engine TOYOTA CELICA 1987 Service Repair Manual

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ENGINE MECHANICAL - Cylinder Block
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EM3765 EM3780
INSPECTIC)N OF CRANKSHAFT
1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.08 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the ’
crankshaft.
NOTE: Use a long spindle on the,,dial gauge.
2. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each
main journal and crank pin.
Journal diameter:
STD size’ 59.994 - 60.012 mm
(2.3620 - 2.3627 in.1
U/S 0.25 59.730 - 59.740 mm
(2.3516 - 2.3520,in.I
Crank pin diameter:
STD size 51.976 - 52.000 mm
(2.0463 - 2.0472 in.)
U/S 0.25 51.725 - 51.735 mm
(2.0364 - 2.0368 in.)
If the diameter is not within specification, check the oil
clearance. If necessary, grind or replace the crankshaft.
(b) Check each main journal and crank pin for taper and
out-of-round as shown.
Maximum taper and out-of-round: 0.02 mm
(0.0008 in.1
If taper or out-of-round is greater than maximum, replace
the crankshaft.
3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 2).
Install new main journal and/or crank pin undersized bear-
ings.

EM-82 , ENGINE MECHANICAL - Cylinder Block
No. 1 Bearing Replacement
No. 1 Bearing No. 2 Bearing
EM14
1
INSPECTION AND REPAIR OF OIL PUMP
DRIVE SHAFT, -BEARINGS AND BUSHING
1. INSPECT OIL PUMP .DRIVE SHAFT Front
c No. 2 Bearing Replacement
No. 2 Bearing
2. (a) Using a micrometer, measure the journal diameter of
pump drive shaft.
Standard journal diameter:
Front 40.959 - 40.975 mm
(1.6126 - 1.6132 in.)
Rear 32.959 - 32.975 mm +
(1.2976 - 1.2982 in.)
(b) Using a cylinder gauge, measure the inside dia,meter
of the pump drive shaft bearing.
Bearing inside diameter:
Front 41 .OOO - 41.025 mm
il.6142 - 1.6152 in.)
Rear 33.000 - 33.025 mm
(1.2992 - 1.3002 in.)
(c) Subtract the journal diameter measurement from the
bearing inside diameter measurement.
Standard oil clearance: 0.025 - 0.066 mm
(0.0010 - 0.0026 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
If the clearance is greater than maximum, replace the
bearing. If necessary, replace the drive shaft.
IF NECESSARY, REPLACE OIL PUMP DRIVE SHAFT
BEARING
(a) Using SST, replace the No. 1 bearing by using No. 2
bearing as a guide.
SST 09215-00100 (09215-.00120, 0921500130,
09215-00140, 09215-00160,09215-00210,
09215-00220)
(b) Using SST, replace the No. 2 bearing by using the No.
1 bearing as a guide.
SST 09215-00100 (09215-00120,09215-00130,
09215-00140, 09215-00210, 0921500220)

ENGINE MECHANICAL -Cylinder Block
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CAUTION: When. inserting the bearings,’ ali@i”ZUEh”;
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EM2990 EM299
EM299
3. lN6PECT OIL PUMP DRIVE SHAFT THRUST
CLEARANCE
Using a thickness gauge, measure the drive shaft thrust
clearance’between the thrust plate and collar.
Standard thrust clearance: 0.06 - 0.13 mm
(0.0024 - 0.0051 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If clearance is greater than maximum, replace the thrust
plate and/or collar.
4. IF NECESSARY, REPt,ACE THRUST PLATE AND
COLLAR
(a) Using SST, remove the thrust plate and collar.
SST 09950-20017
(b) Install the thrust plate and collar in the direction as
shown.
(c) Using a press, install the thrust plate and collar.
5. IF NECESSARY, REPLACE OIL PUMP GUIDE BUSHING
(a) Drive out the bushing from the outer side of the
block.

EM-84 ENGINE MECHANICAL A Cylinder Block
‘I -
Front, Mark 1
hrust Direction (b) Drive in the bushing from the inside of the block with
a suitable tool. .
NOTE: The oil hole should be positioned toward the
crankshaft side.
(c) Make sure the front mark of bushing is positioned
toward the front of block.
REPLACEMENT OF OIL SEALS
NOTE.: There are two methods (A and B) of oil seal rep-
lacement.
1. REPLACE CRANKSHAFT FRONT OIL SEAL
A. If the timing case is removed from the cylinder
block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal.
;‘.
SST 09214-60010 and 09506-35010
(cl Apply MP grease to the oil seal lip.
B. If the timing case is installed to the cylinder
block:
(a) Using SST, remove the oil seal.
SST 09308-55010

ENGINE :MECHANICAL.;:y Cylinder, B&k:
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EM2994
SST (b) Apply MP grease to a new oil, seal lip.
(~1, Using--SST and a hammer, tap in-the oil seal.
SST 09214-60010 and 09506-3501.0 ;”
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2. REPLACE CRANKSHAFT REAR OIL SEAL ‘-. ‘. :
A. If the rear oil seal retainer is removed from the,
cylinder block: ‘: <
.:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal.
SST 09223-41020
(cl Apply MP grease to the oil seal lip.
8. If the rear oil seal retainer is installed to the
cylinder block:
(a) :Using a knife, cut off the lip of the oil seal as shown.
(b) Using a screwdriver, pry out the oil seal.
CAUTION: Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(c) Check the oil seal lip contact surface of the
crankshaft for cracks or damage.
(d)
Apply MP grease to a new oil seal lip.
(e)
Using SST and a hammer, tap in the oil seal.
SST 09223-41020

EM-86
,, ENGINE MF@ANl,CAL - Cjrlinder Block
EM456:
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3. REPLACE PUM+ DRIVE SHAFT OIL SEAL
A. If the timing b&t case is removed from the
cyjinder block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal.
SST 09214-41ClO C
, . . .
(c) Apply MP grease to the oil seal, lip.
A--
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& If the timing belt case is installed to the cylinder
block:
(a) Using a knife, cut off the lip of the oil seal as shown.
(b) Using a screwdriver, pry .out the oil seal.
CAUTION: Be careful not
to damage the crankshaft.
Tape the screwdriver tip.
(c) Check the oil seal lip contact surface of the pump
drive shaft for cracks or damage.
(d) Apply MP grease to a new oil seal lip.
(e) Using SST and a hammer, tap in the oil seal.
SST 09214-41010

I7M-Gb 7M-GTE-
I Front Mark
Froht Mark
1 (Delta)
(Arrow)
Front Mark
(Protrusion) Front Mark
(Protrusion)
EM454
ASSEMBLY OF PISTON AND CONNECTlp?q:,:-a:
ROD __ . . . .
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(See page EM-651 .._
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1. ASSEMBLE PISTON AND CONNECTING ROD
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(a) Install a new snap ring on one side of the piston pin,
hole.
(b) Gradually heat the piston to approx. 60°C (140°F).
(c) Coat the piston pin with engine oil.
IdI Align the front marks of the piston and the connect-
ing rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the pin
hole.
2.
INSTALL q&TON RINGS
(a) Install the oil ring expander and two side rails by
hand.
(b) Using a piston ring expander, install the two com-
pression rings with the code mark facing upward.

EM-88 ENGINE MECHANICAL - Cylinder Block
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Upper Side Compression1
Front
4-- R&i
Ring No. 2 Rail EM464

No. 1 Ex. No. 1
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25 mm (0.98 in.) 22 mm (0.87 in.) EM0771
(c) Position the piston rings so that the ring ends are as
shown.
CAUTION: Do not align the ends.
3. .INSTALL BEARINGS
(a) Align the bearing claw with th,e claw groove of the
connecting.rod or connecting rod cap.
(b) Install the bearing in the con’necting rod and rod cap.
CAUTION: Install the bearings with the oil hole in the;
connecting rod.
ASFEMBLY OF CYLINDER BLOCK
(See page EM-651
NOTE:
l Thoroughly clean all parts to be assembled.
l Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
l Replace all gaskets, O-rings and oil seals with new
parts.
1. (7M-GTE)
INSTALL OIL NOZZLES
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
2. INSTALL MAIN BEARINGS
NOTE: Different the bearing are used for the No. 1 and
ex. No. 1.

ENGINE MECHANICAL A Cylinder Block
EM-@-
3.
4.
5. (a)
Align the bearing claw with the the claw -groove of.
the main bearing cap or cylind,er block.
(b)
Install the bearing in the cylinder block and bearing
caps.
GAUTION:
Install the bearing with the oil hole in the
block.
INSTALL UPPER THRUST WASHERS
Install the thrust washers under the No. 4 main journal
position of the block with the oil grooves facing outward.
PLACE &ANKSHAFT ON CYLINDER BLOCK
INSTALL MAIN BEARING CAPS AND LOWER THRUST
WASHERS
NOTE: Each bearing cap has a number and front mark.
(a) Install the thrust washers on the No. -4 bearing cap
with the grooves facing outward.
(b) Install the bearing caps in numbered order with
arrows facing forward.
(c) Install and uniformly tighten the fourteen cap bolts in
several passes, in the sequence shown.
Torque: 1,040 kg-cm (75 ft-lb, 102 N.mI
(d) Check that the crankshaft turns smoothly.
(e) Check the crankshaft thrust clearance.
(See step 21 on page EM-701

ENGINE MECHANICAL - Cylinder Block
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9. INSTALL OIL PUMP DRIVE SHAFT
(a) While turning the drive shaft, insert slowly to avoid
damaging the drive shaft bearing.
(b) Install the bolt.
Torque:
145 kg-cm (10 ft-lb, 14 N*m)
10. INSTALL REAR OIL SEAL RETAINER
Install
a new gasket and rear oil seal retainer with the five
bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)
11. INSTALL TIMING BELT CASE WITH WATER PUMP
(a) Position new
gaskets on the cylinder block.
(b) Apply sealant to two or three threads of the 10 mm
bolt end.
Sealant: Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Install the timing belt case with the seven bolts and
three nuts.
12. INSTALL OIL PAN
(See page LU-14)
.13. INSTALL PS PUMP BRACKET