Toyota Celica 1994-1998 Repair Guide

Cylinder Head

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REMOVAL & INSTALLATION



5S-FE Engine

See Figures 1 through 10



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Fig. Fig. 1: Exploded view of the cylinder head removal components-5S-FE engine



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Fig. Fig. 2: Exploded view of the cylinder head removal components-5S-FE engine (continued)



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Fig. Fig. 3: Exploded view of the cylinder head removal components-5S-FE engine (continued)



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Fig. Fig. 4: Exploded view of the cylinder head removal components-5S-FE engine (continued)

  1. Release the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding to hinder air bag deployment.
  4.  


CAUTION
Work must be started after 90 seconds from the time the ignition switch is turned to theLOCKposition and the negative battery cable has been disconnected. The SRS is equipped with a back-up power source so that if work is started within 90 seconds of disconnecting the negative battery cable, the SRS may deploy. When the negative terminal cable is disconnected from the battery, memory of the clock and radio will be canceled. Before you start working, make a note of the contents memorized by the audio memory system. When you have finished working, reset the audio systems and adjust the clock. Never use a back-up power supply from outside the vehicle.

  1. Drain the engine coolant into a suitable container.
  2.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old.

  1. Remove the air cleaner and cap assembly.
  2.  
  3. On all models except the 1994-95 non-California models, remove the distributor.
  4.  
  5. Remove the alternator.
  6.  
  7. Remove the front exhaust pipe.
  8.  
  9. Remove the exhaust manifold and front TWC.
  10.  
  11. Unbolt and extract the two O2 sensors from the manifold and TWC.
  12.  
  13. Spearate the exhaust manifold from the TWC.
  14.  
  15. Disconnect the oil pressure switch wiring/.
  16.  
  17. Remove the water outlet. Label and disconnect all wring associated.
  18.  
  19. Remove the water bypass pipe.
  20.  
  21. Remove the throttle body.
  22.  
  23. Disconnect the MAP sensor vacuum hose from the gas filter on the manifold. Remove the brake booster vacuum hose from the intake manifold.
  24.  
  25. Remvoe the EGR valve and vacuum modulator.
  26.  
  27. Remove the intake manifold stay.
  28.  
  29. Disconnect the automatic transaxle control cable from the intake manifold.
  30.  
  31. Remove the air tube. Label all hoses attached to the pipe.
  32.  
  33. Disconnect the knock sensor 1 wiring. Disconnect the ground wires. Be sure to label all the wires.
  34.  
  35. Remvoe the VSV for the EGR.
  36.  
  37. Disconnect the PCV hose from the intake manifold.
  38.  
  39. Disconnect the accelerator, automatic throttle control cables and bracket from the intake manifold and clamps.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Remove the union bolt and 2 gaskets, then disconnect the fuel inlet hose from the delivery pipe.
  44.  
  45. Disocnnect the fuel return hose from the return pipe.
  46.  
  47. Remove the intake manifold.
  48.  
  49. On 1994-95 California models, remove the air hose for the air assist system.
  50.  
  51. Remove the delivery pipe and injectors. Refer to Fuel System .
  52.  


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Disconnect the timing belt from the camshaft timing pulley.
  2.  
  3. Remove the camshaft timing pulley.
  4.  
  5. Remove the No. 1 idler pulley and tension spring.
  6.  
  7. Remove the No. 3 timing belt cover.
  8.  

Support the timing belt, so that the meshing of the crankshaft timing pulley and timing belt does not shift. Do not drop anything inside the timing belt cover.

  1. Remove the engine hangers and alternator bracket.
  2.  
  3. Disconnect the oil pressure sensor wiring and remove the sensor.
  4.  
  5. Remove the 4 nuts, grommets and cylinder head cover.
  6.  
  7. Label the spark plug wires and remove the wires with clamp. Extract the PCV hose and valve from the valve cover.
  8.  
  9. Remove the camshafts. Refer to the procedure later in this section.
  10.  
  11. Uniformily loosen and remove the 10 cylinder head bolts in several passes in the sequence shown.
  12.  



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Fig. Fig. 5: Head bolt loosening sequence-5S-FE engine


WARNING
Cylinder head warpage or cracking could result from removing the bolts in the incorrect order.

  1. Lift the cylinder head from its dowels on the block, and place the head on wooden blocks on a bench.
  2.  

If the head is hard to separate from the block, pry between the head and block with a flat-bladed tool to separate. Be careful not to damage the contact surfaces of the cylinder head or block.

  1. Using a gasket scraper, remove all gasket material from the block surface. Using compressed air, blow the carbon and oil from the bolt holes.
  2.  


CAUTION
Protect your eyes from the flying dirt particles when using high pressured air.

  1. Clean and inspect the cylinder head if reusing the same one.
  2.  

To install:
  1. Place a new gasket on the block and position the cylinder head over the dowels.
  2.  
  3. Apply a light coat of engine oil on the threads and under the heads of the bolts. Install and uniformly tighten the 10 bolts and plate washers in several passes in the sequence shown. Tighten the bolts to 36 ft. lbs. (49 Nm).
  4.  



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Fig. Fig. 6: Cylinder head bolt tightening sequence-5S-FE engine

The bolts are tightened in 2 progressive steps and if any of the bolts has a crack or deformed, it must be replaced.

  1. Mark the front of the cylinder head bolt head with paint.
  2.  
  3. Retighten the cylinder head bolts 90°in the order shown.
  4.  
  5. Check the painted mark is now at the 90°angle in the front.

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    Fig. Fig. 7: Mark the front of the head bolt with paint ...



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    Fig. Fig. 8: ... and retighten the bolts to 90°in order, then make sure the mark is facing front at a 90°angle

  6.  

  1. Install the spark plug tubes. Clean the tube holes and remove any oil. Screw the threads of the plug tube coated with adhesive into the head. Using a spark plug tube nut and a 30mm socket, tighten the plug tubes to 29 ft. lbs. (39 Nm).
  2.  
  3. Install the camshafts.
  4.  
  5. Check and adjust the valve clearance. Apply packing to the grooved of the half-moons, then install them into the cylinder head.
  6.  



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Fig. Fig. 9: Apply seal packing on the half-moons as shown

  1. Install the PCV valve, hose, and spark plug wires clamp.
  2.  
  3. Attach the cylinder head cover.
  4.  



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Fig. Fig. 10: Place sealant on the cylinder head in these places prior to valve cover installation

  1. Apply adhesive to the oil pressure switch, install and secure.
  2.  
  3. Install the engine hangers and secure the retaining bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the No. 3 timing belt cover.
  6.  
  7. Temporarily install the No. 1 idler pulley and tension spring.
  8.  
  9. Install the camshaft timing pulley.
  10.  
  11. Connect the timing belt and camshaft timing pulley.
  12.  
  13. Install the injectors and delivery pipe. Refer to Fuel System .
  14.  
  15. On California models, if removed, attach the air assist hose.
  16.  
  17. Install the intake manifold. Uniformly tighten the bolts in several passes.
  18.  
  19. Connect the fuel inlet hose-to-delivery pipe. Connect the fuel return hose-to-return hose.
  20.  
  21. Install and secure the engine wire harness.
  22.  
  23. Attach the alternator, A/T throttle cables and bracket.
  24.  
  25. Attach the PCV hose to the intake manifold.
  26.  
  27. Install the Vacuum Switching Valve (VSV) for the EGR.
  28.  
  29. Connect the knocks sensor 1 wiring.
  30.  
  31. Install the ground wires.
  32.  
  33. Install the air tube.
  34.  
  35. Attach the A/T throttle cable to the intake manifold.
  36.  
  37. Install the intake manifold stay and secure the bolt to 15 ft. lbs. (21 Nm) and the nut to 32 ft. lbs. (44 Nm).
  38.  
  39. Attach the EGR valve and vacuum modulator.
  40.  
  41. Connect the MAP sensor and EVAP hoses to their proper locations.
  42.  
  43. Install the throttle body.
  44.  
  45. Attach the water bypass pipe.
  46.  
  47. Install the water outlet and connect all wiring and hoses associated with it.
  48.  
  49. Assemble the exhaust manifold and front TWC.
  50.  
  51. Install the O2 sensor to the exhaust manifold and the other O2 sensor to the front TWC.
  52.  
  53. Attach the exhausts manifold to the TWC with new gaskets. Uniformly tighten the nuts in several passes to specification.
  54.  
  55. Install the front exhaust pipe.
  56.  
  57. Install the alternator, distributor and the air cleaner assembly.
  58.  
  59. Fill the cooling system.
  60.  
  61. Reconnect the negative battery cable, fill the engine with coolant and oil, start the engine, warm up, and check for leaks.
  62.  
  63. Install the RH engine undercover, check ignition timing, and road test for proper operation.
  64.  

7A-FE Engine

See Figures 11, 12, 13, 14, 15, 16, 17, 18, 19 and 20


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Disconnect the negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding to hinder air bag deployment.
  2.  
  3. Remove the RH engine undercover.
  4.  



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Fig. Fig. 11: Exploded view of the cylinder removal components-7A-FE engine



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Fig. Fig. 12: Exploded view of the cylinder removal components-7A-FE engine (continued)



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Fig. Fig. 13: Exploded view of the cylinder removal components-7A-FE engine (continued)

  1. Drain the engine coolant into a suitable container.
  2.  
  3. Remove the air cleaner and cap assembly.
  4.  
  5. Remove the spark plug wires and the distributor assembly.
  6.  
  7. Remove the alternator.
  8.  
  9. Disconnect the sub-oxygen and oxygen sensor wiring and remove the front exhaust pipe, the front TWC, and the exhaust manifold.
  10.  
  11. Disconnect the oil pressure switch wiring.
  12.  
  13. Separate the sensor wiring and hoses from the water outlet. Remove the two nuts and gasket; remove the water outlet.
  14.  
  15. Label and disconnect all wires and hoses attached to the water inlet, then remove the inlet and housing assembly.
  16.  
  17. Disconnect the hoses; remove the heat protector and the water bypass pipe.
  18.  
  19. Remove the throttle body assembly.
  20.  
  21. Separate the vacuum hoses from the intake manifold and remove the A/C idle-up valve.
  22.  
  23. Remove the EGR valve, vacuum modulator, vacuum hoses and gasket.
  24.  
  25. Remove the intake manifold stay and disconnect the A/T throttle control cable.
  26.  
  27. Remove the air hoses from the air tube and remove the air tube assembly.
  28.  
  29. Except California vehicles, disconnect the sensing hoses and remove the vacuum pipe.
  30.  
  31. Disengauge the knock sensor connector, remove the bolt and the ground cable from the intake manifold.
  32.  
  33. On California vehicles, remove the VSV for fuel pressure control and EGR. On all vehicles (except California), remove the VSV for EGR.
  34.  
  35. Disconnect the PCV hose from the intake manifold and disconnect the A/T throttle control cable and bracket from the
  36.  

intake manifold.

  1. Disconnect the engine wire harness from the starter bracket. Disengage the VSS sensor connector and the wire harness protector from the LH side of the manifold.
  2.  
  3. Disconnect the fuel inlet hose from the delivery pipe and the fuel return hose from the return pipe.
  4.  
  5. Remove the bolts and nuts, and the intake manifold and discard gasket.
  6.  
  7. On California vehicles, remove the air hose for the air assist system.
  8.  
  9. Remove the fuel delivery pipe and the injectors.
  10.  
  11. Remove the timing belt from the camshaft timing pulley and the camshaft timing pulley.
  12.  
  13. Remove No. 1 idler pulley and tension spring.
  14.  
  15. Remove four bolts and the No. 3 timing belt cover.
  16.  

Support the timing belt, so that the meshing of the crankshaft timing pulley and the timing belt does not shift. Be careful not to drop anything inside the timing belt cover.

  1. Remove the engine hangers and the alternator bracket.
  2.  
  3. Remove the oil pressure switch.
  4.  
  5. Remove the cylinder head cover. Remove the spark plug wire clamp, PCV valve and hoses from the cylinder head cover.
  6.  
  7. Remove the camshafts following the proper sequences and procedures in this section.
  8.  



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Fig. Fig. 14: Cylinder head bolt removal sequence

  1. Uniformly loosen and remove the cylinder head bolts in several passes and in the reverse order of the installation sequence. Lift the cylinder head from the cylinder block disengaging the cylinder head from the block dowel pins.
  2.  



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Fig. Fig. 15: Carefully lift the cylinder head off the block

To install:


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Fig. Fig. 16: Lift the head gasket ...



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Fig. Fig. 17: ... place clean shop rags in the piston ports and scrape all old gasket material off the mating areas

  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.
  2.  
  3. The cylinder head bolts are tightened in three progressive steps. Apply a light coat of engine oil to the cylinder head bolts. Uniformly tighten the 10 cylinder head bolts in several passes and in sequence. The torque for the head bolts is 22 ft. lbs. (29 Nm). Mark the front of the cylinder head bolt with paint. Tighten the cylinder head bolts by 90°in sequence. Tighten an additional 90°and make sure that the paint mark is now positioned toward the rear.
  4.  

If any of the bolts does not meet the torque specification, replace the bolt. Cylinder head bolt lengths of 3.54 inch (90mm) and 4.25 inch (108mm). Install the 3.54 inch (90mm) boltsAin the intake manifold side position. Install the 4.25 inch (108mm) boltsBin the exhaust manifold side positions.



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Fig. Fig. 18: Cylinder head bolt tightening sequence7A-FE engine



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Fig. Fig. 19: Place a paint mark on the front of the head bolt as shown



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Fig. Fig. 20: Next, retighten the bolts, at the end the painted mark should be facing rearward-7A-FE engine

  1. Install the camshafts following the proper sequences and procedures.
  2.  
  3. Check and adjust valve clearance.
  4.  
  5. Install sealant to the two new semi-circular seals and install the seals to the cylinder head.
  6.  
  7. Install the PCV valve and hoses and the spark plug wire clamp to the cylinder head cover.
  8.  
  9. Install the cylinder head cover with a new gasket, the four grommets and nuts and uniformly tighten the nuts in several passes. The torque for the nuts is 17 ft. lbs. (23 Nm).
  10.  
  11. Install the oil pressure switch.
  12.  
  13. Install the alternator bracket and the engine hangers.
  14.  
  15. Install the No. 3 timing belt cover and temporarily install the No. 1 idler pulley and tension spring.
  16.  
  17. Install the camshaft timing pulley and install the timing belt to the pulley. Correctly tension the timing belt and make sure that the belt timing is correct.
  18.  
  19. Install the fuel injectors and the delivery pipe.
  20.  
  21. On California cars, install the air hose for the air assist system.
  22.  
  23. Install the intake manifold and insert the engine wire harness between the head and the intake manifold, install a new gaskets the six bolts and two nuts, and tighten the intake manifold to 25 ft. lbs. (34 Nm)
  24.  
  25. Connect the fuel inlet and return hoses to the delivery and return pipes.
  26.  
  27. Install the engine wire protector and harness to the intake manifold and connect the four fuel injector connectors. Connect the VSS connector.
  28.  
  29. Install the cable bracket to the intake manifold and install the accelerator, A/T control cables and bracket.
  30.  
  31. Connect the PCV hose to the intake manifold.
  32.  
  33. On California vehicles, install the VSV assembly for fuel pressure control and EGR.
  34.  
  35. Except for California vehicles, install the VSV for EGR.
  36.  
  37. Connect the knock sensor connector and install the ground cable with the bolt.
  38.  
  39. Except for California vehicles, install the sensing hoses to the vacuum pipe and mount the pipe with the bolt.
  40.  
  41. Install the air tube and the bracket for the EGR. Connect the hoses to the air pipe.
  42.  
  43. Install the A/T throttle control cable to the clamp on the rear side of the intake manifold. Install the manifold stay and tighten the bolt to 15 ft. lbs. (21 Nm) and tighten the nut to 32 ft. lbs. (44 Nm).
  44.  
  45. Install the EGR valve and the vacuum modulator using a new gasket, connect the two vacuum hoses to the VSV for the EGR, and connect the EGR gas temperature sensor connector. Connect the EVAP hose to the charcoal canister.
  46.  
  47. Install the vacuum sensor hose to the gas filter and the brake booster vacuum hose to the intake manifold.
  48.  
  49. Install the A/C idle up valve.
  50.  
  51. Install the throttle body.
  52.  
  53. Connect the water bypass pipe to the water pump cover; install the water bypass pipe and connect the hoses to the water bypass pipe.
  54.  
  55. Install the water outlet with a new gasket and the two nuts and install the water hoses, vacuum hoses, and connect the sensor connectors.
  56.  
  57. Connect the oil pressure switch connector.
  58.  
  59. Assemble the TWC to the exhaust manifold and install the main oxygen sensor to the exhaust manifold. Install the sub oxygen sensor to the TWC.
  60.  
  61. Install the exhaust manifold to the cylinder head and connect the oxygen sensors connectors.
  62.  
  63. Install the front exhaust pipe and install the alternator with the drive belt.
  64.  
  65. Install the distributor assembly and connect the spark plug wires.
  66.  
  67. Install the air cleaner and cap assembly.
  68.  
  69. Connect the negative battery cable, fill the engine with coolant, start the engine, warm up, and check for leaks. Bleed the cooling system and top off coolant as necessary.
  70.  
  71. Install the RH engine undercover, check ignition timing, and road test the vehicle for proper operation.
  72.  

 
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