TOYOTA CELICA 1987 Service Repair Manual

TOYOb4 ‘.
REPAIR MANUAL

COOLtNG
SYSTEM m
SYSTEM m
SVSTEM m
SYSTEM m
0 1996 TOYOTA MOTOR CORPORATION
All rights reserved. This book may not be re-
produced or copied, in whole or in part, with-
out the written permission of Toyota Motor
Corporation.

,. a,.. .,.,T
Pl9. :-, ,::::;:;:
HOW TO USE THIS MANUAL . . . , . , , . . . . . . . . . . . . . IN-2
I
IDENTIFICATION INFORMATION . . . . . . . . . . . . . . . . . IN-4 m
GENERAL REPAIR INSTRUCTIONS . . . . . . z., . . . . a. IN-4 .
PRECAUTIONS FOR VEHICLES EQUIPPED WITH
A CATALYTIC CONVERTER . . . , . , . . . . . . .
l . . . . . . IN-6
ABBREVIATIONS USED IN THIS MANUAL . . . . . . . . IN-7
,

IN-2 INTRODUiTlON - How to Use This Manual
._. ._. -,-. . .
.
HOW TO USE THIS MANUAL
To assist you in finding your way through this manual, the Set-
tion Title and major heading are given at the top of every page.
An INDEX is provided on the 1 st page of each section to guide
YOU to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain to al/repair operations contained in that section. Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to
help you diagnose the system problem and find the cause. The
repair for each possible cause is referenced in the remedy
COI-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. lt
identifies the components and shows how the
patiS fit
together.
Example:
Oil Pump
Shaft Drive Gear
Oil Pump Outlet Pipe
Oil Pump
Strainer
Drive Shaft
Relief Valve------Q
Oil Pump Cover------&
75 (65 in.-lb, 7.4)
-Union Bolt
(1
cg-cm (ft-lb, N.m : Specified torque
) Non-reusable part
LUO5

INTROkJCT-iON - How to Use This Manual
I IN-3
The procedures are presented in a step-by-ster format:
0 The illustration shows what to do and where to do it.
0 The task heading tells what to do.
0 The detailed text tells how to perform the task and gives
other information such as specifications and warnings.
Example:
J / Task heading: _ w at to do
tllus tra tion:
what to do and where 2. IF NECCESdY, REPLACE DRIVE SH FT BEARING
Using SST, replace the No.1 bearing by sing No. 2 bear-
ing as a guide.
SST 092 15-00100 (092 15-00120, 09 15-00150,
/ 092 1500160,092 15-002 10, 09 14-00220)
Set part No.
i Compone t part No.
D&/ail text: how to do it
(i) Tightecthe No. 3 and No. 7 bearing cap bolt a little at
a time and in the sequence shown n the figure.
Torque: 500 kg-cm (36 ft-lb, 49 NW)
.-Specification
This format provides the experienced technician with a FAST
TRACK to the information needed. The upper case task heading
can be read at a glance and only when necessary, the text
below it provides detailed information. Impor:ant specifications
and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. However, when they
are required you are given the page to go to.
SPECIFICATIONS
Specifications are presented in bold type
the applicable step. You never have to I
look up your specifications. All specifica
Appendix A, Specifications, for quick
WARNINGS, CAUTIONS, N
0 WARNINGS are presented in bold d indicate there is
a possibility of injury to you or ot
0 CAUTIONS are also presented in bold
possibility of damage to the compone
0 NOTES are separated from the text
type. They provide additional infor
ciently perform the repair.

IN-4 Identification Information,
INTRODUCTION - General Repair Instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
Seal Lock Adhesive
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2.
3. During disassembly, keep parts in order to facilitate
reassembly.
Observe the following:
(a)
(b) Before performing electrical work, disconnect ‘the
negative (-1 cable from the battery terminal.
If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
(e)
(f) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
Be sure the cover for the positive (+I terminal is pro-
perly in place.
4.
5. Check hose and wiring connectors to make sure that they
are secure and correct.
Non-reusable parts
(a)’ Always replace cotter pins gaskets, O-rings, oil seals,
etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the “+” symbol.
6. Precoated Parts
Precoated parts are the bolts, nuts, etc. which are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.

INTRODUCTION - General Repair Instructions
IN-S
(b) Recoating of Precoated Parts
(1) Clean off the old adhesive from the part’s
threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
part’s threads.
(c) Precoated parts are indicated in the component
illustrations by the “*” symbol.
7. When necessary, use a sealer or gaskets to prevent leaks.
8. Carefully observe all specifications for bolt torques.
Always use a torque wrench.
9. Use of special service tools (SST) and special service
materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and follow the proper work procedure. A list of SST and
SSM can be found at the back of this manual.
10. When replacing fuses, be sure the new fuse is the correct
amperage. DO NOT exceed the fuse amp rating or use one
of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on a jack alone, even for a small job
that can be finished quickly.
WRONG
CORRECT 12. Observe the following precautions to avoid damaging the
parts:
(a) Do not open the cover or the case of the ECU unless
absolutely necessary. (If the IC terminals are touched,
the IC may be destroyed by static electricity.)
(b) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
(c) When disconnecting vacuum hoses, pull on the end
of the hose, not the middle.
(d) When separating electrical connectors, pull on the
connector itself, not the wires.

‘:CHARG!NG SYSTEM
Page
PRECAUTIONS ..,**....*..*..,,*....,,.*........ CH-2 *
TROUBLESHOOTING ,,..*.....*..........*..... CH-2
CH.ARGlNG SYSTEM CIRCUIT ..,n....*.,.,.*...m C.H-3
ON-VEHICLE INSPECTION .,...,....‘.,,......*~
w-3
ALTERNATOR ,,,~,..,*~.......~....,*,,...~.... CH-7

CH-2 CHARGING SY&EM - Precautions, Troubleshooting
._
: PRECAUTIONS
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
given a quick charge.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is run-
ning.
Discharge warning
light does not light
with ignition ON and
engine not ‘running
Problem
Discharge warning
light does not go out
with engine running
(battery requires fre-
quent recharging
Possible cause
Fuse blown
Light burned out
Wiring connection loose
IC regulator faulty
TROUBLESHOOTING
Remedy
Check “CHG” and
“IGN” fuses
Replace light
Tighten loose connections
Replace IC regulator
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
IC regulator or alternator faulty
Wiring faulty Adjust or replace drive belt
Repair or replace cables
Check “ENG” fuse
Replace fusible link
Check charging system
Repair wiring
Page
CH-7
CH-4
CH-3

:usible
.ink
4LT
MA/
‘M-GE)
,258 Ignition Switch
Fuse
AM2 -0p IG2 (MA) 15~4
c (MS) 7.5A
Fusible
Link
AM2 30A
:usible
-ink
I (MA)
I/IAIN 2.OL (MS)
T Battery
P
/
CHG 7.5 A
I
i
8
I I .
i
m
Alternator
1 ON-VEHICLE INSPECTION
1.
tieI
fel
i 002
CHECK BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard specific gravity
When fully charged at 20°C (66°F):
1.25 - 1.27
If not within specifications, charge the battery.
(b) Check the electro!yte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
’ 2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible links and fuses for continuity.
c
CHOZRRI