check engine TOYOTA CELICA 1987 Service Manual Online

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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.

ENGINE :MECHANICAL.;:y Cylinder, B&k:
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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 ;”
.
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
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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--
*- .
& 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

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

16-2 IGNITION SYSTEM - precautions
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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.

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.
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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)

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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

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.

rutmwCiA rlON SYSTEM - Oil Pressure Che,ck’:q. .’ ‘f,“,; .! . ,_ _,, __ _ ,-tiu,e
Recommended
Viscositv (SAE):
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z 4 16 36
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RANGE ANTICIPA$O B&i% NEXT OIL CHANGE 100 ._. .-- . . .
?’ OIL PR,ESSURE’($liCK . .._.
-. - -_-. _
. _ _.. _ _...
1. 1 CHECK-ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring .
or thinning.
2.
3.
4.
5.
6. If oil quality is poor, replace the oil,
Europe (‘IM-GE) and Australia *
Use API grade SE, SF or better and recommended
viscosity oil.
Europe (7M-GTE)
Use API grade SF or better and recommended
viscosity oil.
Others
Use API grade SC, SD, SE, SF or better and recom-
mended viscosity oil.
CHECK ENGINE OIL LEVEL
The oil level should be between the “L” and “F” marks on
the dipstick.
If low, check for leakage and add oil up to the “F” mark.
REMOVE OIL PRESSURE SENDER GAUGE
INSTALL OIL PRESSURE GAUGE
START ENGINE
Start engine and warm it up to normal operating tem-
perature.
MEASURE OIL PRESSURE
Oil pressure:
At idle 0.3 kg/cm2 (4.3 psi, 29 kPa1
or more
At 3,000 rpm 2.5 - 5.0 kg/cm
(36 - 71 psi, 245 - 490 kPa1
NOTE: Check for oil leakage after reinstalling the oil
pressure sender gauge.