1994 Toyota Camry Changed Head Gasket, now Will not Start

Hello. And thanks for the donation. Much appreciated

Firstly we need to see if you are getting a spark !.

Remove a spark plug

plug it back into it's wire

hold plug and lead at rubber insulater with insulated pair of pliers (do NOT hold with hands you will get a shock)

hold bottom of plug about 1mm away from a good ground point on engine (any clean bolt head etc. Needs to be a clean ground use a bit of sandpaper if needed)

have someone crank engine over for you. You should see spark jumping across spark plug gap?

Let me know?

Ok so we are getting spark .. just check you are getting fuel ..can you smell fuel on plugs after cranking .. I think you are .. when you say it is spluttering, I think you have the timing slightly out ..you will need to check this before we go any further ? make sure your both timing marks are all set correctly ...these HAVE to be spot on ? let me know

You are getting fuel and spark .. you are quite correct your marks are lined up ... but once they are lined up .. before you totally tighten #1 idler pulley to spec .. crank needs to be set @ 45 degree BTDC mark on #1 timing belt cover .. explained below .. so the timing is slightly out on crank ... changeing it @ cam will be pot luck at getting it right .. but i applaud you for your setting skills ..let me know if you need any of the other diagrams !!

Installation
Install No. 2 idler pulley (if removed). Install and tighten bolt to specification. See TORQUE SPECIFICATIONS . Ensure idler pulley is clean and rotates smoothly.
Install No. 1 idler pulley and tension spring (if removed). Pry No. 1 idler pulley away from timing belt area as far as possible. Temporarily tighten No. 1 idler pulley bolt. Ensure idler pulley is clean and rotates smoothly.
Using crankshaft pulley bolt, rotate crankshaft so timing mark on crankshaft sprocket aligns with timing mark on oil pump housing. See Fig. 4 . This will position keyway in crankshaft sprocket at 12 o'clock position.
CAUTION:If reusing timing belt, ensure reference marks on timing belt align with reference marks placed on crankshaft and camshaft sprockets. Ensure timing belt is installed in original direction of rotation.

Ensure all sprockets and idler pulleys are clean. Install timing belt on crankshaft sprocket, oil pump sprocket, No. 1 idler pulley, and then No. 2 idler pulley in sequence.
Install timing belt guide with cupped side away from crankshaft sprocket and flat side toward timing belt. Install No. 1 timing belt cover and new gasket.
Align crankshaft pulley key groove with key in crankshaft. Install crankshaft pulley. Install and tighten crankshaft pulley bolt to specification.
Rotate crankshaft clockwise so cylinder No. 1 is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover. If reusing timing belt, ensure reference mark on timing belt aligns with upper edge of No. 1 timing belt cover.
Rotate camshaft, and align hole in camshaft sprocket with alignment mark on camshaft bearing cap. See Fig. 2 . Install timing belt on camshaft sprocket. If reusing timing belt, ensure reference mark on timing belt aligns with the reference mark on camshaft sprocket. Ensure tension exists on timing belt between the crankshaft and camshaft sprockets.
CAUTION:DO NOT rotate crankshaft counterclockwise, as viewed from timing belt end of engine.

Loosen No. 1 idler pulley bolt 1/2 turn. Rotate crankshaft pulley 2 full revolutions clockwise from TDC to TDC.
Ensure timing mark on crankshaft pulley aligns with "0" mark on No. 1 timing belt cover, and hole in camshaft sprocket aligns with alignment mark on camshaft bearing cap. See Fig. 2 . If timing marks are not aligned, remove timing belt and reinstall.
Rotate crankshaft clockwise 1 and 7/8 revolutions and align crankshaft pulley "0" mark with 45-degree Before Top Dead Center (BTDC) mark on No. 1 timing belt cover. See Fig. 5 .
Tighten No. 1 idler pulley bolt to specification. See TORQUE SPECIFICATIONS . Install No. 2 timing belt cover and gaskets. Install and tighten spark plugs to specification.
To install remaining components, reverse removal procedure. Install all bolts/nuts on right (timing belt side) engine mount before tightening to specification.
On Camry, when installing control rod and bracket on strut tower and right (timing belt side engine mount, tighten bolts to specification in sequence. See Fig. 6 . On MR2, tighten engine mount bolts in correct locations. See Fig. 7 . Adjust drive belts to proper tension.

Can you manually line up the cam timing marks and let me know where the crank timing mark is now ?? is it @45 degree ..@ "0" or is it way out ... does the belt feel tight .. ?? also do you have access to a compression tester ?? and you mentioned the plug you pulled was black covered .. was this an oil wet black or like a coal dusty blackness ?? let me know

NOTE:For 1992-96 Camry, the timing belt tension spring procedure has been revised. See REVISED TIMING BELT TENSION SPRING PROCEDURE (1992-96 CAMRY) .

Revised Timing Belt Tension Spring Procedure (1992-96 Camry)
From Toyota technical service bulletin EG001-99; January 29, 1999: For 1992-96 Camry, the timing belt tension spring procedure was revised. When replacing the timing belt on 1992-96 Camry with 2.2L, tension spring MUST be replaced. The revised tension spring 0 (Part No. 905-7-17003) is a 13-coil design which replaces the original 10-coil design.

spring Free Length
Except 1999-00 Camry......1.811" (46.00 mm)

Yes we need to replace the spring for the 13 coil type .. the newer type is shorter so I don't think we are getting the correct adjustment when setting @45 degree BTDC

5S-FE - REVISED TIMING BELT TENSION SPRING
TECHNICAL SERVICE BULLETIN
Reference Number(s): EG001-99, Date of Issue: January 29, 1999

Related Ref Number(s): EG001-99
ARTICLE BEGINNING
REVISED TIMING BELT TENSION SPRING
Model(s): 1992-1996 Toyota Camry 5S-FE
Section: Engine
Bulletin No.: EG001-99
Date: January 29, 1999
INTRODUCTION
The service replacement Timing Belt for the 5S-FE Engine has been revised. To insure that this belt fits properly, the Timing Belt and Timing Belt Tensioner Spring must be replaced as a set.
AFFECTED VEHICLES
1992-1996 Camry with 5S-FE Engines
PARTS INFORMATION
Refer to Fig. 1 .
PARTS INFORMATION
Previous Part NumberCurrent Part NumberPart Name
90507-1803090507-17003Tension Spring
13568-0904013568-09041Timing Belt

REPAIR PROCEDURE
Replace Tension Spring with revised part when replacing Timing Belt.

OK this vehicle is getting fuel. It's getting spark. We have set the timing up numerous times correctly. It should be firing up. We need to check compression. Can you beg/borrow/steal/rent or buy a compression tester. Most good autoparts stores rent tools out? The only other thing we could check is fuel. Is it getting totally flooded?Remove the plugs after cranking to see if they are drenched with gas. Or is something cutting fuel after initial injection.I'll look into this tonight.

Your compression is almost half what it should be .. even with a well used engine your almost 50 psi out on the minimum required ... why was you changeing the headgasket ? did the car car have a major cut out ?? the sensor in your pic is of the ECT engine coolant temp sensor see diagram below ... let me know

ENGINE COMPRESSION
Check engine compression with engine at normal operating temperature at specified cranking speed, all spark plugs removed and throttle wide open.
COMPRESSION SPECIFICATIONS
Application................................Specification
Compression Ratio.........................9.5:1
Compression Pressure..........178 psi (12.5 kg/cm2 )
Minimum Compression Pressure.....142 psi (10.0 kg/cm2 )
Maximum Variation Between Cylinders....14 psi (1.0 kg/cm2 )

You will need to compression test with plugs removed and oil level correct. The cold will not affect it to much as long as you crank each cylinder around 5 times. The old head gasket did have a leak I can see. But I have seen worse. From what I can see, the leak you pointed out was no where near enough to blow a couple of radiators. I'll be honest with you. I'm thinking this head is cracked or warped? Let me know the results of comp test.

When you had the head milled & cleaned..did they pressure test at the same time .. i would expect them too, but i have never had one done here in the USA, in england they do it as standard ? also you seem have done a fantastic job this being your first headgasket, so please do not take offence when i ask this ... you did torque the head down correctly ..? ..the reason i'm askin is we seem to have compression loss of the same amount on all 4 cylinders .. if the head was cracked or warped, i would expect at least one/two of them to be showing close to normal psi .. and the others showing low .. this engine has a leak somewhere on all 4 .. do you see where i'm coming from ?? you said you could at least get it running before .. was it a real sruggle to start it, then it ran real rough ?? let me know !!

Cylinder Head Bolt
Step 1..............................Ft.Lbs 36 (49)Nm
Step 2..............................Additional 90 Degrees

Thanks for the welcome. It could be the head is cracked/warped, as I said previously it should be checked when milled/cleaned? But it could also be, and I'm not happy saying this too you because of all the good work you put in ! But I'm now thinking after you first installed the gasket and set the timing. It was out. And when you cranked it over it has bent the valves. The only way we can check this is to remove the head again? It would have to be valves in every cylinder. Because the compression loss is across the 4 cylinders. If there are no valves bent then we have to be looking at the head being bad. And we need to have it pressure tested off the vehicle. Again this would have to be a major crack or warp to be across all 4 cylinders. I know this is a major step to take. But I don't see what else we can check without taking the head off? Let me know?

Ohh and the late shifting is trans issue and we can get to that later?