Fuel tank TOYOTA CELICA 1987 Service Repair Manual

EFI SYSTEM - Troubleshooting
FI-1 E
CONTINUED FROM PAGE FI-14 ._
CHECK FUEL SUPPLY TO INJECTOR
1. Fuel in tank
2. Fuel pressure in fuel line
(1) Short terminals +B and FP of the
check connector.
(2) You can feel fuel pressure in fuel
return hose. BAD 1. Fuel line - leakage - deformation
2. Fuse
3. Fuel pump (See age FI-73)
4. Fuel filter
5. Fuel pressure regulator (See. page FI-84)
6. Circuit opening relay (See page FI-1 13)
3. Check circuit opening relay
(See page FI-1 13)
OK
CHECK FUEL PUMP SWITCH IN AIR
FLOW METER (7M-GE)
Check continuity between terminals FP and
El with measuring plate of,air flow meter
,,’
open.
L
I BAD c
Air flow meter (See page FL96)
I OK
CHECK IGNITION TIMING
1. Short terminals T(MA) or TEl (MS) and
El of the check connector.
2. Check ignition timing.
STD: 10’ BTDC @ Idle
short circuited TIMA) or
3
I OK NO Adjust ignition timing (See page EM-l 7)
BAD 1. Wiring connection
2. Power to ECU
(1) .Fusible links
(2) Fuses
(3) EFI main relay
3. Air flow meter
4. Water temp. sensor
5. Air temp. sensor
6. Injection signal circuit
(1) Injector wiring

l-16 EFI SYSTEM - Troubleshooting
SYMPTOM - ENGINE OFTEN STALLS
CHECK DIAGNOSIS SYSTEM
Check for output of diagnostic code.
(See page Fl-26) * Diagnostic code(s) (See pages FI-30, 31, 32)
Malfunction
code(s)
Normal code
CHECK FOR VACUUM LEAKS IN AIR
INTAKE LINE BAD 1. Oil filler cap
2. Oil level gauge
3. Hose connections
4. PCV hose
I OK
CHECK FUEL SUPPLY TO INJECTOR
‘*-- Fuel in tank BAD
L. Fuel pressure in fuel line
(1) Short terminals +B and FP of the check
connector.
(2) You can feel fuel pressure in fuel
return hose. .
3. Check circuit opening relay
(See page FI-113) .
1. Fuel line - leakage - deformation
2. Fuse
3. Fuel.pump (See’ page FI-73)
4. Fuel filter
5. Fuel pressure regulator (See page FI-84)
6. Circuit opening relay (See page FI:1 13).
,
OK
CHECK AIR FILTER
I BAD Element - Clean or replace
OK
CHECK IDLE SPEED
STD: 7M-GE wl TWC 700 rpm
7M-GE w/o TWC 800 rpm
7M-GTE 800 rpm
t w
BAD ISC system
(I 1 Wiring connection
(21 ISC valve
(3) ECU
CHECK IGNITION TIMING ‘-
‘I. Short terminals TiMA) or TEl (MS) and
El of the check connector..
2. Check ignition timing.
STD: 10” BTDC @ Idling
short circuited T(MA) or
1
OK
CHECK SPARK PLUGS
Plug gap:
7M-GE Conventional Tipped Type
0.8 mm (0.031 in.)
7M-GE Platinum Tipped Type
1.1 mm (0.043 in.)
7M-GTE
0.8 mm (0.031 in.)
NOTE: Check compression pressure and
-I------- :+ -nyrpCCpn, c
NO
-I-
BAD - Adjust ignition timing. (See page EM-1 7)
1. Spark plugs
2. Compression pressure
Limit: 9.0 kg/cm2 (128 psi, 883
kPa)
at 250 rpm
3. Valve clearance (Cold)
STD: IN 0.15 - 0.25 mm
(0.06 - 0.010 in.)

?I-78 EFI SYSTEM - Fuel Systeti
-_
REMOVAL OF FUEL PUMP
._
Fuel Pump Bracket
Filter
. i’
@-Rubber Cushion
+ Non-reusable part
FI166
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
2. DRAIN GASOLINE FROM FUEL TANK
WARNING: Do not smoke or work near an open
flame when working on the fuel pump.
3.
4. REMOVE FUEL TANK
REMOVE FUEL PUMP BRACKET FROM FUEL TANK
(a) Remove the screws.
(b) Pull out the fuel pump bracket.
REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Remove the two nuts and disconnect the wires from
the fuel pump.
(b) Pull off the lower side of the fuel pump from the
bracket.
(c) Remove the fuel pump from the fuel hose.

EFI SYSTEM - Fuel System
FI-79
. .
/
A Fulcrum Length
2 - 7 mm (0.08 1 0.28 in.)
Pipe Hose
k ’
em -m-d-‘,
--
0 - 3 mm (0 - 0.12 in.) 6. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Remove the rubber cushion.
(b) Using a‘small screwdriver, remove the clip.
(4 Pull out the pump filter.
INSTALLATION OF FUEL PUMP
(See page Fi-78)
1.
2. INSTALL FUEL PUMP FILTER TO FUEL PUMP
(a) Install’the pump filter with the clip.
(b) install the rubber cushion.
INSTALL FUEL PUMP TO FUEL PUMP BRACKET
(a) Insert the outlet port of the fuel pump into the fuel
hose.
(b) Push the lower side of the fuel pump and install the
fuel pump.
3. INSTALL FUEL PUMP BRACKET
Install a new gasket and the pump bracket with the
screws.
Torque: 35 kg-cm (30 in-lb, 3.4 N-m)
4.
INSTALL FUEL TANK
(a) Apply a thin coat of oil to the flare and tighten the
flare nut.
(b) Then using SST, tighten the nut to the specified tor-
que.
SST 09631~22020
Torque: 310 kg-cm (22 ft-lb, 30 N-m)
NOTE: Use a torque wrench with a fulcrum length 30 cm
(1 1 .181 in.).
CAUTION:
l Tighten the fuel tank mounting bolts, etc. to the
specified torque.
l Tighten ‘the pipe union and flare nut (hose) to the
specified torque.
l Push in the pipe and insert-type hose to the
specified position, and install the clip to the
specified location.
l If reusing the hose, reinstall the clip at the original
location,
5. REFILL GASOLINE
6. CONNECT CABLE TO NEGATIVE TERMINAL OF
BATTERY

LM-4
I ENGINE MECHANICAL -* Troubleshooting
_.
TROUBLESHOOTING
Problem Possible cause I Remedy Page
Engine overheats Cooling system faulty Troubleshoot cooling system co-4
Incorrect ignition timing Reset timing EM-1 7
Engine will not crank or Starting system faulty Troubleshoot starting system ST-2
cranks slowly : .
Engine will not start/ Vacuum leaks Repair as necessary
hard to start 0 PCV hoses ”
(cranks OK) 0 (w/ EGR)
EGR valve
0 Intake manifold
0 Air intake chamber
0 Throttle body
0 ISC valve
Pulling in air between air flow meter and Repair as necessary FI-96, 93
throttle body
Ignition problems Perform spark test IG-5, 12
0 Ignition coil
0 Igniter
0 (7M-GE)
Distributor
(7M-GTE)
Cam position sensor
High-tension cord disconnected or broken Inspect cord IG-6, 13
No fuel supply to injector Troubleshoot EFI system FI-I 2
l No fuel in tank
0 Fuel pump not working
l Fuel filter clogged
0 Fuel line clogged or leaking
EFI system problems Repair as necessary
ISC system problem Check ISC system FL- 108
Spark plugs faulty Inspect plugs IG-7
Low compression Check compression EM-26, 2
Rough idle, stalls or Vacuum leaks Repair as necessary
misses 0 PCV hoses
0 (w/ EGR)
EGR valve
0 Intake manifold
0 Air intake chamber
0 Throttle body I
0 ISC valve
Pulling in air between sir flow meter and FI-96, 9
throttle body
Incorrect idle speed Check ISC system FI- 108
Incorrect ignition timing Reset timing EM-1 7
Ignition problems Perform spark test IG-5, 12
0 Ignition coil
0 Igniter
0 (-/M-GE)
Distributor
(-/M-GTE)
Cam position sensor
High-tension cord faulty Inspect cord IG-6, 13
EFI system problems Repair as necessary

ENGINE MECHANICAL - Cylinder Head
EM-&j
REMOVAL OF CYLINDER HEAD
1. (See pages EM-37, 38)
REMOVE AiiERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.
2.
3.
4. (7M-GTE)
REMOVE PS RESERVOIR TANK
Remove the two bolts, nut and, reservoir tank with bracket.
(‘IM-GTE),
REMOVE CAM POSITION SENSOR
REMOVE AIR INTAKE CHAMBER WITH CONNECTOR
(a) Remove the PCV pipe.
(b) Disconnect following connectors:
. (7M-GE)
Cold start injector connector
l Throttle position sensor connector
l ISC valve connector
(c) Disconnect following hoses: aI
l BVSV hose from throttle body
l EGR hoses from throttle.boby
l Vacuum transmitting p.ipe hose from intake cham-
ber
0 Pressure regulator hose
;, I
l VSV (for fuel pressure up) &es
. (7 M-GE)
Diaphragm hose
(d) Disconnect following hoses:
-
0 (7M-GTE)
Auxiliary air pipe hose from vacuum transmitting
pipe hose
l No.1 water by-pass hose from ISC valve
. (7M-GE)
No.3 water by-pass hose from throttle body ,
0 (-/M-GTE)
No.3 water by-pass hose from water by-pass pipe
(e) (w/ EGR)
Remove the EGR pipe mounting bolts.
(f) Remove the manifold stay mounting bolts.

-.
,y. ,. P > .: (i) install the EGR
pipe mounting bolts.
:i
(k) Install the manifold ‘stay mounting bolt.
(I) Connect following hoses:
. 47M-GE)
No.3 water by-pass hose to throttle body
(‘IM-GTE)
0 Auxiliary air pipe hose to vacuum transmitting pipe ’
l No.1 water by-pass hose to ISC valve .
(m) Connect following hoses: .,
. (7M-GE)
Diaphragm hose
0 VSWfor fuel. pressure up)hoses
l Pressure regulator hose
0 EGR hoses to throttle body and vacuum transmit-
ting pipe.
0 Vacuum transmitting pipe hose to intake chamber
-I
0 BVSV hose to throttle body
(r-r) Connect following wires:
0 ISC valve connector
0 Throttle position sensor connector
0 (‘/M-GE)
Cold start injector connector.
(01 Install the PCV pipe.
16. (‘IM-GTE)
INSTALL CAM POSITION SENSOR
(See steps 1, 2 on page 10-26)
17. (7M-GTE)
INSTALL PS RESERVOIR TANK
Install the PS reservoir tank with bracket.
18. INSTALL ALTERNATOR AND ADJUSTING BAR
(a) Install the alternator and adjusting bar.
(b) Install the drive belt.
(See page EM-361
(c) Connect the No.3 PCV pipe.