Toyota Celica 1986-1993 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION




WARNING
Make sure all wires, hoses, vacuum lines, brackets and bolts are marked to simplify installation. When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old. Use the loosening and torque sequences to avoid warping or cracking components.


CAUTION
On models with an air bag, wait at least 30 seconds from the time that the ignition switch is turned to the lock position and the battery is disconnected before performing any further work. Wear eye protection and use a shop towel and pan to catch spilling fuel when releasing the fuel pressure.

2S-E Engine
  1. Disconnect the battery ground.
  2.  
  3. Drain the coolant.
  4.  
  5. Disconnect the throttle cable.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Disconnect and tag all wires connected to or running across the head.
  10.  
  11. Disconnect and tag all vacuum hoses connected to or running across the head.
  12.  
  13. Remove the vacuum pipe from the head cover.
  14.  
  15. Disconnect and tag any remaining cables.
  16.  
  17. Remove the alternator.
  18.  
  19. Mark and remove the distributor.
  20.  
  21. Remove the upper radiator hose and bypass hose.
  22.  
  23. Unbolt and remove the water outlet housing.
  24.  
  25. Disconnect the heater hoses.
  26.  



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Fig. Fig. 1 Removing the cylinder head2S-E engine



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Fig. Fig. 2 Camshaft housing bolt removal sequence2S-E engine

  1. Disconnect the two air hoses from the fuel injection air valve.
  2.  
  3. Unbolt and remove the rear end housing.
  4.  



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Fig. Fig. 3 Cylinder head bolt removal sequence2S-E engine



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Fig. Fig. 4 Cylinder head bolt installation sequence2S-E engine

  1. Remove the heater pipe.
  2.  
  3. Disconnect the fuel line at the filter and the fuel return line at the return pipe. Use eye protection and use a shop towel and container to catch spilling fuel.
  4.  
  5. Raise and support the car on jackstands.
  6.  
  7. Drain the engine oil.
  8.  
  9. Disconnect the exhaust pipe at the manifold.
  10.  
  11. Disconnect the power steering pump hoses.
  12.  
  13. Remove the intake manifold stay.
  14.  



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Fig. Fig. 5 Camshaft housing bolt installation sequence2S-E engine



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Fig. Fig. 6 Adding engine oil after a repair. Do NOT ruin a good job by forgetting to add oil.

  1. Lower the car.
  2.  
  3. Remove the timing belt.
  4.  
  5. Remove the No. 1 idler pulley and tension spring.
  6.  
  7. Remove the throttle body.
  8.  
  9. Remove the valve cover.
  10.  
  11. Unbolt and remove the camshaft housing. Loosen the bolts gradually in the order shown.
  12.  
  13. Remove the rocker arms and lash adjusters.
  14.  
  15. Loosen and remove the head bolts, in three passes in the order shown. Lift the head from the engine and place it on wood blocks in a clean work area.
  16.  

To Install:

  1. Installation is the reverse of removal. Refer to the "Torque Specifications Chart" as required. Note the following points:
    1. Always use a new head gasket.
    2.  
    3. Tighten the head bolts, in three passes, in the order shown, to 47 ft. lbs. (64 Nm).
    4.  
    5. When installing the camshaft housing, note that rtv silicone gasket compound is used in place of a gasket. Run a 2mm bead of compound around the sealing surface of the housing. Torque the housing bolts, in three passes, in the order shown, to 11 ft. lbs. (15 Nm).
    6.  
    7. Torque the fuel line connections to 22 ft. lbs. (29 Nm).
    8.  
    9. Recheck fluid levels, perform engine adjustments and road test the car.
    10.  

  2.  

3S-GE And 3S-GTE Engines
  1. Disconnect the cable at the negative terminal of the battery.
  2.  
  3. Drain the engine coolant. On the 1988-89 3S-GTE engine drain the intercooler coolant.
  4.  
  5. Tag and disconnect the ignition coil connector and the spark plug wire at the ignition coil. Remove the upper suspension brace. Remove the intercooler, if necessary for clearance.
  6.  
  7. On models with at, disconnect the throttle cable with its bracket from the throttle body.
  8.  
  9. Disconnect the accelerator cable from the throttle body.
  10.  
  11. Remove the radiator overflow tank.
  12.  
  13. Remove the cruise control actuator and its bracket.
  14.  
  15. Disconnect the air flow meter connector. Remove the air cleaner cap clips. Loosen the hose clamp and remove the air cleaner hose and the air flow meter along with the air cleaner top. Lift out the filter element and then remove the air cleaner case.
  16.  
  17. Tag and disconnect the oxygen sensor lead. Remove the exhaust manifold heat insulator and disconnect or remove the front exhaust pipe.
  18.  
  19. Remove the alternator and its main bracket.
  20.  
  21. Raise the front of the vehicle and support it with safety stands. Remove the right front wheel.
  22.  
  23. Remove the right side engine under cover and remove the lower suspension crossmember.
  24.  
  25. On the 3S-GTE engine remove the turbocharger assembly and catalytic converter attaching exhaust clamps.
  26.  
  27. Remove the exhaust manifold stay and the EGR pipe. Unbolt the manifold and remove it along with the lower heat insulator.
  28.  
  29. Remove the distributor.
  30.  
  31. Tag and disconnect the oil pressure switch connector.
  32.  
  33. Tag and disconnect all electrical leads and vacuum hoses at the water outlet. Remove the upper radiator hoses, the heater outlet hose and the water bypass hose. Remove the water outlet.
  34.  
  35. Disconnect the heater inlet hose and the water bypass hose and then remove the water bypass pipe.
  36.  
  37. Disconnect the throttle position sensor lead, the ventilation hose, the air valve hose and any emission control vacuum hoses at the throttle body. Remove the four bolts and lift out the throttle body.
  38.  
  39. Remove the forward engine hanger and the No. 2 intake manifold stay.
  40.  
  41. Remove the EGR vacuum modulator.
  42.  
  43. Tag and disconnect any remaining vacuum hoses which may interfere with cylinder head removal.
  44.  
  45. Tag and disconnect the fuel injector electrical leads at the injector.
  46.  
  47. Disconnect the fuel inlet hose at the fuel filter. Disconnect the fuel return hose at the return pipe.
  48.  
  49. Remove the No. 1 and No. 3 intake manifold stays.
  50.  
  51. Tag and disconnect the two VSV connectors. Disconnect the two power steering vacuum hoses.
  52.  
  53. Remove the intake manifold and the air control valve.
  54.  
  55. Remove the fuel delivery pipe with the injectors attached. Pull the four injector insulators out of the injector holes in the cylinder head.
  56.  
  57. Remove the cylinder head cover. Remove the spark plugs.
  58.  
  59. Remove the No. 1 engine hanger.
  60.  
  61. Remove the power steering reservoir and position it out of the way with the hydraulic lines still attached.
  62.  
  63. Remove the camshaft timing pulleys. Remove the No. 1 idler pulley and tension spring.
  64.  
  65. Remove the bolt holding the No. 2 and No. 3 timing covers. Remove the four mounting bolts and remove the No. 3 timing cover.
  66.  
  67. Loosen and remove the camshaft bearing caps, in several stages, in the order shown. Lift out the camshafts and the oil seal.
  68.  


WARNING
When removing the camshaft bearing caps, keep them in the proper order.

  1. Loosen and remove the cylinder head bolts in several stages with the proper socket tool, in the order shown. Remove the cylinder head.
  2.  

To Install:

  1. To install position the cylinder head onto the cylinder block with a new gasket. Lightly coat the cylinder head bolts with engine oil. Install them into the head and tighten them in several passes, in the sequence shown and to the following torque:

    3S-GE engine: 40 ft. lbs. (53 Nm).
     
    1988-89 3S-GTE engine: 40 ft. lbs. (53 Nm), plus an additional 90 degrees.
     
    1990-93 3S-GTE engine: 36 ft. lbs. (49 Nm), plus an additional 90 degrees.
     

  2.  


WARNING
On the 3S-GTE engine, place paint marks on the bolts right before tightening the additional 90 degrees to keep track of the angle tightened.



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Fig. Fig. 7 Removing the cylinder head3S-GE engine



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Fig. Fig. 8 Removing the cylinder head1988-89 3S-GTE engine

  1. Position the camshafts into the cylinder head so that the No. 1 cam lobes are facing outward.
  2.  



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Fig. Fig. 9 Removing the cylinder head1990-93 3S-GTE engine



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Fig. Fig. 1 0Removing the cylinder head1990-93 3S-GTE engine

  1. Apply silicone sealant to the outer edge of the mating surface on the No. 1 bearing cap only. Position the bearing caps over each journal with the arrows pointing forward and the proper order from the front to the rear.
  2.  



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Fig. Fig. 1 1Camshaft bolt removal sequence3S-GE and 3S-GTE engines



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Fig. Fig. 1 2Cylinder head bolt removal sequence3S-GE and 3S-GTE engines

  1. Lightly coat the cap bolt threads with engine oil.
  2.  
  3. Tighten them in several stages, in the sequence shown, to 14 ft. lbs. (19 Nm).
  4.  



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Fig. Fig. 1 3Cylinder head bolt removal using special socket tool3S-GE and 3S-GTE engines shown



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Fig. Fig. 1 4Cylinder head bolt installation sequence3S-GE and 3S-GTE engines



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Fig. Fig. 1 5Camshaft bolt installation sequence3S-GE and 3S-GTE engines

  1. Coat the inside of a new oil seal with grease and carefully tap it onto the camshaft with a drift (sst No. 09223-50010) or equivalent.
  2.  
  3. Install the No. 3 timing belt cover.
  4.  
  5. Connect the idler pulley tension spring to the pulley and the pin on the cylinder head. Install the idler pulley onto the pivot pin, force it to the left as far as it will go and tighten it. Make sure that the tension spring is not out of groove in the pin.
  6.  
  7. Install the camshaft timing pulleys and the timing belt, using the proper procedures.
  8.  
  9. Installation of the remaining components is in the reverse order of removal. Tighten the lower suspension crossmember end bolts to 154 ft. lbs. (208 Nm) and the center bolt to 29 ft. lbs. (39 Nm). Tighten the upper suspension brace bolts to 15 ft. lbs. (20 Nm) and the nuts to 47 ft. lbs. (64 Nm). Refill the engine with coolant an check the idle speed and ignition timing. Road test the vehicle for proper operation.
  10.  

3S-FE And 5S-FE Engines


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Fig. Fig. 1 6Removing the cylinder head1990-93 3S-GTE engine



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Fig. Fig. 1 7Removing the cylinder head5S-FE engine

  1. Disconnect the negative battery cable. Drain the coolant.
  2.  



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Fig. Fig. 1 8Removing exhaust camshaft3S-FE and 5S-FE engines



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Fig. Fig. 1 9Removing intake camshaft3S-FE and 5S-FE engines

  1. If equipped with automatic transmission, disconnect the throttle cable and bracket from the throttle body.
  2.  



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Fig. Fig. 2 0Securing the exhaust camshaft sub gear to main gear with service bolt3S-FE and 5S-FE engines



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Fig. Fig. 2 1Cylinder head bolt removal using special socket tool3S-FE and 5S-FE engines shown

  1. Disconnect the accelerator cable and bracket from the throttle body and intake chamber.
  2.  



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Fig. Fig. 2 2Cylinder head bolt removal sequence3S-FE and 5S-FE engines



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Fig. Fig. 2 3Cylinder head bolt installation sequence3S-FE and 5S-FE engines



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Fig. Fig. 2 4Installing exhaust camshaft gear to intake camshaft gear by matching timing marks3S-FE and 5S-FE engines

  1. If equipped with cruise control, remove the actuator and bracket. Remove the air cleaner hose. Remove the alternator.
  2.  



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Fig. Fig. 2 5Intake camshaft bearing cap bolt torque sequence3S-FE and 5S-FE engines



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Fig. Fig. 2 6Exhaust camshaft bearing cap bolt torque sequence3S-FE and 5S-FE engines

  1. On the 5S-FE engine remove the air conditioning compressor as required, without disconnecting the hoses. Remove the oil pressure gauge, engine hangers and alternator upper bracket.
  2.  
  3. Raise and support the vehicle safely. Remove the right tire and wheel assembly.
  4.  
  5. Remove the right under cover. Remove the suspension lower crossmember. Disconnect the exhaust pipe from the catalytic converter. Separate the exhaust pipe from the catalytic converter.
  6.  
  7. Disconnect the water temperature sender gauge connector, water temperature sensor connector, cold start injector time switch connector, upper radiator hose, water hoses, and the emission control vacuum hoses.
  8.  
  9. Remove the water outlet and gaskets. Remove the distributor. Remove the water bypass pipe. Remove the EGR valve and modulator.
  10.  
  11. Remove the throttle body assembly. Remove the cold start injector pipe. Remove the air intake chamber air hose, the throttle body air hose, and the power steering pump hoses, if equipped. Remove the air tube.
  12.  
  13. Remove the intake manifold retaining bolts. Remove the intake manifold. Remove the fuel delivery pipe and the injectors. Remove the spark plugs.
  14.  
  15. Remove the camshaft timing pulley. Remove the No. 1 idler pulley and tension spring. Remove the No. 3 timing belt cover. Properly support the timing belt so that meshing of the crankshaft timing pulley does not occur and the timing belt does not shift.
  16.  
  17. Remove the valve cover. Arrange the grommets in order so that they can be reinstalled in the correct order.
  18.  
  19. To remove the exhaust camshaft, set the knock pin of the exhaust camshaft at 10-45° BTDC of camshaft angle. This angle will help to lift the exhaust camshaft level and evenly by pushing No. 2 and No. 4 cylinder camshaft lobes of the exhaust camshaft toward their valve lifters.
  20.  
  21. Secure the exhaust camshaft sub gear to the main gear with a 16-20mm x 6mm x 1mm bolt. When removing the exhaust camshaft be sure that the torsional spring force of the sub gear has been eliminated.
  22.  
  23. Remove the No. 1 and No. 2 rear bearing cap bolts and remove the cap. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several phases and in the proper sequence. Do NOT remove bearing cap (No. 3) bolts No. 9 and 10 at this time. Remove No. 1, 2, and 4 bearing caps.
  24.  
  25. Alternately loosen and remove bearing cap (No. 3) bolts No. 9 and 10. As these bolts are loosened check to see that the camshaft is being lifted out straight and level.
  26.  


WARNING
If the camshaft is not lifting out straight and level retighten No. 9 and 10 bearing cap (No. 3) bolts. Reverse Steps 16 through 14, than start over from Step 14. Do NOT attempt to pry the camshaft from its mounting.

  1. Remove the exhaust camshaft from the engine.
  2.  
  3. To remove the intake camshaft, set the knock pin of the intake camshaft at 80-115° BTDC of camshaft angle. This angle will help to lift the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the intake camshaft toward their valve lifters.
  4.  
  5. Remove the No. 1 and No. 2 rear bearing cap bolts and remove the front bearing cap and oil seal. If the cap will not come apart easily, leave it in place without the bolts.
  6.  
  7. Uniformly loosen and remove bearing cap bolts No. 3 to No. 8 in several phases and in the proper sequence. Do NOT remove bearing cap (No. 2) bolts No. 9 and 10 at this time. Remove No. 1, 3, and 4 bearing caps.
  8.  
  9. Alternately loosen and remove bearing cap (No. 2) bolts No. 9 and 10. As these bolts are loosened and after breaking the adhesion on the front bearing cap, check to see that the camshaft is being lifted out straight and level.
  10.  


WARNING
If the camshaft is not lifting out straight and level retighten No. 9 and 10 bearing cap bolts. Reverse Steps 22 through 19, than start over from Step 19. Do NOT attempt to pry the camshaft from its mounting.

  1. Remove the intake camshaft from the engine.
  2.  
  3. Loosen then remove the cylinder head bolts in three phases and in the proper sequence. Remove the cylinder head from the engine.
  4.  

To Install:

  1. Install the cylinder head gasket on the cylinder head block. Place the cylinder head in position on the cylinder head gasket.
  2.  
  3. Be sure to use a new head gasket. Apply a light coat of clean engine oil to the threads of the head bolts before installation. Torque the cylinder head bolts to specification and in three phases:

    3S-FE engine: 47 ft. lbs. (64 Nm).
     
    5S-FE engine: 36 ft. lbs. (49 Nm), plus an additional 90 degrees.
     

  4.  


WARNING
On the 5S-FE engine, place paint marks on the bolts right before tightening the additional 90 degrees to keep track of the angle tightened.

  1. Before installing the intake camshaft, apply multi purpose grease to the thrust portion of the camshaft. Position the camshaft at 80-115° BTDC of camshaft angle on the cylinder head. Apply seal packing kit 08826-00080, or equivalent, to the front bearing cap. Coat the bearing cap bolts with clean engine oil. Uniformly (bearing caps in the correct location) and in several phases tighten the camshaft bearing caps to 14 ft. lbs. (19 Nm).
  2.  
  3. To install the exhaust camshaft, set the knock pin of the camshaft at 10-45° BTDC of camshaft angle. Apply multipurpose grease to the thrust portion of the camshaft. Position the exhaust camshaft gear with the intake camshaft gear so that the timing marks are in alignment with one another. Be sure to use the proper alignment marks on the gears. Do NOT use the assembly reference marks.
  4.  
  5. Turn the intake camshaft clockwise or counterclockwise little by little until the exhaust camshaft sits in the bearing journals evenly without rocking the camshaft on the bearing journals.
  6.  
  7. Coat the bearing cap bolts with clean engine oil. Uniformly (bearing caps in the correct location) and in several phases tighten the camshaft bearing caps to 14 ft. lbs. (19 Nm). Remove the service bolt from the assembly.
  8.  
  9. Check and adjust the valve clearance as necessary.
  10.  
  11. Install the timing pulley, intake and exhaust manifold assemblies and all necessary components that were removed, using the proper procedures.
  12.  
  13. Install the cylinder head cover with new gasket and semi-circular plugs in the correct position.
  14.  
  15. Install or reconnect all vacuum hoses, lines, water hoses, electrical connections.
  16.  
  17. Fill engine the specified coolant to the correct level. Start the engine and check for leaks. Adjust ignition timing.
  18.  
  19. Check for abnormal noise, shock, slippage, correct shift points and smooth operation. Recheck all fluid levels.
  20.  

4A-FE Engine
  1. Disconnect the negative battery cable. Drain the coolant.
  2.  



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Fig. Fig. 2 7Removing the cylinder head4A-FE engine



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Fig. Fig. 2 8Cylinder head bolt removal sequence4A-FE engine

  1. If equipped with automatic transmission, disconnect the throttle cable and bracket from the throttle body.
  2.  
  3. Disconnect the accelerator cable and bracket from the throttle body.
  4.  
  5. Remove the air cleaner cap and hose.
  6.  



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Fig. Fig. 2 9Cylinder head bolt installation sequence. Make sure the bolts go in their original positions4A-FE engine

  1. Remove the engine under covers. Remove the suspension lower crossmember.
  2.  
  3. Disconnect the front exhaust pipe. Remove the distributor.
  4.  
  5. Remove the water outlet and gaskets. Remove the water inlet and inlet housing.
  6.  



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Fig. Fig. 3 0Exhaust camshaft bearing cap bolt torque sequence4A-FE engine



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Fig. Fig. 3 1Matching intake and exhaust camshaft gear timing marks. There are also timing marks (for TDC) on each gear. Do NOT use these marks4A-FE engine

  1. Disconnect the water temperature sender gauge connector, water temperature sensor connector, cold start injector time switch connector, radiator hose, water hoses, and the emission control vacuum hoses.
  2.  
  3. Disconnect all vacuum hoses. Remove the P/S pump without disconnecting hoses.
  4.  
  5. Remove the throttle body assembly. Remove the cold start injector pipe. Remove the cold start injector, delivery pipe and fuel injectors.
  6.  
  7. Remove the ACV assembly. Disconnect engine wiring from the timing belt cover and from the intake manifold.
  8.  
  9. Remove the vacuum pipe, EGR vacuum modulator and EGR VSV assembly.
  10.  
  11. Remove the EGR valve and gasket. Remove the water inlet pipe and fuel return hose from the fuel filter.
  12.  
  13. Remove the intake manifold assembly with retaining manifold stay (bracket).
  14.  
  15. Remove the valve cover. Arrange the grommets in order so that they can be reinstalled in the correct order.
  16.  
  17. Remove the camshaft timing pulley. Remove the No. 1 idler pulley and tension spring. Remove the No. 3 timing belt cover. Properly support the timing belt so that meshing of the crankshaft timing pulley does not occur and the timing belt does not shift.
  18.  
  19. Remove the fan belt adjusting bar (bracket), engine hangers and power steering drive belt adjusting strut or bracket.
  20.  
  21. Remove the intake camshaft, set the knock pin of the intake camshaft so it is slightly above the top of the cylinder head. This angle will help to lift the intake camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the camshaft toward their valve lifters.
  22.  
  23. Remove the bearing cap bolts and remove the front bearing cap.
  24.  
  25. Secure the intake camshaft sub gear to the main gear with a 16-20mm x 6mm x 1mm bolt. When removing the camshaft be sure that the torsional spring force of the sub gear has been eliminated.
  26.  
  27. Uniformly loosen and remove bearing cap bolts in several phases and in the proper sequence. Remove bearing caps and camshaft.
  28.  
  29. Remove the exhaust camshaft, set the knock pin of the exhaust camshaft so it is slightly counterclockwise from the vertical axis of the camshaft. This angle will help to lift the camshaft level and evenly by pushing No. 1 and No. 3 cylinder camshaft lobes of the camshaft toward their valve lifters.
  30.  
  31. Remove the bearing cap bolts and remove the front bearing cap and oil seal.
  32.  
  33. Uniformly loosen and remove bearing cap bolts in several phases and in the proper sequence. Remove bearing caps and camshaft.
  34.  
  35. Loosen then remove the cylinder head bolts in three phases and in the proper sequence. Remove the cylinder head from the engine (cylinder head mounted on dowel pins-head bolts are different sizes; note location).
  36.  

To Install:

  1. Install the cylinder head on the cylinder head block. Place the cylinder head in position on the cylinder head gasket.
  2.  
  3. Be sure to use a new head gasket. Apply a light coat of clean engine oil to the threads of the head bolts before installation. Torque the cylinder head bolts to 44 ft. lbs. (60 Nm) in three phases.
  4.  
  5. Before installing the exhaust camshaft, apply multi purpose grease to the thrust portion of the camshaft. Position the camshaft so the knock pin is located slightly counterclockwise from the vertical axis of the camshaft. Apply seal packing kit 08826-00080 or equivalent and apply it to the front bearing cap. Coat the bearing cap bolts with clean engine oil. Uniformly (bearing caps in the correct location) and in several phases tighten the camshaft bearing caps to 9 ft. lbs. (13 Nm). Install camshaft oil seal
  6.  
  7. To install the intake camshaft, set the knock pin of the camshaft slightly above the top of the cylinder head. Apply multipurpose grease to the thrust portion of the camshaft. Position the intake camshaft gear with the exhaust camshaft gear so that the assembly or installation marks are in alignment (side by side) with one another. Be sure to use the proper alignment or installation marks on the gears. Do NOT use the timing marks.
  8.  
  9. Turn the camshaft clockwise or counterclockwise little by little until the camshaft sits in the bearing journals evenly. Coat the bearing cap bolts with clean engine oil. Uniformly (bearing caps in the correct location) and in several phases tighten the camshaft bearing caps to 9 ft. lbs. (13 Nm). Remove the service bolt from the assembly.
  10.  
  11. Turn the exhaust camshaft clockwise and set it with knock pin facing upward. Check that the timing marks of the camshaft gears are aligned in the correct position. The assembly installation marks are straight up and the timing marks are side by side.
  12.  
  13. Check and adjust the valve clearance as necessary.
  14.  
  15. Install the timing pulley, timing belt, intake and exhaust manifold assemblies and all necessary components that were removed, using the proper procedures.
  16.  
  17. Install the cylinder head cover with new gasket and semi-circular plugs in the correct position.
  18.  
  19. Install the fan belt adjusting bar (bracket), engine hangers and power steering drive belt adjusting strut or bracket.
  20.  
  21. Install or reconnect all vacuum hoses, lines, water hoses, electrical connections.
  22.  
  23. Fill engine the specified coolant to the correct level. Start the engine and check for leaks. Adjust ignition timing.
  24.  
  25. Check for abnormal noise and smooth operation. Recheck all fluid levels.
  26.  

CLEANING & INSPECTION



When the rocker assembly and valve train have been removed from the cylinder head (see Valves and Springs below), set the cylinder head on two wooden blocks on the bench, combustion chamber side up. Using a scraper or putty knife, carefully scrape away any gasket material that may have stuck to the head-to-block mating surface when the head was removed. Make sure you do NOT gouge the mating surface with the tool.

Using a wire brush chucked into your electric drill, remove the carbon in each combustion chamber. Make sure the brush is actually removing the carbon and not merely burnishing it. Clean all the valve guides using a valve guide brush (available at most auto parts or auto tool shops) and solvent. A fine-bristled rifle bore cleaning brush also works here. Inspect the threads of each spark plug hole by screwing a plug into each, making sure it screws down completely. Heli-Coil® any plug hole that is damaged.


WARNING
Do NOT hot tank the cylinder head! The head material on most engines is aluminum, which is ruined if subjected to the hot tank solution.



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Fig. Fig. 3 2Using wire brush for combustion chamber carbon removalCelica

Finally, go over the entire head with a clean shop rag soaked in solvent to remove any grit, old gasket particles, etc. Blow out the bolt holes, coolant galleys, intake and exhaust ports, valve guides and plug holes with compressed air. Then, check for cracks using a dye penetrant. If cracked, replace the cylinder head.

RESURFACING



If the cylinder head is warped beyond a certain limit, the cylinder head must be replaced, not resurfaced. While the head is removed, check the head-to-block mating surface for straightness. If the engine has overheated and blown a head gasket, this must be done as a matter of course.

Using a precision steel straightedge and a blade-type feeler gauge, check the surface of the head across its length, width and diagonal length as shown in the illustrations. Also check the intake and exhaust manifold mating surfaces and the camshaft housing surface on the 2S-E engine. Compare the cylinder head warpage to the following maximum specifications:



Block side, 2S-E engine: 0.0020 inch (0.05mm).
 
Camshaft housing side, 2S-E engine: 0.0020 inch (0.05mm).
 
Manifold side, 2S-E engine: 0.0031 inch (0.08mm).
 
Block side, 3S-GE engine: 0.0080 inch (0.20mm).
 
Intake manifold side, 3S-GE engine: 0.0080 inch (0.20mm).
 
Exhaust manifold side, 3S-GE engine: 0.0120 inch (0.30mm).
 
Block side, 3S-FE engine: 0.0020 inch (0.05mm).
 
Manifold side, 3S-FE engine: 0.0031 inch (0.08mm).
 
Block side, 4A-FE engine: 0.0020 inch (0.05mm).
 
Manifold side, 4A-FE engine: 0.0039 inch (0.10mm).
 
Block side, 3S-GTE engine: 0.0079 inch (0.20mm).
 
T-vis valve side, 3S-GTE engine: 0.0079 inch (0.20mm).
 
Exhaust manifold side, 3S-GTE engine: 0.0118 inch (0.30mm).
 
Block side, 5S-FE engine: 0.0020 inch (0.05mm).
 
Manifold side, 5S-FE engine: 0.0031 inch (0.08mm).
 



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Fig. Fig. 3 3Checking the cylinder head for warpage2S-E engine



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Fig. Fig. 3 4Checking the cylinder head for warpage3S-GE engine



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Fig. Fig. 3 5Checking the cylinder head for warpage3S-FE engine



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Fig. Fig. 3 6Checking the cylinder head for warpage4A-FE engine



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Fig. Fig. 3 7Checking the cylinder head for warpage3S-GTE engine



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Fig. Fig. 3 8Checking the cylinder head for warpage5S-FE engine

 
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