engine TOYOTA CELICA 1987 Service Workshop Manual

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

ENGtNE MECHANKAL - Troubleshootinn EM-S
TROUBLESHOOTING (Cont’d)
-.
Problem Possible cause Remedy Page
sough idle, stalls or Spark plugs faulty Inspect plugs IG-7
misses (cont’d)
Engine overheats Check cooling system ’ co-4
Low compression Check compression EM-26, 2;
Engine hesitates/ Vacuum leaks Repair as necessary
poor acceleration 0 PCV hoses
. (w/ EGR)
EGR valve
0 Intake manifold
’ 0 Air intake chamber .c
0 Throttle body
0 ISC valve
Pulling in air between air flow meter and Repair as necessary FI-96, 96
throttle body
Incorrect ignition timing Reset timing _ EM-1 7
Emission control system problem
(cold engine)
0 (w/ EGR)
EGR system always on Check EGR system
High-tension cord faulty Inspect cord 1G-6,
Fuel system clogged Check fuel system FI-7
Air cleaner clogged Check air cleaner EM-7
EFI system problems Repair as necessary
Spark plugs faulty Inspect plugs IG-7
Engine overheats Check cooling system co-4
Low compression Check compression EM-26, 2
Engine diesels EFI system problems Repair as necessary
(runs after ignition
switch is turned off)
Muffler explosion Deceleration fuel cut system always off Check EFI (fuel cut) system FI-128
(after fire) on
deceleration only
Muffler explosion Air cleaner clogged Check air cleaner EM-7
(after fire) all the time
EFI system problem Repair as necessary
incorrect ignition timing Reset timing EM-l.7
Engine backfires Vacuum leak Check hoses and repair as
l PCV hoses necessary
. (w/ EGR)
EGR valve c
0 Intake manifold
0 Air intake chamber
l Throttle body
0 ISC valve
Pulling in air between air flow meter and Repair as necessary Fl-96, 91
throttle body
EFI system problem Repair as necessary
Insufficient fuel flow Troubleshoot fuel system
Incorrect ignition timing Reset timing EM-l 7
Carbon deposits in combustion chambers Inspect cylinder head EM-97

EM-6 ENGINE MECHANICAL - Troubleshooting
Problem
:- Excessive oil
consumption
Poor fuel economy
Unpleasant odor -.
TROUBLESHOOTING (Cont’d) ._
Possible cause
Oil leak
PCV line clogged
Piston rings worn or damaged
Valve stem and guide worn
Valve stem seal worn
Fuel leak
Air cleaner clogged
Incorrect ignition timing
EFI system problems
l Injector faulty
0 Deceleration fuel cut system faulty
Idle speed too high
Spark plugs faulty
EGR system always on
Low compression
Tires improperly inflated
Clutch slips
Brakes drag
Incorrect idle speed
Incorrect ignition timing
‘Vacuum leaks
0 PCV hoses
0 (w/ EGR)
EGR valve ’
0 Intake manifold
l Air intake chamber
l Throttle body
EFI system problems Remedy
Repair as necessary
Check PCV system
Check rings
Check valves
Check seals ~’
Repair as necessary
Check air cleaner
Reset timing
Repair as necessary
Check ISC system
Inspect plugs
Check EGR system
Check compression
Inflate tires to proper pressun
Troubleshoot clutch
Troubleshoot brakes
Check ISC system
Reset timing
Repair as necessary
Repair as necessary Page
EM-65
EM-37
EM-37
EM-7
EM-l 7
FI-108
IG-7
M-26, 2’
FI-108
EM-l 7

ENGINE MECHANICAL 2 Engine Tune-up
. . EM-7
ENGINE TUNE-UP
INSPECTlOi OF ENGINE COOLANT
(See page CO-51
INSPECTION OF ENGINE OIL
(See page LU-5)
t MA02931
INSPECTION Oi’AIR FILTER
(a) Visually check that the air cleaner element is not
excessively dirty, damaged or oily.
(b) Clean the element with compr&sed air.
First blow from back side thoroughly. Then blow off
the front side of the element.
INSPECTION OF BATTERY
(See page CH-3)
INSPECTION OF HIGH-TENSION CORDS
(See pages IG-6, 13)
INSPECTION OF SPARK PLUGS
(See pages 19-7 to 9)
INSPECTION OF DRIVE BELT
(See page CH-41

EM-8 ENGINE MECHANICAL -I Engine Tune-up
-.
lNS.PECTlON AND. ADJUSTMEtiT OF VALVE
CLEARANCE’
NOTE: Check and adjust the valve clearance while the
engine is cold.
1. REM?VE AIR INTAKE CONNECTOR
j
(a) Remove the PCV pipe.
(b) (ex. MS RHD)
.Disconnect the accelerator connecting rod.
(c) Disconnect the water by-pass hoses from the throt-
tie body.
(d) Disconnect following hoses:
. (w/ EGR)
VSV hose(for EGR) .
l . (w/ TWC)
BVSV hose
. (w/ EGR)
EGR vacuum modulator hoses
0 No.7 air hose
(e) Disconnect the throttle position sensor connector.
(f) Remove the. throttle body bracket(s).
(g) Remove the air intake connector bracket mounting
bolts.
c J
I (h) Remove the four bolts, two nuts, air intake connect01
and gasket.
2. REMOVE CYLINDER HEAD COVERS
(See pages EM-59,601

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.
. .
. .
(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:
-.
:
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)
I
F11868

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 ;- ,
. .
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?‘
;
.7. MEASURE VALVE CLEARANCE
.~. :. 1See+tep 3 oti page EM-91 3
6: ‘ADJUST VALVE CLEARANCE
j:
’ :
ISee ,tep 4 on pages EML9, 10)
: . i’... ..a .
; “.
~ ‘,
.
>*-* 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
, -
r
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.
,,,1
. . -:
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