove the head mounting bolts gradually in three passes working from the ends of the cylinder head inward.
  34.  
  35. Lift the head straight up from the engine block.
  36.  
  37. Clean all gasket surfaces.
  38.  
  39. Service as necessary. Install in the reverse order of removal. Install a new cylinder head gasket. Torque the cylinder head mounting bolts in three progressive steps. Torque to 22 ft. lbs. (30 Nm) in the first pass. 36 ft. lbs. (49 Nm) in the second pass, and finally for the third pass, tighten the head bolts an additional 90° from the second pass. Tighten the bolts in sequence from the center of the head outwards (refer to the torque sequence illustration).
  40.  
  41. Adjust the valves by turning the crankshaft pulley until the groove in the pulley is aligned with the 0 mark on the timing belt cover. Check that No. 1 cylinder rocker arms are loose and No. 4 rocker arms are tight. If not, turn the engine one complete revolution and align the marks again. Adjust the valves to correct specifications. Turn one complete revolution and adjust the remaining valves. Complete installation, start the engine and check ignition timing. Road test for proper operation.
  42.  

5e-FE Engine

Specific to:

Toyota Tercel 1996

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding.
  2.  
  3. Relieve the fuel pressure.
  4.  
  5. Remove the right engine undercover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect the front exhaust pipe from the exhaust manifold by removing the two bolts and two compression springs.
  10.  
  11. Disconnect the accelerator and on vehicles equipped with automatic transmissions, disconnect the throttle cable.
  12.  
  13. Remove the air cleaner and air intake collector assembly.
  14.  
  15. Disconnect the fuel inlet and return hoses from the delivery pipe. Plug the hoses to prevent fuel leakage.
  16.  
  17. If equipped with power steering, remove the power steering pump and bracket. Do not disconnect the power steering hoses. Set and safely support the power steering pump aside.
  18.  
  19. Remove the ignition coils, spark plug wires, and spark plugs. Make sure to mark the position of the spark plug wires.
  20.  
  21. Tag and disconnect all electrical wire and vacuum hoses that interfere with removal of the cylinder head.
  22.  
  23. Remove the EGR pipe, EGR valve, and vacuum modulator.
  24.  
  25. Disconnect the radiator, water inlet and heater hoses.
  26.  
  27. Remove the water inlet and outlet housing.
  28.  
  29. Remove the throttle body assembly.
  30.  
  31. Remove the exhaust manifold.
  32.  
  33. Remove the fuel rail and injector assembly.
  34.  
  35. Remove the intake manifold.
  36.  
  37. Remove the valve cover.
  38.  
  39. Remove the No. 2 timing belt cover by removing the 4 bolts.
  40.  
  41. Remove the alternator belt, then the No. 3 timing belt cover from the No. 1 timing belt cover.
  42.  
  43. Turn the crankshaft pulley and align its groove with the timing mark 0 on the No. 1 timing belt cover.
  44.  
  45. Check that the hole of the camshaft timing pulley on the side with the 5E-FE mark is aligned with the timing mark on the No. 1 bearing cap. If the marks do not line up, turn the crankshaft pulley one (1) revolution and check marks.
  46.  
  47. Place matchmarks on the timing belt, loosen the No. 1 idler pulley and carefully remove the belt.
  48.  
  49. Remove the No. 2 idler pulley.
    NOTE
    Keep tension on the belt so it does not shift position and do not allow the crankshaft to rotate. This includes allowing the vehicle to roll while in gear. Do not allow anything to drop inside the belt cover, including dirt. The belt can be damaged. Do not let the belt come into contact with water, oil or grease.

  50.  
  51. Remove the camshaft timing pulley.
  52.  
  53. Remove the camshafts following the proper sequences and procedures.
  54.  
  55. Loosen the cylinder head bolts in several passes and in the reverse order of the installation sequence.
  56.  
  57. Remove the cylinder head from the engine. There are two different bolt lengths. Make note of there positions and replace the cylinder bolts in their original position.
    WARNING
    Failure to loosen the bolts as described can result in cylinder head warpage or cracking.

  58.  

To install:

  1. Clean the gasket mating surfaces using care not to damage the aluminum components, replace the gasket, then lower the cylinder head onto the engine. Make sure the dowel pins are aligned and no hoses or wires are between the head and cylinder block.
    NOTE
    The head bolts stretch and must be replaced once removed.

  2.  
  3. Lightly oil and place the 2 different size head bolts in their correct positions and tighten them in several passes in the proper sequence, evenly until arriving at a torque of 33 ft. lbs. (44 Nm).

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-5E-FE engine

  4.  
  5. Mark each bolt with a reference mark and tighten each bolt in sequence an additional 90 degrees.

    Click image to see an enlarged view

    Fig. Tightening head bolts-5E-FE engine

  6.  
  7. Install the camshafts following the proper sequences and procedures.
  8.  
  9. Install the camshaft timing pulley in its original position and torque the bolt to 37 ft. lbs. (50 Nm).
  10.  
  11. Install the No. 2 idler pulley, tightening the bolt to 20 ft. lbs. (27 Nm).
  12.  
  13. Install the timing belt on the matchmarks and tension it properly.
  14.  
  15. Install the No. 3 timing belt cover, the alternator belt and the No. 2 timing belt cover with its gasket and 4 bolts.
  16.  
  17. Install the valve cover with the proper gasket and sealer and torque the nuts to 61 inch lbs. (7 Nm).
  18.  
  19. Install the intake manifold and torque the nuts and bolts evenly to 14 ft. lbs. (19 Nm).
  20.  
  21. Install the intake manifold stay with the bolt and nut. Torque the nut and bolt to 15 ft. lbs. (20 Nm).
  22.  
  23. Install the MAP sensor vacuum line and the brake booster.
  24.  
  25. Install the fuel injector rail assembly, using new grommets and O-rings. Lightly lubricate the O-rings with gasoline and check that the injectors can be rotated smoothly once pressed in.
  26.  
  27. Using a new gasket, install the exhaust manifold to the engine. Evenly tighten the nuts in several passes and then torque each nut to 35 ft. lbs. (48 Nm).
  28.  
  29. Place the exhaust manifold stay on the engine and exhaust manifold. Tighten the bolt and then the two (2) nuts to 29 ft. lbs. (40 Nm).
  30.  
  31. Install the exhaust manifold heat insulator with the three bolts and torque to 69 inch lbs. (8 Nm).
  32.  
  33. Install the water inlet and outlet housings.
  34.  
  35. Connect the radiator, heating and water inlet hoses.
  36.  
  37. Install the EGR valve, and vacuum modulator. Torque the EGR bolts to 13 ft. lbs. (18 Nm).
  38.  
  39. Install the EGR pipe and torque the union nut to 29 ft. lbs. (40 Nm) and the two nuts to 22 ft. lbs. (30 Nm).
  40.  
  41. Install the throttle body.
  42.  
  43. Reconnect all remaining electrical and vacuum hose fittings.
  44.  
  45. Install the ignition coils and spark plugs.
  46.  
  47. Install the power steering pump bracket. Torque the three bolts to 32 ft. lbs. (43 Nm). Install the power steering belt and adjust the belt.
  48.  
  49. Connect the fuel return hose and the union bolt for the fuel inlet hose. Torque the union bolt to 22 ft. lbs. (29 Nm).
  50.  
  51. Install the air cleaner assembly with the air intake connector.
  52.  
  53. Install and adjust the accelerator cable.
  54.  
  55. If equipped with A/T, install and adjust the throttle cable.
  56.  
  57. Using a new gasket, install the exhaust pipe using two springs and two bolts. Torque the bolts to 46 ft. lbs. (62 Nm).
  58.  
  59. Install the right-hand engine undercover.
  60.  
  61. Connect the battery cable, refill all fluids, and start the engine. Check the ignition timing and check for engine leaks.
  62.  

 
label.common.footer.alt.autozoneLogo