TOYOTA CELICA 1987 Service Repair Manual

ENGINE MECHANICAL - Engine Tune-up
3.
* MEA&E VALVE CLEARANCE I
4. (a) Set No.1 cylinder to TDC/compression.
l Turn the crankshaft pulley and align its groove
with the “0” mark on the No.1 timing belt cover,
l Check that the valve lifters on the No.1 cylinder
are loose and valve lifters on the No.6 cylinder are
tight.
If not, turn the crankshaft pulley one complete revolution.
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. .
(b) Measure the clearance of No.1 (INI and No.4 (IN) and
No.1 (EX) and No.5 (EX) valves.
. . . .
l Measure only those valves indicated in the figure.,
0 Record the measurements which are. out of
specification. They will be used later to determine
the required reblacement shims.
Valve clearance (Cold) :
Intake 0.15 - 0.25 mm (0.0059 - 0.0098
Exhaust 0.20 - 0.30 mm (0.0079 - 0.0118
(c(c) Turn the crankshaft pulley 2/3 revolution (240”) and
measure the clearance of No.3 (IN) and No.5 (IN) and
No.3 (EX) and No.6 (EX) valves.
4 Check that the valve lifters on the No.3 cylinder
are loose.
0 Measure only those valves indicated in the figure.
l Record the measurements which are out of
specification. They will be used later to determine
the required replacement shims.
(d) Turn the crankshaft pulley 2/3 revolution ,(240°) and
measure the clearance of No.2 (IN) and No.6 (IN) and
No.2 (EX) and No.4 (EX) valves. : .-:1’.
0 Check that the valve lifters on the No.2 cyli i,:..?
are loose. c
.i
0 Measure only those valves indidated in the figure.
-I 0 Record the measurements which are out of
specification. They will be used later to determine
the required replacement shims.
ADJUST VALVE CLEARANCE .
(a) Remove the adjusting shim. ,
0 Turn the crankshaft.pulley to’ position the lobe on
the adjusting valve camshaft upward.
0 Using SST (A), press down the valve lifter and
place SST (B) between the camshaft and valve
lifter. Remove SST (A).
SST 09248-55010
NOTE: Before pressing down the valve lifter, position the
notch toward the spark plug.

EM-10 ._ ENGINE MECHANICAL - Engine Tune-up
EM053:
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38
EM4537
7. 5.
6.
l Remove the adjusting shim with a small
screwdriver and magnetic finger.
_.
._
(b) Determine the replacement shim size by using the
following (Formula or Chart).
i Using a mkxometer, measure the thickness of the
shim which was removed.
l Cal&late the thickness of the new shim so the
valve clearance comes within specified value.
T
. . . . . . *, Thickness of shim used
A . ...,,, * Valve clearance measured
N
. . . . . . . . Thickness of shim new
Intake N = T +-(A - 0.20 mm (0.0079 in.))
Exhaust N = T + (A - 0.25 mm (0.0098 in.))
l Select a new shim with a thickness as close as
possible to the calculated value.
NOTE: Shims are available in 17 sizes, in increments’of .,;.
0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.1 to
3.300 mm (0.1299 in.).
(cl Install a new adjusting shim.
l Place a new adjusting shim on the valve lifter.
l Using SST (A), press down the valve lifter and
remove SST (B).
c ,.
SST 09248-55010 :,y
RECHECK VALVE CLEARANCE
INSTALL CYLINDER HEAD COVERS
(See pages EM-59, 60)
INSTALL AIR INTAKE CONNECTQR
(a) Install a new gasket and air intake connector with the
four bolts and two nuts.
Torque : 180 kg-cm (13 ft-lb,. 18 N.m)
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F11868

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.(b) Install the air intake connector bracket mounting
bolts.
. .
. ~(6) ’ Install the.throttle body bracket’(s).
(d) Connect the throttle position sensor connector.
(e) ! Connect following hoses:
0 No.7 air hose
0 (w/ EGR) 6.
‘E6R vaixum modulator hoses
. (w/WC)’
BVSW hose
.’
l (w/ EGR)
VSV hose (for EGR)
1 (f) Connect the water by-pass hoses.
(g) (ex. MS RHD) ::‘. . ‘.
Connect the accelerator connecting rod.
.++:s (h) Install the: PCV pipe;. .:, ‘.f. -.,,
: ‘:
:, -’
‘2.. 1 :
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c , .

EM-12 ENGINE MECHANICAL - Engine Tune-up
r
(7M-GTE)
1. REMOVE ISC PIPE
(a) Disconn&t the hoses from the ISC pipe.
(b) Remove‘the two bolts and ISC pipe.
2. REMOVE PCV PIPE WITH HOSES
(a) Disconnect the oxygen sensor wire from the two
clamp.
:
(b) Disconnect the No.4 PCV hose from the ‘PCV pitie.
(c) Remove the two bolts.
(d) Disconnect the PCV pipe with hoses from the
cylinder head covers and throttle body.
‘. ,$’
ci ;- ,
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3. REMOVE INTAKE AIR CONNECTOR
(a) Disconnect the air valve hose from the intake air con-
nector.
(b) Loosen the clamp and remove the two bolts.
(c) Remove the intake air connector.
4. REMOVE IGNITION COVER
(a) Remove the oil filler cap.
(b) Remove the five nuts and ignition coil cover.
c ,r
5. REMOVE IGNITION COIL WITH BRACKET
(a) Disconnect the connector and ground strap.
(b) Remove the nut.
(c) Remove the No.1 and No.2 high-tension cords from
the ignition coil and clamp.
IdI Remove the ignition coil with bracket and high-ten-
sion cords.
(e) Remove the No.1 and No.2 high-tension cords from
the spark plugs.

ENGINE MECHANICAL &Engine Tune-up
EM-1 3
1
6. REMOVE CYLlNDER HEAD cOVERS
. .
(a) Remove the accelerator link.
(b) Disconn.ect the No.3 PCV hose.
(c) Remove the cylinder. head covers.
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- ,; f...C?‘
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.7. MEASURE VALVE CLEARANCE
.~. :. 1See+tep 3 oti page EM-91 3
6: ‘ADJUST VALVE CLEARANCE
j:
’ :
ISee ,tep 4 on pages EML9, 10)
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>*-* r-2. i.:
I / ‘.. . . 9. RFCHECK’ VALVE CLEARANCE
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10. INSTALL CYLiNDER HEAD COVERS
(See pages EM-59,601 ,_ .:
, ,-‘G j i rl.1. IN&ALL.lGNITION COIL WITH BRACKET
< .‘. ,_ ..- ,, ,,C’
:,la) Install theNo. and No.2 high-tension cords to spark
.. :I
l$w. .
._ i
$) &tall the ignition’coil withbracket and high-tension;.
cord. (Seepage I’C-,y 5)’ ;
(c) Install the No.‘l and No.2 high-tensioncords to igni-
tion coil and clamp. ,. ‘. “-. _
.;;
‘. ;
6, ..: ,-
.: .,,.. ‘y,’ I,.
(d) Install and torque the nut.
Torque : 55 Kg-cm (48 in..-lb, 5.4 Nnrn)
NOTE: Do not over tighten the nut.
(e) Connect the ground strap and connector.
12. INSTALL IGNITION COIL COVER
(a) Install the ignition coil cover with the five nuts.
fb) Install the oil filler cap.

EM-14 ,ENG!NE M&XlANICAL~ - Engine Tuhe-up
13. lNSTALL INTAKE AIR CONNECTOR
(a) Install the intake air connector to throttle body.
6) Iristall and tighten the two nuts. li
s
s
(cl Tighten the clamp.
Ed) Connect the air valve hose to intake air connector. i
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14;: INSTALL PCV PIPE WITH HOSES
(a) install the PCV pipe with hoses to the throttle body
.and cylinder head covers.
I . . /
, (b) . Install and tighten the two bolts.
,r ., F) .:, Connect the No.4 PCV hose to the PCV pipe.
(d) Connect the oxygen sensor wire to the two clam
‘,
. . . L. ,.
1: .15. INSTALL ISC PIPE
(a) Install the ISC pipe with the two bolts.
‘(b) Connect the hoses to the ISC pipe.
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i - -’ : ‘S -‘Adjii&i~ .#irn Selection Wing Chart
Shim thickness mm (in.)
!aranc
1 - 0, se ( cold I) :
-25 mm (0 .006 -0 .OlO in.) Shim
No. Thickness SiLrn ” Thickness
02 2.500 (0.0984) 20 2.95O’iO.1161)
04 2.550 (0.1004) 22 3.000 (0.118i)
06 2.600 (0.1024) 24 3.050 (0.1201)
08 2.650 (0.1043)
26 3.100 (0.1220)
10 2.700 (0.1063) 28 3.150 (0.1240)
12 2.750 (0.1083)
30 3.200 (0.1260)
1
Example: A 2.800 mm shim is Installed and the
measured clearance is 0.450 mm
Replace the 2.800 mm shim with
shim No. 24 (3.050 mm).

EM-16 ENGINE MECHANICA!. - Engine Tune-up
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Adjusting Shim Selection Using Chart
EXHAUST .-_
Lnstdod Shim Thlcknosr (mm) I
.-...
0~30~30)32/32~32132~4)34j34/34j
_. Shim thickness mm (in.)
Exhaust valve clearance (cold) :
0.20 - 0.30 mm (0.008 - 0.012 in.)
Example: A 2.800 mm shim is Installed and th
measured clearance is 0.450 mm
Replace the 2.800 mm shim with
shim No. 22 (3.000 mm).

ENGINE MECHANICAL. - Engine Tune-up
EM-?1 7.
INS’PECTIOlil ‘AhiD ADJUSTMENT O:F .-
IGNITION TIMING
1. VriARiiA. UP ENGINE.
Allow the engine to. reach normal operating temperature.
2.
CbNNECT TACHOMETER AND TIMING LIGHT TO
ENGINE
Connect the tachometer positive terminal to the check
connector terminal IG 0 .
CHECK CONNECTOR LOCATION: .,
s See pages FI-110, 111
CAUTION:
l Never allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.
, 4% 3.
EC21 18
s As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before using.
NOTE (7M-GTE): Connect the timing light pickup to t
No.6 cylinder high-tension cord.
CHECK IGNITION TIMING
(a) Using a service wire, short terminals T(MA) or
TEI (MS) and El of the check connector.
CHEC,K CCNNECTOR LOCATION.:
See pages FI- 1’10, 111
(b) Check the idle. speed.
Idle speed: /-
7M-GE w/ TWC 700 rpm
w/o TWC 800 rpm
7M-GTE 800 rpm
(c) Using a timing light, check the ignition timing.
Ignition timing: IO” BTDC @ idle
[w/ short-circuited T (TEl) and El
and Transmission in “N” range]
c,
If necessary, loosen the distributor (7M-GE) or cam posz-’
tion sensor (7M-GTE) bolt and turn the distributor (cam
position sensor) to align the marks. Recheck the timing
- after tightening the distributor (cam position sensor).
Torque: 140 kg-cm (10 ft-lb, 14 N-m)
(cl) Unshort the check connector.

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EM-18 ENGINE MECHANICAL - Engine Tune-up
4. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7M-GE ._ 10 -‘.13” BTDC @ idle
7M-GTE More than 12” BTDC @ idle
DISCONNECT TACHOMETER AND TIMING LIGHT
FROM ENGJNE