Toyota Cressida and Van 1983-1990

Cylinder Head

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REMOVAL & INSTALLATION



5M-GE Engine


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Fig. Fig. 1 Exploded view of the cylinder head assembly-5M-GE engine



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Fig. Fig. 2 When removing the cylinder head, always purchase a new gasket kit-5M-GE engine



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Fig. Fig. 3 Cylinder head bolt removal sequence-5M-GE engine



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Fig. Fig. 4 Camshaft housing bolt tightening sequence-5M-GE engine



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Fig. Fig. 5 Cylinder head bolt tightening sequence-5M-GE engine



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Fig. Fig. 6 Camshaft timing pulley markings-5M-GE engine

  1. Rotate the engine so as to bring the number one cylinder up to top dead center of its compression stroke. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the exhaust pipe from the exhaust manifold.
  8.  
  9. Remove the throttle cable bracket from the cylinder head if equipped with automatic transmission, and remove the accelerator and actuator cable bracket.
  10.  
  11. Tag and disconnect the cylinder head ground cable, the oxygen sensor wire, the distributor connector, oil pressure sending unit, alternator wires, the high tension coil wire, the water temperature sending, the thermo switch wires, the starter wires, the ECT connectors, the solenoid resistor wire connector and the knock sensor wire.
  12.  
  13. Tag and disconnect the brake booster vacuum hose from the air intake chamber, along with the EGR valve vacuum hose. Disconnect the actuator vacuum hose from the air intake chamber, if equipped with cruise control. Disconnect the heater bypass hoses from the engine.
  14.  
  15. Disconnect the upper radiator hose from the thermostat housing, and disconnect the 2 heater hoses.
  16.  
  17. Disconnect the No. 1 air hose from the air intake connector. Remove the 2 clamp bolts, loosen the throttle body hose clamp and remove the air intake connector and the connector pipe.
  18.  
  19. Disconnect the No.1 water by-pass hose from the idle speed control valve. Disconnect the No.2 water by-pass hose from the throttle body.
  20.  
  21. Tag and disconnect all emission control hoses from the throttle body and air intake chamber, the 2 PCV hoses from the cam cover and the fuel hose from the fuel hose support.
  22.  
  23. Remove the air intake chamber stay and the vacuum pipe and ground cable. Remove the bolt that attaches the spark plug wire clip, leaving the wires attached to the clip.
  24.  
  25. Make an alignment mark on the distributor base and the engine block. Remove the distributor from the cylinder head with the cap and wires attached, by removing the distributor holding bolt.
  26.  
  27. Remove the spark plugs. Disconnect and tag the following connections:

    Cold start injector wire
     
    Water temperature sensor wire
     
    Start injection time switch wire
     
    Water temperature sending unit wire
     
    Throttle position sensor wire connector
     
    Idle speed control valve wire connectors
     

  28.  
  29. Disconnect the cold start injector fuel hose from the delivery pipe.
  30.  
  31. Loosen the nut of the EGR pipe, remove the 5 bolts and 2 nuts that retain the air intake chamber and remove the chamber and gasket.
  32.  
  33. Remove the glove box and remove the ECU module. Disconnect the 3 connectors and pull the ECU wire harness out through the engine side of the firewall.
  34.  
  35. Remove the pulsation damper and the No. 1 fuel pipe. Remove the water outlet housing by first loosening the clamp and disconnecting the water by pass hose. Then remove the 2 bolts from the outlet and remove it from the engine.
  36.  
  37. Remove the eight bolts and 2 nuts holding the intake manifold to the engine and remove the intake manifold and gasket.
  38.  
  39. Remove the power steering pump pulley with drive belt and remove the power steering pump bracket. Remove the power steering pump from the bracket without disconnecting the fluid hoses. Position the pump out of the way.
  40.  
  41. Disconnect the oxygen sensor connector. Remove the heat insulator retaining nuts and remove the insulators. Remove the exhaust manifold retaining nuts and remove the exhaust manifold.
  42.  
  43. Remove the retaining bolts of the No.3 timing belt cover and remove the cover and gasket.
  44.  
  45. Loosen the idler pulley set bolt and shift the idler pulley towards the alternator side. Finger-tighten the set bolt and then relieve the timing belt tension.
  46.  
  47. Remove the timing belt from the camshaft timing pulleys.
  48.  
  49. Using a suitable camshaft pulley holding tool, remove the camshaft pulley set bolts and remove the pulleys along with the match pin.
  50.  

Do not make use of the timing belt tension when removing and installing the pulley set bolt. The exhaust and intake sides each use a different type of pulley and they are not interchangeable.

  1. Remove the 2 bolts holding the timing belt cover stay bracket and remove the stay bracket. Remove the 3 bolts from the oil pressure regulator and remove the regulator and gasket.
  2.  
  3. Remove the No.2 timing belt cover retaining bolts and nuts and remove the cover with gasket.
  4.  
  5. Tag and disconnect any other wires, linkage and/or hoses still attached to the cylinder head or may interfere with its removal.
  6.  
  7. Carefully remove the 14 head bolts gradually in two or three passes and in the proper sequence.
  8.  
  9. Carefully lift the cylinder head from the dowels on the cylinder block and remove it. Remove the old gasket material from the head and cylinder block.
  10.  

To install:

  1. Install the EGR cooler.
  2.  
  3. Install a small bead of a suitable high temperature silicone sealer to the 4 corners of the cylinder head and engine block mating surface.
  4.  
  5. Place a new cylinder head gasket over the dowel pins on the cylinder block.
  6.  
  7. Position the cylinder head over the dowel pins. Once the cylinder head is seated properly over the gasket and engine block, install the cylinder head bolts. Tighten the head bolts gradually in 3 passes working from the middle out, to obtain a final torque of 58 ft. lbs. (78 Nm).
  8.  
  9. Install the No.2 timing belt cover and gasket and tighten the bolts and nuts to 9 ft. lbs. (13 Nm).
  10.  
  11. Install the oil pressure regulator along with a new gasket onto the cylinder head.
  12.  
  13. Install the timing belt cover stay bracket and bolts.
  14.  
  15. Install the camshaft timing pulleys and timing belt as follows:
  16.  
    1. Make sure that the match hole on the No. 2 journal of the camshaft housing is aligned with that of the camshaft.
    2.  
    3. If not aligned properly, temporarily install the camshaft timing pulley and insert the match pin into the pin hole. Then align the match holes by turning the camshaft timing pulley.
    4.  
    5. Install the camshaft timing pulleys with the guide facing the direction as indicated. The exhaust side will be with the pulley guide facing the No. 2 timing belt cover. The intake side will be with the pulley guide facing the front side.
    6.  
    7. Align the matchmarks of the No.2 timing belt cover with those of the camshaft timing pulleys and of the crankshaft pulley. Be sure that the No. 1 cylinder is set to top dead center on its compression stroke, which it should be if the engine has not been disturbed.
    8.  
    9. Install the timing belt with the belt having the proper tension between the crankshaft timing pulley and the camshaft timing pulley on the exhaust side.
    10.  
    11. Loosen the idler pulley set bolt and stretch the timing belt. Tighten the idler pulley set bolt to 36 ft. lbs. (49 Nm). Be sure that the timing belt tension is applied evenly throughout the belt.
    12.  
    13. There are 3 pin holes on the camshaft and timing pulleys. Select the one overlapped hole and insert the pin into it.
    14.  


If there is no overlapping hole, find one that is nearly overlapped and rotate the crankshaft slightly to overlap it and insert the pin.

    1. The crankshaft pulley angle can be adjusted approximately 3° by changing the pin hole to the next one.
    2.  
    3. Using a suitable camshaft pulley holding tool, install the camshaft pulley set bolts and torque them to 50 ft. lbs. (69 Nm).
    4.  



WARNING
Do not disturb the timing belt tension when tightening the camshaft pulley bolt.

    1. Loosen the idler pulley set bolt. Turn the crankshaft clockwise 2 times and retighten the idler pulley set bolt.
    2.  
    3. Install the No. 3 timing belt cover and gasket along with the retaining bolts.
    4.  


  1. Position a new exhaust manifold gasket onto the cylinder head. Install the exhaust manifold with retaining nuts and tighten the nuts to 29 ft. lbs. (39 Nm).
  2.  
  3. Install the heat insulators.
  4.  
  5. Install the power steering pump and stay bracket. Install the power steering pump pulley with the drive belt. Adjust the belt to obtain the proper tension. Tighten the idler pulley nut and adjusting bolt.
  6.  
  7. Position a new intake manifold gasket onto the cylinder head. Install the intake manifold with retaining nuts and tighten the nuts to 13 ft. lbs. (18 Nm). Connect the EFI wiring harness to the ECU.
  8.  
  9. Install the water outlet housing with the 2 bolts. Connect the water by-pass hose and tighten the clamp.
  10.  
  11. Finger-tighten the pulsation damper and union bolt with a new gaskets on the fuel pipe. Tighten the fuel pipe, being careful not to bend it.
  12.  
  13. Position a new air intake chamber gasket onto the intake manifold. Install the air chamber with the retaining bolts and nuts. Tighten the nut of the EGR valve connecting pipe.
  14.  
  15. Install a new gasket on the cold start injector fuel hose delivery pipe and install the fuel hose, another gasket and the union bolt to the delivery pipe.
  16.  
  17. Install the following connectors:

    Cold start injector wire
     
    Water temperature sensor wire
     
    Start injection time switch wire
     
    Water temperature sending unit wire
     
    Throttle position sensor wire connector
     
    Idle speed control valve wire connectors
     

  18.  
  19. Using the alignment mark made earlier on the distributor and being sure the No. 1 cylinder is set up at top dead center of its compression stroke. Install the distributor assembly.
  20.  
  21. Install the spark plugs, spark plug wire clips with bolt and the spark plug wires.
  22.  
  23. Install the air intake chamber stay bracket, vacuum pipe and ground cable with 3 bolts.
  24.  
  25. Reconnect all emission control hoses to the throttle body and air intake chamber, the 2 PCV hoses to the cam cover and the fuel hose to the fuel hose support.
  26.  
  27. Reconnect the No. 1 water by-pass hose to the idle speed control valve. Reconnect the No. 2 water bypass hose to the throttle body.
  28.  
  29. Reconnect the No. 1 air hose to the air intake connector. Install the 2 clamp bolts, tighten the throttle body hose clamp and install the air intake connector and the connector pipe.
  30.  
  31. Install the 2 heater hoses and install the radiator upper hose.
  32.  
  33. Reconnect the brake booster vacuum hose to the air intake chamber, along with the EGR valve vacuum hose. Reconnect the actuator vacuum hose to the air intake chamber, if equipped with cruise control. Reconnect the heater bypass hoses to the engine.
  34.  
  35. Reconnect the cylinder head ground cable, the oxygen sensor wire, the distributor connector, oil pressure sending unit, alternator wires, the high tension coil wire, the water temperature sending, the thermo switch wires, the starter wires, the ECT connectors, the solenoid resistor wire connector and the knock sensor wire.
  36.  
  37. Install the throttle cable bracket to the cylinder head if equipped with automatic transmission, and install the accelerator and actuator cable bracket.
  38.  
  39. Reconnect the exhaust pipe to the exhaust manifold.
  40.  
  41. Close the engine block and radiator draincocks and refill the cooling system.
  42.  
  43. Reconnect the negative battery cable. Start the engine. If the engine is hard to start it may be necessary to have someone turn the base of the distributor left or right to get close to the base timing marks and allowing the engine to start.
  44.  
  45. Perform all engine adjustments. Road test the vehicle and then make all final adjustments. Be sure to also check for any leaks and refill as necessary.
  46.  

7M-GE Engine


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Fig. Fig. 7 Exploded view of the cylinder head-7M-GE engine



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Fig. Fig. 8 When removing the cylinder head, always purchase a new gasket kit-7M-GE engine



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Fig. Fig. 9 Cylinder head bolt removal sequence-7M-GE engine



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Fig. Fig. 10 Cylinder head bolt tightening sequence-7M-GE engine



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Fig. Fig. 11 Camshaft cap bolt tightening sequence-7M-GE engine



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Fig. Fig. 12 Camshaft timing pulley markings-7M-GE engine

  1. Rotate the engine so as to bring up the No. 1 cylinder to top dead center of its compression stroke. Disconnect the negative battery cable. Drain the cooling system.
  2.  
  3. Raise and support the vehicle safely. Disconnect the exhaust pipe from the exhaust manifold. Disconnect the cruise control cable, if equipped.
  4.  
  5. Disconnect the accelerator cable. Disconnect the throttle cable, if equipped with automatic transmission. Disconnect the engine ground strap.
  6.  
  7. Remove the No. 1 air cleaner hose along with the intake air pipe assembly and air intake connector.
  8.  
  9. Remove the PCV pipe with hoses. Remove the vacuum transmitting pipe and air intake connector bracket. Disconnect the ground strap from the right rear side of the engine.
  10.  
  11. Disconnect the cruise control vacuum hose, the charcoal canister hose and the brake booster hose.
  12.  
  13. Remove the radiator and heater inlet hoses. Disconnect the No. 3 PCV hose.
  14.  
  15. Remove the alternator assembly.
  16.  
  17. Remove the air intake chamber along with the following:

    Throttle position sensor connector
     
    Idle speed control valve connector
     
    Vacuum switching valve hose from the throttle body
     
    The EGR hoses from the throttle body
     
    The vacuum transmitting pipe hoses from the intake chamber
     
    Pressure regulator hose
     
    Pollution system air hose
     
    No. 1 water bypass hose from the intake manifold
     
    No. 3 water bypass hose from the water bypass pipe
     
    2 bolts and the manifold stay
     
    Cold start injector tube assembly
     

  18.  
  19. Remove the mount bolts for the EGR pipe.
  20.  
  21. Remove the EGR vacuum modulator from the bracket.
  22.  
  23. Disconnect the engine wire harness from the clamps of the air intake chamber.
  24.  
  25. Remove the bolt holding the vacuum transmitting pipe to the No. 2 fuel pipe stay bracket.
  26.  
  27. Remove the vacuum transmitting pipes and air intake chamber retaining nuts and bolts. Remove this assembly along with the gasket from the engine.
  28.  
  29. Disconnect the cold start injector connector.
  30.  
  31. Disconnect the following wiring connectors:

    The oxygen sensor connector
     
    The oil pressure sender gauge connector
     
    Water temperature sensor connector
     
    Water temperature sender gauge connector
     
    Cold start injector time switch connector
     
    Distributor connector
     
    Igniter connector
     
    Noise filter connector
     
    Injector connectors
     
    Vacuum switching valve connector
     
    Knock sensor connector
     
    EGR gas temperature sensor connector (if so equipped)
     
    The ground strap from the intake manifold
     
    Starter connector
     
    Transmission connector
     
    Air conditioning compressor connector
     
    Check engine connector
     
    Relay block connector
     

  32.  
  33. Disconnect the engine wire from each clamp.
  34.  
  35. Remove the No. 1 fuel pipe.
  36.  
  37. Disconnect the fuel hose from the No. 2 fuel pipe. Remove the bolt, union bolt and No. 2 fuel pipe and gaskets.
  38.  
  39. Make an alignment mark on the distributor base and the engine block. Remove the distributor from the cylinder head with the cap and wires attached, by removing the distributor holding bolt.
  40.  
  41. Remove the engine oil dipstick.
  42.  
  43. Remove the exhaust manifold retaining nuts and remove the manifold along with the gasket.
  44.  
  45. Remove the union bolts, unions along with the No. 4 water bypass hose and gaskets. Disconnect the No. 6 water bypass hose from the water bypass pipe.
  46.  
  47. Remove the water outlet retaining bolt and nuts and remove the water outlet along with the gasket.
  48.  
  49. Remove the cylinder head cover retaining bolts and remove the cylinder head covers. Remove the center cylinder head cover and gasket.
  50.  
  51. Remove the spark plugs.
  52.  
  53. Remove the timing belt and camshaft timing pulleys as follows:
  54.  
    1. Remove the 4 bolts from the fluid coupling (fan clutch) flange.
    2.  
    3. Loosen the fan belt adjusting bolt and nut of the power steering pump.
    4.  
    5. Remove the fan shroud mounting nuts.
    6.  
    7. Remove the four bolts, fan clutch, water pump pulley and fan shroud.
    8.  
    9. Remove the power steering pump belt.
    10.  
    11. Remove the No. 3 timing cover retaining bolts and nuts. Remove the cover and gasket.
    12.  
    13. Turn the crankshaft pulley and align its groove with the 0 mark on the No. 1 timing belt cover. If the engine has not been disturbed, the engine should still be in this position.
    14.  
    15. Check that the alignment marks on the camshaft timing pulleys and the No. 2 timing belt cover are aligned. If not, turn the crankshaft pulley one complete revolution.
    16.  
    17. Loosen the mount bolt of the idler pulley and shift it to the left as far as it can go. Temporarily tighten the mount bolt thus relieving the tension on the timing belt.
    18.  
    19. Remove the timing belt from the camshaft timing pulley. Be sure to support the belt so that the meshing of the crankshaft timing pulley and timing belt do not shift. Be careful not to drop anything inside of the timing belt cover. Do not allow the belt to come in contact with oil, water or dust.
    20.  

      If reusing the timing belt, please mark the direction of rotation before removing it. But a word to the wise, if you are this far into the cylinder head repair of your vehicle, it would be wise to replace the timing belt at this time, so as to avoid this situation in the near future.

    21. Using a suitable camshaft pulley holding tool, remove the camshaft pulley set bolts and remove the pulleys along with the match pin. Do not make use of the timing belt tensioner when removing and installing the pulley set bolt.
    22.  


  1. Tag and disconnect any other wires, linkage and/or hoses still attached to the cylinder head or may interfere with its removal.
  2.  
  3. Carefully remove the head bolts gradually in two or three passes and in the proper sequence.
  4.  
  5. Carefully lift the cylinder head from the dowels on the cylinder block and remove it. Remove the old gasket material from the head and cylinder block.
  6.  

To install:

  1. Install a small bead of a suitable high temperature silicone sealer to the corners of the cylinder head and engine block mating surface.
  2.  
  3. Place a new cylinder head gasket over the dowel pins on the cylinder block.
  4.  
  5. Position the cylinder head over the dowel pins. Connect the No. 5 water bypass hose to the union. Apply a light coat of engine oil on the threads and under the cylinder head bolts.
  6.  
  7. Once the cylinder head is seated properly over the gasket and engine block, install the cylinder head bolts. Tighten the head bolts gradually in 3 passes working from the middle out, to obtain a final torque of 58 ft. lbs. (78 Nm).
  8.  
  9. Install the camshaft timing pulleys and timing belt as follows:
  10.  
    1. Turn the crankshaft pulley and align its groove with the 0 mark on the No. 1 timing belt cover. If the engine has not been disturbed, the engine should still be in this position.
    2.  
    3. Align the alignment marks on the camshaft timing pulleys and the No. 2 timing belt cover. Install the timing pulley.
    4.  
    5. Install the straight pin into the hole.
    6.  
    7. When replacing the camshaft or the camshaft timing pulley, always align the center holes of the camshaft and timing pulleys and insert the straight pin. When reusing the camshaft or camshaft timing pulleys, check that the straight pin hole position is in the same position it was at disassembly, insert the straight pin. Install the plate washer and pulley bolt.
    8.  
    9. Using a suitable camshaft pulley holding tool, check the pin hole position, hold the pulley and tighten the pulley bolts to 36 ft. lbs. (49 Nm).
    10.  
    11. Check that the matchmarks on the camshaft timing pulley are aligned with those on the No. 2 timing belt cover.
    12.  
    13. Install the timing belt to the intake camshaft timing pulley, the exhaust camshaft timing pulley and the idler pulley.
    14.  
    15. Loosen the idler pulley mount bolt until the pulley is moved slightly by the spring tension. Tighten the idler pulley mount bolt to 36 ft. lbs. (49 Nm).
    16.  
    17. Check that the timing belt tension is equal all the way through. Turn the crankshaft pulley 2 revolutions clockwise from TDC to TDC.
    18.  
    19. Check that the alignment marks on the camshaft timing pulleys are aligned with those on the No. 2 timing belt cover.
    20.  
    21. If the marks do not align, remove the belt and install it again.
    22.  
    23. Install the No. 3 timing cover gasket, cover and retaining bolts.
    24.  
    25. Install the power steering pump belt.
    26.  
    27. Install the four bolts, fan clutch, water pump pulley and fan shroud.
    28.  
    29. Install the fan shroud mounting nuts.
    30.  
    31. Tighten the fan belt adjusting bolt and nut of the power steering pump.
    32.  
    33. Install the 4 bolts to the fluid coupling (fan clutch) flange.
    34.  

  11. Install the spark plugs.
  12.  
  13. Install the cylinder head cover gaskets, covers and retaining bolts.
  14.  
  15. Install the water outlet housing gasket, housing, retaining bolt and nuts.
  16.  
  17. Install the union bolts, unions along with the No. 4 water bypass hose and gaskets. Reconnect the No. 6 water bypass hose to the water bypass pipe.
  18.  
  19. Install the exhaust manifold gasket, manifold and retaining nuts. Tighten the nuts to 29 ft. lbs. (39 Nm).
  20.  
  21. Install the engine oil dipstick.
  22.  
  23. Using the alignment mark made earlier on the distributor base and the engine block, be sure the No. 1 cylinder is still at top dead center of its compression stroke. Install the distributor to the cylinder head with the cap and wires attached, install the distributor holding bolt.
  24.  
  25. Reconnect the fuel hose to the No. 2 fuel pipe. Install the bolt, union bolt and No. 2 fuel pipe and gaskets. Tighten the union bolt to 18 ft. lbs. (25 Nm).
  26.  
  27. Install the No. 1 fuel pipe. Tighten the union bolt to 29 ft. lbs. (25 Nm) and the fuel pipe to 22 ft. lbs. (29 Nm).
  28.  
  29. Reconnect the engine wire to each clamp.
  30.  
  31. Reconnect the following wiring connectors:

    The oxygen sensor connector
     
    The oil pressure sender gauge connector
     
    Water temperature sensor connector
     
    Water temperature sender gauge connector
     
    Cold start injector time switch connector
     
    Distributor connector
     
    Igniter connector
     
    Noise filter connector
     
    Injector connectors
     
    Vacuum switching valve connector
     
    Knock sensor connector
     
    EGR gas temperature sensor connector (if so equipped)
     
    The ground strap from the intake manifold
     
    Starter connector
     
    Transmission connector
     
    Air conditioning compressor connector
     
    Check engine connector
     
    Relay block connector
     

  32.  
  33. Reconnect the cold start injector connector.
  34.  
  35. Install the vacuum transmitting pipes and air intake chamber along with a new gasket and the retaining nuts and bolts.
  36.  
  37. Install the bolt holding the vacuum transmitting pipe to the No. 2 fuel pipe stay bracket.
  38.  
  39. Reconnect the engine wire harness to the clamps of the air intake chamber.
  40.  
  41. Install the EGR vacuum modulator to the bracket.
  42.  
  43. Install the mount bolts for the EGR pipe.
  44.  
  45. Install the air intake chamber along with the following:

    Throttle position sensor connector
     
    Idle speed control valve connector
     
    Vacuum switching valve hose from the throttle body
     
    The EGR hoses from the throttle body
     
    The vacuum transmitting pipe hoses from the intake chamber
     
    Pressure regulator hose
     
    Pollution system air hose
     
    No. 1 water bypass hose from the intake manifold
     
    No. 3 water bypass hose from the water bypass pipe
     
    2 bolts and the manifold stay
     
    Cold start injector tube assembly
     

  46.  
  47. Install the alternator assembly.
  48.  
  49. Install the radiator and heater inlet hoses. Reconnect the No. 3 PCV hose.
  50.  
  51. Reconnect the cruise control vacuum hose, the charcoal canister hose and the brake booster hose.
  52.  
  53. Install the PCV pipe with hoses. Install the vacuum transmitting pipe and air intake connector bracket. Reconnect the ground strap to the right rear side of the engine.
  54.  
  55. Install the No. 1 air cleaner hose along with the intake air pipe assembly and air intake connector.
  56.  
  57. Reconnect the accelerator cable. Reconnect the throttle cable, if equipped with automatic transmission. Reconnect the engine ground strap.
  58.  
  59. Reconnect the exhaust pipe to the exhaust manifold. Reconnect the cruise control cable, if equipped. Lower the vehicle.
  60.  
  61. Close the engine block and radiator draincocks and refill the cooling system.
  62.  
  63. Reconnect the negative battery cable. Start the engine. If the engine is hard to start it may be necessary to have someone turn the base of the distributor left or right to get close to the base timing marks and allowing the engine to start.
  64.  
  65. Perform all engine adjustments. Road test the vehicle and then make all final adjustments. Be sure to also check for any leaks and refill as necessary.
  66.  

3Y-EC and 4Y-EC Engines


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Fig. Fig. 13 Exploded view of the cylinder head-3Y-EC and 4Y-EC engines



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Fig. Fig. 14 Cylinder head and engine overhaul gasket kits-3Y-EC and 4Y-EC engines



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Fig. Fig. 15 Cylinder head bolt removal sequence-3Y-EC and 4Y-EC engines



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Fig. Fig. 16 Cylinder head bolt tightening sequence- 3Y-EC and 4Y-EC engines



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Fig. Fig. 17 Rocker shaft bolt tightening sequence- 3Y-EC and 4Y-EC engines



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Fig. Fig. 18 Remove the rocker arm shaft assembly from the cylinder head-3Y-EC and 4Y-EC engines



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Fig. Fig. 19 When removing the pushrods, place them in a marked cardboard sheet to keep them in order



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Fig. Fig. 20 Uniformly loosen and remove the cylinder head bolts



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Fig. Fig. 21 Lift the cylinder head and intake/exhaust manifold assembly off the block



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Fig. Fig. 22 Before installing the cylinder head on the block, clean and scrape the mating surfaces



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Fig. Fig. 23 When installing the cylinder head, uniformly tighten the cylinder head bolts in the proper sequence

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the right front seat.
  4.  
  5. Remove the engine service hole cover.
  6.  
  7. Drain the coolant.
  8.  
  9. Disconnect the following hoses:

    Radiator inlet hoses
     
    Radiator breather hose
     
    Reservoir tank hose
     
    Heater outlet hose
     
    Radiator outlet hose
     
    Brake booster hose
     
    Fuel inlet hose
     
    Fuel outlet hose
     
    Charcoal canister hose
     

  10.  
  11. Disconnect and tag all vacuum hoses attached to various engine parts.
  12.  
  13. Disconnect the following wire connectors:

    The alternator connector and B terminal
     
    The air flow meter connector
     
    The solenoid resistor connector
     
    Water temperature sending unit connector
     
    The oil pressure switch connector
     
    The ignition connectors at the distributor
     
    The air conditioning compressor connector, if so equipped
     
    The air conditioning idle up solenoid connector, if so equipped
     
    The vacuum switching valve, if so equipped
     
    The coolant temperature switch
     

  14.  
  15. Disconnect and tag all cables attached to various engine parts.
  16.  
  17. Remove the air cleaner hose.
  18.  
  19. Unbolt the power steering pump and secure it out of the way.
  20.  
  21. Disconnect the accelerator cable and the throttle cable from the throttle linkage.
  22.  
  23. Remove the throttle body from the air intake chamber.
  24.  
  25. Remove the nuts and bolts retaining the EGR valve to the intake manifold. Disconnect the union nut from the exhaust manifold and remove the EGR valve.
  26.  
  27. Disconnect the cold start injector pipe, water by-pass hose and pressure regulator hose.
  28.  
  29. Remove the air intake chamber brackets. Be sure to use a 12 mm socket wrench to remove the rear chamber bracket.
  30.  
  31. Remove the air intake chamber with the air valve.
  32.  
  33. Remove the wire clamp bolt of the fuel injector, disconnect the injector connectors from the injectors.
  34.  
  35. Remove the exhaust manifold bracket, heater pipe bracket, fuel inlet pipe union bolt from the fuel filter and the fuel outlet hose.
  36.  
  37. Remove the spark plugs and spark plug tubes.
  38.  
  39. Remove the cylinder head cover retaining bolts, cover and gasket.
  40.  
  41. Uniformly loosen and remove the 3 bolts and 2 nuts holding the rocker arm assembly in the cylinder head.
  42.  
  43. Remove the pushrods and keep them in their proper order.
  44.  
  45. Uniformly loosen and remove the cylinder head bolts. Lift the cylinder head manifold assembly from the dowels in the block and place it on 2 wooden blocks on a suitable work bench.
  46.  

To install:

  1. Install a small bead of a suitable high temperature silicone sealer to the corners of the cylinder head and engine block mating surface.
  2.  
  3. Place a new cylinder head gasket over the dowel pins on the cylinder block.
  4.  
  5. Position the cylinder head over the dowel pins. Apply a light coat of engine oil on the threads and under the cylinder head bolts.
  6.  
  7. Once the cylinder head is seated properly over the gasket and engine block, install the cylinder head bolts. Tighten the head bolts gradually in 3 passes working from the middle out, to obtain a final torque of 65 ft. lbs. for the 14mm bolts and 14 ft. lbs. for the 12mm bolts.
  8.  
  9. Make sure the pushrods are installed in the correct position.
  10.  
  11. Hold the pushrods in place and install the rocker arm shaft assembly.
  12.  
  13. Uniformly tighten the 3 bolts and 2 nuts in several passes until a final torque of 17 ft. lbs. (24 Nm) is obtained.
  14.  
  15. Using a new gasket, install the rocker arm cover. Tighten the bolts to 13 ft. lbs. (18 Nm).
  16.  
  17. Install the cylinder head cover gaskets, cover and retaining bolts.
  18.  
  19. Install the spark plugs and spark plug tubes.
  20.  
  21. Install the exhaust manifold bracket, heater pipe bracket, fuel inlet pipe union bolt from the fuel filter and the fuel outlet hose.
  22.  
  23. Install the wire clamp bolt to the fuel injector, reconnect the injector connectors to the injectors.
  24.  
  25. Install the air intake chamber with the air valve.
  26.  
  27. Install the air intake chamber brackets. Be sure to use a 12mm socket wrench to install the rear chamber bracket.
  28.  
  29. Reconnect the cold start injector pipe, water bypass hose and pressure regulator hose.
  30.  
  31. Install the EGR valve along with the nuts and bolts retaining the EGR valve to the intake manifold. Reconnect the union nut from the exhaust manifold.
  32.  
  33. Install the throttle body to the air intake chamber.
  34.  
  35. Reconnect the accelerator cable and the throttle cable to the throttle linkage.
  36.  
  37. Install the power steering pump assembly.
  38.  
  39. Reconnect all cables attached to various engine parts.
  40.  
  41. Reconnect the following wire connectors:

    The alternator connector and B terminal
     
    The air flow meter connector
     
    The solenoid resistor connector
     
    Water temperature sending unit connector
     
    The oil pressure switch connector
     
    The ignition connectors at the distributor
     
    The air conditioning compressor connector, if so equipped
     
    The air conditioning idle up solenoid connector, if so equipped
     
    The vacuum switching valve, if so equipped
     
    The coolant temperature switch
     

  42.  
  43. Reconnect all vacuum hoses attached to various engine parts.
  44.  
  45. Reconnect the following hoses:

    Radiator inlet hoses
     
    Radiator breather hose
     
    Reservoir tank hose
     
    Heater outlet hose
     
    Radiator outlet hose
     
    Brake booster hose
     
    Fuel inlet hose
     
    Fuel outlet hose
     
    Charcoal canister hose
     

  46.  
  47. Install the air cleaner assembly.
  48.  
  49. Refill the coolant system.
  50.  
  51. Install the engine service hole cover.
  52.  
  53. Install the right front seat.
  54.  
  55. Reconnect the negative battery cable.
  56.  
  57. Start the engine. Perform all engine adjustments. Road test the vehicle and then make all final adjustments. Be sure to also check for any leaks and refill fluids as necessary.
  58.  

CLEANING & INSPECTING





Click image to see an enlarged view

Fig. Fig. 24 When removing nuts, bolts and other parts, place them in a tray or other container



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Fig. Fig. 25 Use a gasket scraper to remove the bulk of the old head gasket from the mating surface



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Fig. Fig. 26 An electric drill equipped with a wire wheel will expedite complete gasket removal



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Fig. Fig. 27 Check the cylinder head for warpage along the center using a straightedge and a feeler gauge



Click image to see an enlarged view

Fig. Fig. 28 Be sure to check for warpage across the cylinder head at both diagonals

Unless you are very familiar with engine rebuilding, it would be less time consuming and more cost efficient to send your old cylinder head out and have it rebuilt by a professional machine shop. Most machine shops guarantee their work and, that way, if there is a problem with the cylinder head rebuild, you can always take it back to be corrected at no extra cost to yourself.

  1. With the cylinder head removed from the car engine (see Cylinder Head Removal and Installation). Place the head on a workbench and remove any manifolds that are may be still connected. Remove all rocker arm retaining parts and the rocker arms, if still installed or the camshaft (see Camshaft Removal).
  2.  
  3. Turn the cylinder head over so that the mounting surface is facing up and support evenly on wooden blocks.
  4.  


WARNING
If an aluminum cylinder head, exercise care when cleaning.

  1. Use a scraper and remove all of the gasket material stuck to the head mounting surface. Mount a wire carbon removal brush in an electric drill and clean away the carbon on the valves and head combustion chambers.
  2.  
  3. Use a suitable dye penetrant, check the combustion chamber, intake and exhaust ports, head surfaces and the top of the head for cracks. If cracked, replace the cylinder head.
  4.  


WARNING
When scraping or decarbonizing the cylinder head, take care not to damage or nick the gasket mounting surface.

  1. Number the valve heads with a permanent felt-tip marker for cylinder location.
  2.  

RESURFACING





Click image to see an enlarged view

Fig. Fig. 29 Check the cylinder head for flatness across the head surface

If the cylinder head is warped, resurfacing by a machine shop is required. Place a straightedge across the gasket surface of the head. Using feeler gauges, determine the clearance at the center and along the length between the head and straightedge. Measure clearance at the center and along the lengths of both diagonals. If warpage exceeds the following specifications, the cylinder head must be resurfaced.



Maximum cylinder head warpage: 0.10mm
 
Maximum intake manifold surface warpage: 0.10mm
 
Maximum exhaust manifold surface warpage:
 

5M-GE engine-0.10mm

7M-GE engine-0.8mm



Maximum camshaft housing surface warpage: 0.10mm
 
Maximum cylinder head (block side) warpage:
 

3Y-EC and 4Y-EC engines-0.15mm



Click image to see an enlarged view

Fig. Fig. 30 Checks should be made both straight across the cylinder head and at both diagonals

 
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