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1991 Corolla Head Gasket Replacement


Brad Granath
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So, I picked up this 91 Corolla the other day.

Series: AE92L-DEMRKA
Year: 1991
Engine Model: A4-FE v1
Mileage: 240,000

It had an issue with coolant and oil mixing, so I popped the head off to take a look at the head gasket. The gasket has definitely failed, so I'm replacing that. A few questions:

1) I heard somewhere that head gaskets don't just fail on their own, and that if I don't find the original problem, the new head gasket will just pop again. The head does not appear to be warped at all, the radiator is new, and the water pump seems OK. One cylinder (the one near the gasket failure) definitely had some water in it. Upon disassembly of the head, I found that the exhaust manifold was cracked down the middle (as well as a muffler that had rusted off), so I picked up a exhaust manifold and muffler at the Pick n Pull. Is there anything else I should look at?

2) When I apply the new gasket, should I put a little sealant on it to hold it in place while I'm installing it, or is this a NO CONTAMINANTS! situation? I don't see anywhere in the repair manual that mentions doing anything like that, but the head and block were covered in gasket gunk. What's the best way to prepare the surfaces of the block and head to make the best seal on the gasket?

3) I want to make sure I get things cleaned out before I put it back together. I'm not in a position to take the block apart, so that has to stay in the car. I'm gonna blow out the oil passages and bolt holes out with compressed air. The water jackets seem a little rusty/scaley, and probably have a little bit of shaved off gasket gunk in them now, but I really can't reach them. Can I just connect a garden hose to the water inlet and stick a pan under the outlet and flush it out after I've put the head back on?

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