engine TOYOTA CELICA 1987 Service Manual PDF

EM-16 ENGINE MECHANICA!. - Engine Tune-up
-.
Adjusting Shim Selection Using Chart
EXHAUST .-_
Lnstdod Shim Thlcknosr (mm) I
.-...
0~30~30)32/32~32132~4)34j34/34j
_. Shim thickness mm (in.)
Exhaust valve clearance (cold) :
0.20 - 0.30 mm (0.008 - 0.012 in.)
Example: A 2.800 mm shim is Installed and th
measured clearance is 0.450 mm
Replace the 2.800 mm shim with
shim No. 22 (3.000 mm).

ENGINE MECHANICAL. - Engine Tune-up
EM-?1 7.
INS’PECTIOlil ‘AhiD ADJUSTMENT O:F .-
IGNITION TIMING
1. VriARiiA. UP ENGINE.
Allow the engine to. reach normal operating temperature.
2.
CbNNECT TACHOMETER AND TIMING LIGHT TO
ENGINE
Connect the tachometer positive terminal to the check
connector terminal IG 0 .
CHECK CONNECTOR LOCATION: .,
s See pages FI-110, 111
CAUTION:
l Never allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or ignition coil.
, 4% 3.
EC21 18
s As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the compatibility of your unit before using.
NOTE (7M-GTE): Connect the timing light pickup to t
No.6 cylinder high-tension cord.
CHECK IGNITION TIMING
(a) Using a service wire, short terminals T(MA) or
TEI (MS) and El of the check connector.
CHEC,K CCNNECTOR LOCATION.:
See pages FI- 1’10, 111
(b) Check the idle. speed.
Idle speed: /-
7M-GE w/ TWC 700 rpm
w/o TWC 800 rpm
7M-GTE 800 rpm
(c) Using a timing light, check the ignition timing.
Ignition timing: IO” BTDC @ idle
[w/ short-circuited T (TEl) and El
and Transmission in “N” range]
c,
If necessary, loosen the distributor (7M-GE) or cam posz-’
tion sensor (7M-GTE) bolt and turn the distributor (cam
position sensor) to align the marks. Recheck the timing
- after tightening the distributor (cam position sensor).
Torque: 140 kg-cm (10 ft-lb, 14 N-m)
(cl) Unshort the check connector.

. .
EM-18 ENGINE MECHANICAL - Engine Tune-up
4. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7M-GE ._ 10 -‘.13” BTDC @ idle
7M-GTE More than 12” BTDC @ idle
DISCONNECT TACHOMETER AND TIMING LIGHT
FROM ENGJNE

ENGINE MECHANICAL! Y) Engine Tune-up
Qy r\:y 9,.
, ,. . .,
1. 1. ., I ,,.,q,, ./. . . .
. . . . . . . J>
,; ..1’- -INSPECTION AND ADJUSTMENT OFIDLE
I
$‘,’ ,, :.. ,:
MIXTURE (w/o TWC)
2,
.: .,;.
4.
5. tNSPECT AND ADJUST IDLE CO CONCENTRATION
120 Seconds Tachometer
$0
H v
EC016
,
A. INITIAL CONDITIONS
(a) Ajr cleaner Jnstalled
(b) Normal engine operating temberature
(cf All pipes and hoses of air intake system connected
(d) All accessories switched off
‘6) All vacuum lines properly connected
(f) EFI system~‘w&g connectors fully plugged
c(g) I.gnitio$ timing set correctly
(h) Transmission. i.n,.N range
CONNECT TACHCBMETER TO ENGINE
(See page EM-171
CHECK IDLE SPEED
Idle speed: 800 rpm
CAUTION:
a Always use a CO meter,.,when adjusting the idle mix-
ture. It is not necessary to adjust with the idle mix-
ture adjusting screw in. most vehicles if they are in
good condition. If a CO meter is not available, DO
NOT ATTEMPT TO ADJUST WITH THE SCREW.
l If a CO meter is not available and it is absolutely
necessary to adjust with the idle mixture adjusting
screw, or if the air flow meter is replaced, use the
alternative method.
~, r’.
’ _‘i..
METHOD WITH CO METER
(a) Check that the CO meter is properly calibrated.
(b) Race the engine for approx. 120 seconds at appr 1,
2,500 rpm before measuring the concentration. r
‘-..*
(c) Wait 1 - 3 minutes after racing the engine to allow
the concentration to stabilize.
(df Insert a testing probe at least 40 cm (1.3 ft) into the
tailpipe, and measure the concentration with a short
time.
Idle CO concentration: 1.0 -t- 0.5 %

EM-20 ENGIN lVlECHAN!CAL - Engine Tune-up
-.
EM288
c
HC
Aigh
High
High co
Normal
Low
High ‘- ‘, If the CO concentration is not as specified, adjust the idle
mixture by.furning the idle mixture adjusting screw with
SST.
SST 09243-00020 >
0 If the CO concentration is within specification, this
adjustment is complete.
l if the CO concentration cannot be corrected by idle
mixture adjustment, see the table below for other possi-
t ble causes. w
Troubleshooting
SYMPTOMS
Rough idle
’ ’
.-‘:I -
Rough idle
(Fluctuating HC reading)
Rough idle
(Black smoke from exhaust CAUSES
1. Faulty ignition:
0 Incorrect timing
0 Fouled, shorted or improperly gapped plugs
6 Open or crossed high-tension cords
0 Cracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valve
4. Leaky intake and exhaust valves
5. Lea,kv cvlinder
1. Vacuum leak:
0 Vacuum hose
0 EGR valve
0 Intake manifold (Air intake chamber)
0 Throttle body
l Cylinder head gasket,
0 Brake booster line
2. Lean mixture causing misfire
1. Restricted air filter
2. Faulty ,EFI system:
0 Faulty pressure regulator
0 Clogged fuel return line
0 Faulty air flow meter
0 Defective water temp. sensor
0 Defective air temp. sensor
0 Faulty ECU
l Faulty injector
0 Faulty cold start injector
l Faulty throttle position sensor

EM-22 ENGINE MECHANICAL - Engine Tune-up
INSPECTION OF IDLE HC/CO
CONCENTRATION (w/ TWC)
NOTE: This check method is used only to determine
whether or not the idle HWCO complies with regulations.
1. INSTALL CONDITIONS
(a) Air cleaner installed
(b) Normal engine operating temperature
(c) All pipes and hoses of intake system connected
(d) All accessories switches off
(e) All vacuum lines properly connected
NOTE: All vacuum hoses for EGR system etc. should be
properly connected
(f) EFI system wiring connectors fully p!ugged
(g) Ignition timing set correctly ‘.
(h) Transmission in “N” range
6) Tachometer and HWCO meter at hand and calibrated
2. WARM UP ENGINE
Allow the engine to reach normal operating temperature.
3. CONNECT TACHOMETER TO ENGINE
(See page EM- 17)
w ‘I” FI16C
4. CHECK IDLE SPEED
Idle speed :
7M-GE 700 rpm
7M-GTE 800 rpm
5. CHECK OXYGEN SENSOR OPERATION
(a) Using a service wire, short terminals T and El’of the
check connector.
CHECK CONNECTOR LOCATION: See page FI-I 10
(b) Connect the positive (+I probe of a voltmeter to ter-
minal VF of the check connector, and negative (-1
probe to terminal E 1.
(c) Hold the engine speed at 2,500 rpm for approx. 2
minutes.
(d) Then, maintaining engine at 2,500 rpm, count how
many times needle of voltmeter fluctuates between 0
and 5 V.
Minimum needle fluctuation : ’
8 times for every 10 seconds
If the fluctuation is less than minimum, check the air
induction system for leakage, If necessary, see EFI
SYSTEM.

, ENGINE ,MECHANICAL ‘& EriZjinb T.ufi&up $&p&a
,. I ,.,, (..,..,
-. .,
_ 69,
7.
8. . RACE ENGINE AT 2,500 RPM APPROX. 2 MINUTES.,
IkRT TESTING PROBE OF HCKO METER INTO TAIL
PIPE AT a0 cm (1.3 ftt)
MEAS,URE HC/CO CONCENTRATION AT IDLE
Wait $t lest one minute before measuring to allow the
concentration to stabilize.
Complete the measuring within -three minutes.
Idle CO concentration:
0 - 0.5 %
If the CO/HC concentration do& not conform to your
regulations, see the table in page EM-20 for possi,ble
cause+. I

. .
/:
EM-24 ENGINE MECHANICAL - Engine Tune-up
INSPECTION’ AND ADJlJSTtiENT OF DASH
-- POT .(DP) SYSTEM
1. WARM UP ENGINE
2. CONNECT TACHOMETER TO ENGINE
(See page EM-171
3. CHECK IDLE SPEED
M-GE
IIP DiTphragm
I
Ed
!M-GTE
C
7

2)
i
.
1
.
1
7lVi-GE
-
i
IM-GTE
/ rottle Valve
leased
alve ’
4. INSPECT AND ADJUST DP SETTING.SPEED
(a) Maintain the engine speed at 3,000 rpm.
(b) Pinch the vacuum hose between the DP and VTV.
.,
i
(c) Release the throttle valve.
(d) Check that the DP is set.
DP setting speed : 2,000 rpm

‘.
.’
J’
ENGINE MECHANICAL.- Engine Tun&up
7M-GE
-.
7M-GTE
7M-GE
Release
FM-GTE
Approx. if not at specified speed, adjust with the. DP adjUitiri&
Screw. , 1
5,~ CHECK OPERATION OF VTV
(a) f:;;ye DP speed in the same ptocedure as above; (a)
(b) Release the pinched hose and check that the engine
returns to idle speed in approx. 1 second.

EM-26 ENGINE MECHANICAL - Compression Check
d
COMPRESSION CHECK
NOTE: If there is lack of power, excessive oil consump-
tion or poor fuel mileage, measure the cylinder compres-
sion pressure.
(7M-GE)
1.
2.
3.
4.
5.
6. REMOVE SPARK PLUGS (See page IO-71
7.
EM3003
WARM UP ENGINE
DISCONNECT COLD START INJECTOR CONNECTOR
DISCONNECT SOLEtiOlD RESISTOR CONNECTOR
DISCONNECT DISTRIBUTOR CONNECTOR
REMOVE THROTTLE BODY
(a) Remove the PCV hose.
(b) Disconnect the water by-pass hoses and plug the
hose end.
(c) Disconnect following hoses:
. fwl EGR)
VSV hoses
. (wl TWC)
BVSV hoses
. (w/ EGR)
EGR vacuum modulator hoses
l No.7 air hose
id) Disconnect the throttle position sensor connector.
(e) Remove the throttle body bracket(s).
(f) Remove the four bolts, throttle body and gasket.
CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) While cranking the engine with the starter motor,
measure the compression pressure.
NOTE: Always use a
fully charged battery to obtain an
engine revolution of more than 250 rpm.
(c) Repeat steps Ia) through Ib) for each cylinder.
Compression pressure:
11.0 kg/cm2 (156 psi, 1,079 kPa) or more
Minimum pressure:
9.0 kg/cm2 (128 psi, 883 kPa)
Difference between each cylinder:
1 .O kg/cm2 (14 psi, 98 kPa) or less
(d) If cylinder compression in one or more cylinders is
low, pour a smali amount of engine oil into the
cylinder through the spark plug hole and repeat steps
(a) through (b) for the cylinder with low compression.
0 If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damaged.
0 If pressure stays low, a valve may be sticking or
seating improperly, or there may be leakage past
the gasket.