1987 TOYOTA CELICA Service Repair Manual

ENGINE MECHANICAL - Cylinder Head
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IN88 00 00 00 00 00
88 88 88 ,ge 88
No. 1 No. .2 No. 3 No. 4 No. 5 No. 6
EM06’
SSSEMBLY OF CYLINDER HEAD ..‘. ““..I.
See pages EM-37, 381
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NOTE:
0 Thoroughly clean all parts to be assembled.
0 Before installing the parts, apply neti engine oil to all
sliding and rotating surfaces.
0 Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Insert the valves in the cylinder head valve guide
bushing. Make sure the valves are installed in the cor-
rect order.
(b) Using SST, install new oil seals on the valve guide
bushings.
SST 09201-41020
(c) Install spring seats, springs and spring retainers.
(d) Using SST, compress the valve retainers and place
two keepers around the valve stem.
SST 09202-70010
(e) Tap the stem lightly to assure proper fit.
2. INSTALL VALVE LIFTERS WITH SHIMS
Make sure the valve lifters with their shims are installed in
the correct order.
3. INSTALL CAMSHAFTS AND blL SEALS
(a) Apply engine oil to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.

EM-56
ENGINE MECHANICAL - Cylinder f-lead
I-
I: Intake
E: ljxhaust No.? - No. 7
Front Mark Intake
Exhaust (4 Coat all bearing journals with engine oil.
(d) Place the camshafts on the cylinder head as shown in
the figure,
NOTE: The eihaust camshaft has a distributor (‘IM-GE)
or cam position sensor (7M-GTE) drive gear.
(e) Apply seal packing to the areas indicated in the
figure.
Seal packing:
Part No.06826-00080 or equivalent
NOTE: Install the No.1 bearing cap immediately after
applying the. seal packing.
(f) Place bearing caps on each journal with the front
marks pointing toward the front.
(g) Tighten each bearing cap bolt a little at a time and in
the sequence shown in the figure.
(h) Using SST, drive in a new camshaft oil seal.
SST 09223-50010
NOTE: Be careful not to install the oil seal slantwise.

ENGINE MECHANICAL - Cylinder Head
EM-67
EM302
EM2921
(i) Tighten the No.3 and No.7 bearing cap bolts a little at
a time and in the sequence shown in the figure.
Torque:
20.0 kg-c* (14 ft-lb, 20 N-ml
(i) Torque each bearing cap bolt a little at a time and in
the sequence shown in the figure.
Torque : 200 kg-cm (14 ft-lb, 20 N-m)
(k) Check the camshaft thrust clearance.
4.
(w/ EGR)
INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts.
Torque :
140 kg-cm (IO ft-lb, 14 Nmrn)
(w/o EGR)
INSTALL EGR HOLE PLATE
Install a new gasket and EGR hole plate with the two bolts.
5. INSTALL HEATER UNION
(a) Install a new gasket, union, another gasket and union
bolt to the cylinder head.
(b) Torque the union bolt.
Torque:
600 kg-cm (43 ft-lb, 59 N-m)
6. INSTALL NO.2 ENGINE HANGER AND GROUND
STRAP
Torque:
400 kg-cm (29 ft-lb, 39 N-m)
7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) (w/ EGR)
0 Install the intake manifold and VSV with the two
nuts and seven bolts.
l Install the EGR valve with the two nuts.
l Torque the bolts and nuts.
Torque: 180 kg-cm (13 ft-lb, 18 Nnrn)

EM-58
ENGINE MECHANICAL - Cylinder Head
-.
(w/o EGR)
0 install.-the intake manifold four nuts and seven
bolts.
l Torque the bolts and nuts.
Torque :
180 kg-cm (13 ft-lb, 18 N.mI
8.
INSTALL DELIVERY PIPE WITH INJECTORS
(a)
Install the six insulators into the injector hole of the
cylinder head.
(b) Install the black rings on the upper portion of each of
the three spacers. Then install the spacers on the
delivery pipe mounting holes of the cylinder head.
(c) Place the injectors together with delivery pipe on the
cylinder head.
(d) Make sure that the injectors rotate smoothly.
(e) Install the three thinner spacers and bolts.
Torque the bolts.
Torque :
180 kg-cm (13 ft-lb, 18 N*m)
9.
INSTALL ALTERNATOR BRACKET
Torque :
400 kg-cm (29 ft-lb, 39 N.rnI
16. INSTALL NO.2 TIMING BELT COVER

ENGINE MECHANICAL - CylinderHead
EM&Q
C Front
EX
EM300’
:
‘INSTALLATl.QN’OF CYLINDER
(See pages EM-37, 38)
1. INSTALL CYLINDER HEAD
(a) Apply seal packing to the two i
Seal packing: Part No. 08826-00080 or equiyafent
(b) Place a new cylinder head gasket on the cylinder
block.
CAUTION: Be careful of the’installation direction.
!
(c) Place the cylinder head on the cylinder head gasket,
and connect the No.5 water by-pass hose to the
union.
Id) Apply a light coat of the.,engine oil on the threads and
under the cylinder head ‘bolts.
(e) Using SST, install and uniformity tighten the fourteen
cylinder head bolts. in several passes and in the
sequence shown.
SST 09043-38 100
Torque: >800 kg-cm (E8 ft-lb, 78 N=m)
2.
3.
4. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT ’
(See steps 8 to 12 and 14 on pages EM-34 to 36)
INSTALL SPARK PLUGS
(See page 16-71 ~
INSTALL CYLINDER HEAD COVERS
(a) Using SST, install the No.3 cylinder head cover and
heater hose clamp.
SST 09923-00010 in.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)

EM-60
ENGINE MECHANICAL c Cylinder Head
(b) Apply seal packing to the cylinder head as shown in
the figure.
Seal packing: .-Part No.08826-00080 or equivalent
*
(cl Install the No.1 and No.2 cylinder head covers.
Torque: 25 kg-cm (22 in-lb, 2.5 N*m)
(d) (MA)
Install the heater hose clamp.
(e) (7M-GTE)
Install the accelerator link.
5.
INSTALL WATER OUTLET HOUSING
EM302
(a) Install a new gasket and water outlet housing with
the bolt and two nuts.
(b) Connect the No.6 water by-pass hose.
(cl, (7M-GE)
Install a new gasket, union, another gasket and union
bolt to the water outlet housing.
Front * 6. INSTALL EXHAUST MANIFOLD
(a) Face a new exhaust gasket so the protrusion is facing
the rear and install on the cylinder head.
EM2949

ENGINE MECHANICAL- - .Cyli,nder Head
I.
(b) Install the
exhaust manifold with the seven nuts.
Torque: 400.kg-cm ‘(29 ft-lb, 39 N-m)
(c) (7M-GTE)
Install the exhaust manifold stay with the three bolts.
‘.
.(d) (TM-GTE)
install the heat insulators with the five bolts.
7. (7M-GTE)
INSTALL TURBOCHARGER
(See steps 4 to 8 and 10 to 12 on pages TC-15 to 17)
8. (7M-GE)‘
INSTALL OIL DIPSTICK
9. (7M-GE)
.
INSTALL DISTRIBUTOR AND HIGH-TENSION CORDS
(See page 10-22)

EM-62
ENGINE MECHANICAL + Cylinder Head
11. INSTALL NO.2 FUEL PIPE
(a) Install a r-13~ gasket, No.2 fuel pipe, another gasket
and union bolt to the pressure regulator.
Torque: 2bO kg-cm (18 ft-lb, 28 N-m)
(b) Install the No.2 fuel pipe to the delivery pipe with the
bolt.
12. INSTALL ~0.1 FUEL PIPE AND PULSATION DAMP&~
(a) Install a new gasket, No.1 fuel pipe, another gasket
and pulsation damper to the delivery pipe.
Torque: 400 kg-cm (29 ft-lb, 39 N*m)
(b) Install the No.1 fuel pipe and VSV to the intake
manifold.
(c) Connect the No.1 fuel pipe to the fuel support (MA)
or fuel filter (MS).
13. INSTALL ENGINE WIRE
(a) Install the engine wire to the each clamps.
(b) Connect following wires:
0 Three VSV connectors
0 Knock sensor connector
0 Ground strap to intake manifold
l Injector connectors
l Distributor connector
l Cold start injector time switch connector
0 Water temp. sender gauge connector
l Water temp. sensor connector
l Oil pressure sender gauge connector
l (w/ nvc)
Oxygen sensor connector
14. (7M-GTE)
INSTALL IGNITION COIL WITH BRACKET
(See steps 11, 12 on page EM-1 31
15. INSTALL AIR INTAKE CHAMBER WITH CONNECTOR
(a) Position a new gasket on the intake manifold.
(b) (7M-GTE)
Connect the cold start injector connector