engine TOYOTA CELICA 1987 Service Repair Manual

EM-92 _. ENGINE MECHANICAL +’ Cylinder Block
-..
: .
;,,
“.’
‘i4. (7M-GE w/ Oil Cooler)
INSTALL Oil.. REGULATOR
Install a new gasket and oil regulator with. the two bolts.
(7M-GE w/o Oil Cooler and.7M-GTE)
INSTALL OIL HOLE COVER PLATE
Install a new gasket and oil hole cover plate with the two .
bolts.
15. (7M-GE)
INSTALL NEW OIL FILTER
(See page LU-6)
16. INSTALL ENGlNE MOUNTING BRACKETS
17. INSTALL FUEL RETURN PIPE SUPPORT
Install a new insulator and fuel pipe support with the two
nuts. :
Torque: 130 kg-cm (69 ft-lb, ‘1.3 N&l
18. (7M-GE)
INSTALL VACUUM CONTROL VALVE SET
19. INSTALL GROUND STRAP TO CYLI’NDER BLOCK
20. lN,STALL WATER BY- PASS PIPE
(a) “Install a new gasket and water by-pass pipe to the
timing belt case with the two nuts.
Torque: 140 kg-cm (IO ft-!b, 14 N-m)
(b) Install the water by-pass pipe tqthe cylinder block
with the three bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
21. INSTALL CYLINDER HEAD
(See steps 1 and 4 to 18 on pages EM-59 to 64)
22. INSTALL TIMING BELT
(See step 1 to 8 and 10 to 15 on pages EM33 to 36)
23. REMOVE ENGiNE STAND
24. INSTALL REAR END PLATE
Torque: 130. kg-cm (9 ft-lb, 13 N.m)
25. INSTALL FLYWHEEL OR DRIVE PLATE ON
CRANKSHAFT
(a) Install the flywheel or drive plate on crankshaft.
(b) Install and uniformly tighten the bolts in several
passes, in the sequence shown.
Torque: 750 kg-cm (54 ft-lb, 74 N*m)

16-2 IGNITION SYSTEM - precautions
-.
PRECAUTIONS
1.
2.
3.
4.
5.
6.
. *
Do not leave the ignition switch on for more than 10
minutes if the engine does not start.
When a tachometer is connected to the system; con-
nect the tachometer test probe to the check connector
terminal IG 0 .
CHECK CONNECTOR LOCATION:
See pages FI-110, 111
As some tachometers are not compatible with this
ignition system, we recommended that you confirm
the compatibility of your unit before using.
NEVER allow the tachometer terminals to touch
ground as it could result in damage to the igniter and/
or ignition coil.
Do not disconnect the battery while the engine is run-
ning.
Make sure that the igniter is properly grounded to the
body.

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Problem
Engine will not star-t/
hard to start
(cranks OK)
Rough idle or stalls
Engine hesitates/
poor acceleration
Muffler explosion
(after fire) all the
time
Engine backfires
Poor fuel economy
Engine overheats
TROUBLESHOOTING
Possible causes
Incorrect ignition timing
Ignition problems
0 Ignition coil
. (7M-GTE)
Igniter
. (7M-GE)
Distributor
(7M-GTE)
Cam position sensor
l High-tension cords
Ignition wiring disconnected
or broken
Spark plugs faulty
Ignition wiring faulty
Incorrect ignition timing
Ignition problems
0 Ignition coil
. I7M-GTE)
Igniter
. (7M-GE)
Distributor
(7M-GTE)
Cam position sensor
0 High-tension cords
Spark plugs faulty
Ignition wiring faulty
Incorrect ignition timing
Incorrect ignition timing
Incorrect ignition timing
Spark plugs faulty
Incorrect ignition timing
Incorrect ignition timing Remedy
Reset timing
lrkpect coil
Inspect igniter
Inspect distributor
Inspect cam position sensor
Inspect high-tension cords
Inspect wiring
Inspect plugs
Inspect wiring
Reset timing
Inspect coil
Inspect igniter
Inspect distributor
Inspect cam position sensor
Inspect high-tension cords
Inspect plugs
Inspect wiring
Reset timing
Reset timing
Reset timing
Inspect plugs
Reset timing
Reset timing =
Page-.. :
-
EM-17
IG-10 or 14
IG-17
IG-11
IG-1%
IG-6 or 13
IG-7
EM-l 7
IG-10 or 11
IG-17
IG-I 1
IG-18
IG-6 or 13
IG-7
EM-l 7
EM-1 7

IQ-4
IGNITION SYSTEM - Ignition System Circuit
IGNlTlON SYSTEM CIRCUIT
7M-GE, Ignition Switch lanitian Cnil
AM2 30A
Fusible Link
MAIN 2.OL
(MA)
~“. _._. _ _..
AM29~2
I “i!l A II
I
(MS)
I
Spark Plug l-1 II
R Igniter
1
7M-GTE
I
Ignition Switch
AM2 30A
Fusible Link
MAIN 2.OL
Battery IG2
To Tachometer
1 f
Cam Position
Sensor
r--1
G2 IGT
NE
IGdA
NO
IGdB f
To Tachome:
n Spark Plug
Igniter
: I=
B
I=
Ignition Coil
It08
ELECTRONIC SPARK ADVANCE (ESA)
The ECU is programmed with data for optimum ignitio
timing under any and all operating conditions. Using dat
provided by sensors which monitor various engine func
tions (rpm,
intake air volume, eng. temperature, etc.) th
microcomputer (ECU) triggers the spark at precisely th
right instant.

IGNITION SYSTEM - On-Vehicle Inspection (7M-GE)
IO-6 *
-. ON-VEHICLE INSPECTION (7M43E)‘;
SPARK TEST --
CHECK THAT SPARK OCCURS
(a) Disconnect high-tension cord from the distributor.
(b) Hold the end about 12.5 mm (0.49 in.) from body of
vehicle.
(G) See if spark occurs while engine is being cranked.
NOTE: To prevent gasoline from being injected from
injectors during this test, crank the engine for no more
than l-2 seconds at a time.
If the spark does not occur, perform the test as follows:
SPARK TEST
1
NO
,‘.
CHECK CONNECTION OF IGNITION COIL, BAD
Connect securely.
IGNITER AND DISTRIBUTOR CONNECTORS c
OK
CHECK RESISTANCE OF HIGH-TENSION
CORDS (See page IG-6) ’ BAD
Replace the cord(s).
OK
CHECK POWER SUPPLY TO IGNITION COIL
1. Ignition switch turn to ON.
2. Check that there is battery voltage at
ignition coil positive I+) terminal. Check wiring between ignition switch to
BAD
switch to ignition coil.
OK
CHECK RESISTANCE OF IGNITION COIL
(See page IG-10) 9
BAD Replace the ignition coil.
*
OK
1 , , 1
CHECK RESISTANCE OF DISTRIBUTOR
SIGNAL GENERATOR (PICK UP .COIL)
Resistance: 140 - 180 sz
OK BAD Replace the distributor.
m
CHECK AIR GAP OF DISTRIBUTOR
Air Gap: Each 0.2 - 0.4 mm
(0.008 - 0.016 in.) BAD
Replace the distributor.
L
OK
CHECK IGt SIGNAL FROM ECU
(See pages FI-51, 70) BAD
Check wiring between ECU and distributor,
only then try another ECU.
OK
t ,
TRY ANOTHER IGNITER
1 i

6. REMOVE IGNITION COIL COVER
(a) Remove the oil filler cap.
‘...”
I I
I(30598
Ohmmeter
/
IGO
7. REMOVE IGNITION C0l.L WITH BRACKET
(a) Remove the nut.
(b) Disconnect the No.1 and No.2 high-tension cords
from the ignition coil and clamp.
(cl Remove the ignition coil with bracket and high-ten-
sion cords.
id) Remove the No.1 and No.2 high-tension cords from
the spark plugs.
8.
9. REMOVE SPARK PLUGS
Using SST, remove the spark plug.
SST 09155-16100
PERFORM SPARK TEST
Ia) Install the oil filler cap.
(b) Install the spark plugs to each high-tension cord.
(4 Ground the spark plug.
(d) Disconnect the solenoid resistor and cold start injec-
tor connectors.
(e) See if spark occurs while engine is being cranked.
INSPECTION OF HIGH-TENSION CORDS
INSPECT HIGH-TENSION CORD RESISTANCE
Using an ohmmeter, measure the resistance.
Maximum resistance: 25 kfl per cord
If resistance exceeds maximum, check the terminals.
If necessary, replace the high-tension cord.
INSPECTION OF SPARK PLUGS
(See pages IG-7, 8)

IGNITION SY-$TEM
- Cam Position Sensor (‘/M-GTE)
IO-27
(cl Connect the PS idle up air hose.
(d) Connect the air flow meter connector.
(e) Connect the PCV hose and three air hoses.
5. INSTALL NO.4 AIR CLEANER PIPE WITH NO.1 AND
NO.2 AIR CLEANER HOSES
6. CONNECT CAM POSITION SENSOR CONNECTOR
7.
WARM UP ENGINE
Allow the engine to reach normal operating temperature.
8. ADJUST IGNITION TIMING (See page EM-171

-.
. .
..,I -_
LUBRICATION SYSTEM: . . I-
Page
DESCRIPTION . . ..*.*.........*......*........
LU-2
TROUBLESHOOTING ..I....*........*.‘....... b-4
OIL PRESSURE CHECK . . , . . . . . .
l . . . . . . , . . . . . . . ‘LU-5
REPLACEMENT OF ENGINE OIL
AND OIL FILTER I*......**.~.....~..,,,,..,.
LU-6
OIL PUMP *I...~.......~.~.,,,...~...~‘,,...,.
LU-6
OIL COOLER AND OIL PRESSURE
REGULATOR (7M-GE) . . . . . . . . . . . . . . . . . . . . . . . LU-15
OIL COOLER AND OIL PRESSURE
REGULATOR (7M-GTE) . . . . . . . . . . . . . . a. . . . . . LU-16

LU-2
-4UBRlCATlON SYSTEM - Description
DESCRIPTION --
A fully pressurized, fully filtered lubrication system has been adopted for this engine.
7M-GE (MS) 7M-GE (MA)
Oil Co&x
7M-GTE (A/T)
Oil Choler
( VALVE GUIDES -
.---- PISTONS
t
.- - - - CONNECTING
RODS
t
.----
{ CRANKSHAFT 1
I *OIL FILTER BRACKET
+---+ RELIEF VALVE 1
1 RELIEF VALVE
I
I I
OIL PUMP
t
I OIL STRAINER
t
OIL PAN l 7M-GTE only

LUBRICATION SYSTEM - Description
.,LU-3
A pressure feeding lubrication system has been
adopted to supply oil to the moving parts of this
engine. The lubrication system consists of an oil
pan, oil pump, oil filter and other external parts
which supply oil to the moving parts in the engine
block. The oil circuit is shown in the illustration at
the top of the previous page. Oil from the oil pan is
pumped up by the oil pump. After it passes
through the oil filter, it is fed through the various
oil holes in the crankshaft and cylinder block. After
passing through the cylinder block and performing
its lubricating function, the oil is returned by gra-
vity to the oil pan. A dipstick on the side of the
cylinder block is provided to check the oil level.
OIL PUMP
The oil pump pumps up oil from the oil pan and
sends it under pressure to the various parts of the
engine. An oil strainer is mounted in front of the
inlet to the oil pump. The oil pump itself is a gear
pump, which uses a drive gear and driven gear
inside the pump body. When the drive gear
rotates, the driven gear rotates in the opposite
direction. When the gear teeth disengage oil is
drak n in, and when the gear teeth engage oil is
discharged.
OIL PRESSURE REGULATOR
At high engine speeds, the engine oil supplied
bY thr oil pump exceeds the capacity of the engine
10 utiiize it.
For that reason, the oil pressure regula-
tor i ,>rks to prevent an oversupply of oil. During
norm.tl oil
supply, a coil spring and valve keep the
bYPcls:s closed, but when too much oil is being fed,
the I’tt’essure becomes extremely high, overpower-
9 the force of the spring and opening the valves.
This ;:ilows the excess oil to flow through the
Yalvtj :snd return to the oil pan. Olii FILTER
The oil filter is a full flow type filter with a built-
in paper filter element. Particles of :metal ‘from
wear, a&born dirt, carbon and other impurities can ’
get in the oil during use and could cause acceler-
ated wear or siezing if allowed to circulate through
the engine. The oil filter, integrated into the oil line,
removes these impurities as the oil passes through
it. The filter is mounted outside the engine to
simplify replacement of the filter element. A relief
valve is also included ahead of the filter element to
relieve the high oil pressure in case the filter ele-
ment becomes clogged with impurities. The relief
valve opens when the oil pressure overpowers the
force of the spring. Oil passing through the relief
valve bypasses the oil filter and flows directly into
the main oil hole in the engine.