1992 Toyota Cressida

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1 Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

2 Fig. 7: Exploded View Of Typical Cylinder Head & Components Fig. 8: Cylinder Head Bolt Removal Sequence Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

3 Fig. 9: Cylinder Head Bolt Installation Sequence Installation (Cressida) 1. Install EGR cooler, No. 2 timing belt cover, intake manifold, heater union and gaskets on cylinder head (if removed). Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS TABLE - CRESSIDA. CAUTION: Ensure spacers are installed on cylinder head with Black ring facing upward, away from cylinder head. 2. Install insulators for delivery pipe on cylinder head. Install Black ring on spacers for delivery pipe. Install spacers in delivery pipe holes on cylinder head. 3. Install injectors and delivery pipe. Ensure injectors rotate smoothly with delivery pipe installed. Install delivery pipe bolts, and tighten them to specification. See TORQUE SPECIFICATIONS TABLE - CRESSIDA. 4. Install camshafts. Use proper installation procedure. See CAMSHAFT. Ensure all surfaces are clean. 5. Apply sealant at front of cylinder block. See Fig. 10. Install NEW cylinder head gasket in proper position. See Fig. 10. Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

4 Fig. 10: Applying Sealant To Cylinder Block & Installing Cylinder Head Gasket 6. Carefully lower cylinder head into position, and connect coolant by-pass hose to union. Apply light coat of oil to threads and underside of cylinder head bolts. 7. Install cylinder head bolts. Using hex adapter, tighten cylinder head bolts to specification in sequence using several steps. See Fig. 8 and Fig. 9. See TORQUE SPECIFICATIONS TABLE - CRESSIDA. 8. If camshaft or cylinder head components were serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. 9. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS TABLE - CRESSIDA. Before installing No. 1 and No. 2 valve covers, apply sealant at indicated areas on front of cylinder head. See Fig Ensure gasket for exhaust manifold is installed with protrusion toward rear of cylinder head. See Fig. 11. Coat distributor "O" ring with engine oil. 11. When installing distributor, rotate crankshaft clockwise so No. 1 cylinder is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

5 12. Align protrusion of distributor gear with groove on distributor housing. See Fig. 12 and Fig. 13. Install distributor so bolt hole on cylinder head aligns with center of distributor flange. Install distributor retaining bolt. Adjust fluid levels, control cables and ignition timing. Fig. 11: Installing Exhaust Manifold Gasket Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

6 Fig. 12: Installing Distributor Or Camshaft Position Sens (Cressida & Supra Non-Turbo) Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

7 Fig. 13: Installing Distributor Or Camshaft Position Sensor (Supra Turbo) Removal (Supra) 1. Disconnect negative battery cable. Drain cooling system. Disconnect accelerator cable, throttle valve cable (A/T models) and cruise control cable. WARNING: To prevent air bag deployment (if equipped), disconnect negative battery cable at least 60 seconds before working on vehicle. 2. Remove air cleaner hose and intake air pipes. Disconnect necessary electrical connections, coolant hoses, control cables, fuel lines and vacuum hoses. Remove alternator. 3. On turbo models, remove power steering fluid reservoir. On all models, remove PCV tubing with hoses. Remove support braces and air intake connector. See Fig Place suitable container under cold start injector fuel line. Cover fuel line connection using shop towel. Slowly loosen fuel line union bolt to release fuel pressure. Once fuel pressure is released, remove union bolts, gaskets and cold start injector fuel line. 5. Remove EGR pipe retaining bolts. On non-turbo models, remove EGR vacuum modulator from bracket. On all models, remove necessary piping, retaining bolts/nuts, air intake chamber and gasket. See Fig Remove fuel pipes from delivery pipe, fuel pressure regulator or pulsation damper, and fuel filter. Disconnect spark plug wires. 7. Remove retaining bolt and distributor (non-turbo models) or camshaft position sensor (turbo models). Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

8 Remove oil dipstick and necessary piping to access valve covers. Disconnect exhaust pipe from exhaust manifold or turbocharger outlet elbow (if equipped). 8. On turbo models, remove turbocharger (if necessary). See TURBOCHARGER under REMOVAL & INSTALLATION. Remove ignition coil assembly and bracket. 9. On all models, remove retaining nuts, exhaust manifold and gasket. Remove coolant outlet housing (if necessary). Remove No. 1, No. 2 and No. 3 valve covers, and gaskets. See Fig Remove spark plugs. Remove timing belt and camshaft timing pulleys. See TIMING BELT. CAUTION: Cylinder head bolts must be removed in proper sequence to prevent cylinder head warpage. 11. Using Hex Adapter ( ), loosen cylinder head bolts in sequence using several steps. See Fig. 8 and Fig. 9. Remove cylinder head bolts. Lift cylinder head upward, and disconnect coolant by-pass hose from union. Remove cylinder head and gasket. NOTE: If cylinder head removal is difficult, pry between cylinder head and projected area near front of cylinder block. DO NOT damage sealing surfaces on cylinder block and cylinder head. 12. Remove No. 2 timing belt cover, delivery pipe, insulators and spacers from cylinder head. DO NOT allow injectors to fall from delivery pipe during removal. 13. Remove retaining bolts/nuts, intake manifold and gasket, and EGR cooler. See Fig. 7. Remove bolt and heater union, which heater coolant line connects to, from rear of cylinder head. Remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION. Inspection (Supra) 1. Inspect cylinder head warpage at cylinder block and manifold areas. Replace cylinder head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. 2. Check intake manifold, air intake chamber and exhaust manifold warpage. If warpage exceeds specification, replace appropriate components. See WARPAGE SPECIFICATIONS TABLE (SUPRA). 3. Inspect cylinder block deck surface for warpage. Replace cylinder block if deck warpage exceeds specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS. Inspect camshaft and components. See CAMSHAFT under REMOVAL & INSTALLATION. WARPAGE SPECIFICATIONS (SUPRA) Application Maximum Warpage: In. (mm) Air Intake Chamber.0039(.099) Exhaust Manifold Turbo Models.0197(.500) Non-Turbo Models.0295(.749) Intake Manifold.0039(.099) Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

9 Installation (Supra) 1. Install EGR cooler, No. 2 timing belt cover, intake manifold, heater union and gaskets on cylinder head (if removed). Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS TABLE - SUPRA. CAUTION: Ensure spacers are installed on cylinder head with Black ring facing upward, away from cylinder head. 2. Install insulators for delivery pipe on cylinder head. Install Black ring on spacers for delivery pipe. Install spacers in delivery pipe holes on cylinder head. 3. Install injectors and delivery pipe. Ensure injectors rotate smoothly with delivery pipe installed. Install delivery pipe retaining bolts, and tighten them to specification. See TORQUE SPECIFICATIONS TABLE - SUPRA. 4. Install camshafts. Use proper installation procedure. See CAMSHAFT. Ensure all surfaces are clean. 5. Apply sealant at front of cylinder block. See Fig. 10. Install NEW cylinder head gasket in proper position. See Fig Carefully lower cylinder head into position, and connect coolant by-pass hose to union. Apply light coat of oil to threads and underside of cylinder head bolts. 7. Install cylinder head bolts. Using hex adapter, tighten cylinder head bolts to specification in sequence using several steps. See Fig. 8 and Fig. 9. See TORQUE SPECIFICATIONS TABLE - SUPRA. 8. If camshaft or cylinder head components were serviced, adjust valve clearance. See VALVE CLEARANCE ADJUSTMENT under ADJUSTMENTS. 9. To install remaining components, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS TABLE - SUPRA Before installing No. 1 and No. 2 valve covers, apply sealant at indicated areas on front of cylinder head. See Fig Ensure gasket for exhaust manifold is installed with protrusion toward rear of cylinder head. See Fig. 11. On turbo models, ensure proper procedure is followed when installing turbocharger. See TURBOCHARGER under REMOVAL & INSTALLATION. 11. Coat distributor or camshaft position sensor "O" ring with engine oil. When installing distributor or camshaft position sensor, rotate crankshaft clockwise so No. 1 cylinder is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on timing belt cover. 12. On non-turbo models, align protrusion of distributor gear with groove on distributor housing. See Fig. 12 and Fig. 13. Install distributor so bolt hole on cylinder head aligns with center of distributor flange. Install distributor retaining bolt. 13. On turbo models, align drilled mark on gear with groove on camshaft position sensor housing. See Fig. 12 and Fig. 13. Install camshaft position sensor so bolt hole on cylinder head aligns with center of camshaft position sensor flange. 14. Install camshaft position sensor retaining bolt. On all models, adjust fluid levels, control cables and ignition timing. TURBOCHARGER Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

10 Removal (Supra Turbo) 1. Disconnect negative battery cable. Drain cooling system. Disconnect intake air hoses from turbocharger. Disconnect PCV hose and electrical connector at airflow meter. 2. Disconnect necessary hoses, and remove intake air hose, air cleaner cap and airflow meter. Disconnect oxygen sensor. Remove nuts, washer and heat insulator from turbocharger. 3. Remove engine oil dipstick, dipstick tube and "O" ring. Remove retaining nuts, and disconnect exhaust pipe from outlet elbow. Remove retaining nuts and union bolt, and disconnect oil pipe from cylinder block. See Fig Remove retaining bracket and support brace. Disconnect coolant hose from coolant pipe. Disconnect union pipe from coolant outlet housing. Remove retaining nuts, turbocharger and gasket. Remove coolant pipe, oil pipe and gaskets from turbocharger (if necessary). Inspection WARNING: To prevent air bag deployment (if equipped), disconnect negative battery cable at least 60 seconds before working on vehicle. 1. Ensure impeller wheel (air intake side) rotates smoothly and does not bind or drag. Replace turbocharger if impeller wheel binds or drags. 2. Install dial indicator with stem resting on shaft at impeller wheel. Push shaft back and forth, and note turbocharger end play. 3. Install dial indicator with stem in oil outlet hole and resting on shaft. See Fig. 15 and Fig. 16. Move shaft upward and downward, and check radial play. Replace turbocharger assembly if end play or radial play exceeds specification. See TURBOCHARGER SPECIFICATIONS table. NOTE: Ensure dial indicator stem is through opening in spacer bearing and resting on shaft when checking radial play. TURBOCHARGER SPECIFICATIONS Application In. (mm) Maximum End Play.0051(.130) Maximum Radial Play.0071(.180) Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

11 Fig. 14: Exploded View Of Turbocharger & Components Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

12 Fig. 15: Checking Turbocharger End Play Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

13 Fig. 16: Checking Turbocharger Radial Play CAUTION: Ensure at least 20 cc of clean engine oil is poured into oil inlet on turbocharger while rotating impeller wheel to prevent bearing damage. Installation 1. Pour at least 20 cc of clean engine oil into oil inlet on turbocharger while rotating impeller wheel. Install coolant pipe, oil pipe and gaskets (if removed). Tighten nuts to specification. See TORQUE SPECIFICATIONS TABLE - SUPRA. 2. Install NEW gasket on exhaust manifold, with protrusion facing away from front of engine. See Fig. 17. Install NEW gasket on oil return hole in cylinder block. Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

14 3. Install turbocharger on exhaust manifold. Install turbocharger nuts finger tight. DO NOT tighten them to specification yet. Install oil pipe-to-cylinder block nuts finger tight only. Install gaskets and oil pipe-tocylinder block union bolt finger tight only. 4. Tighten turbocharger nuts, oil pipe-to-cylinder block nuts and then oil pipe-to-cylinder block union bolt to specification in sequence. See TORQUE SPECIFICATIONS TABLE - SUPRA. 5. Install gaskets and union pipe-to-coolant outlet housing union bolt. To install remaining components, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS TABLE - SUPRA. Fill cooling system. Fig. 17: Installing Turbocharger Gasket On Exhaust Manifold CRANKSHAFT FRONT SEAL Removal & Installation (Timing Case Installed) 1. Remove timing belt and crankshaft timing pulley. See TIMING BELT under REMOVAL & INSTALLATION. Using Seal Puller (SST ), remove seal from timing case. 2. To install, apply grease to sealing lip of NEW seal. Using hammer, Driver (SST ) and Seal Installer (SST ), install seal. To install remaining components, reverse removal procedure. Removal & Installation (Timing Case Removed) Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

15 Using screwdriver and hammer, tap seal from timing case. To install, apply grease to sealing lip of NEW seal. Using hammer, Driver (SST ) and Seal Installer (SST ), install seal. OIL PUMP DRIVE SHAFT SEAL NOTE: See OIL PUMP DRIVE SHAFT SEAL under ENGINE OILING. TIMING BELT WARNING: To prevent air bag deployment (if equipped), disconnect negative battery cable at least 60 seconds before working on vehicle. Removal 1. Disconnect negative battery cable. Drain cooling system, and remove radiator. 2. Remove spark plugs. Remove thermostat housing, thermostat and gasket. Remove accessory drive belts, fan and water pump pulley. Remove No. 3 timing belt cover and gasket. See Fig. 18. Monday, May 16, :32:47 PM Page Mitchell Repair Information Company, LLC.

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