alternator TOYOTA CELICA 1987 Service Repair Manual

‘:CHARG!NG SYSTEM
Page
PRECAUTIONS ..,**....*..*..,,*....,,.*........ CH-2 *
TROUBLESHOOTING ,,..*.....*..........*..... CH-2
CH.ARGlNG SYSTEM CIRCUIT ..,n....*.,.,.*...m C.H-3
ON-VEHICLE INSPECTION .,...,....‘.,,......*~
w-3
ALTERNATOR ,,,~,..,*~.......~....,*,,...~.... CH-7

CH-2 CHARGING SY&EM - Precautions, Troubleshooting
._
: PRECAUTIONS
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
given a quick charge.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is run-
ning.
Discharge warning
light does not light
with ignition ON and
engine not ‘running
Problem
Discharge warning
light does not go out
with engine running
(battery requires fre-
quent recharging
Possible cause
Fuse blown
Light burned out
Wiring connection loose
IC regulator faulty
TROUBLESHOOTING
Remedy
Check “CHG” and
“IGN” fuses
Replace light
Tighten loose connections
Replace IC regulator
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
IC regulator or alternator faulty
Wiring faulty Adjust or replace drive belt
Repair or replace cables
Check “ENG” fuse
Replace fusible link
Check charging system
Repair wiring
Page
CH-7
CH-4
CH-3

:usible
.ink
4LT
MA/
‘M-GE)
,258 Ignition Switch
Fuse
AM2 -0p IG2 (MA) 15~4
c (MS) 7.5A
Fusible
Link
AM2 30A
:usible
-ink
I (MA)
I/IAIN 2.OL (MS)
T Battery
P
/
CHG 7.5 A
I
i
8
I I .
i
m
Alternator
1 ON-VEHICLE INSPECTION
1.
tieI
fel
i 002
CHECK BATTERY SPECIFIC GRAVITY
(a) Check the specific gravity of each cell.
Standard specific gravity
When fully charged at 20°C (66°F):
1.25 - 1.27
If not within specifications, charge the battery.
(b) Check the electro!yte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
’ 2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
(b) Check the fusible links and fuses for continuity.
c
CHOZRRI

co-4 CQOLING SYSTEM - Troubleshootmg
TROUBLESHOOTING
, Problem
Engine overheats Possible cause
Alternator drive belt loose or missing
Dirt, leaves or insects in radiator or
condenser
Hoses, water pump, water outlet
housing, radiator, heater, core plugs
or head gasket leakage
Thermostat faulty
Ignition timing
retarded
Fluid coupling faulty
Radiator hose plugged or rotted
Water pump faulty
Radiator plugged or cap faulty
Cylinder head or block cracked or
phwd Remedy
Adjust or replace belt
Clean radiator or condenser
Repair as necessary
Check thermostat
Set timing
Replace fluid coupling
Replace hose
Replace water pump
Check radiator
Repair as necessary Page
CH-4
CO-8
EM-l 7
CO-6
CO-6
co-9

CO-6
C6OLlNG SYSTEM - Water Puma
WATER ilJMP
COMPONENTS
Fluid Ckqling Water P;lmp Pulley Water Pump
+ Non-reusable part COOL3
c REMOVAL OF WATER PUMP ._
1. REMOVE ALTERNATOR DRIVE BELT, FLUID
COUPLING AND WATER PUMP PULLEY
(a) Loosen the water pump pulley set nuts.
(b) Loosen the pivot bolt, adjusting bolt and nut, and
remove the drive belt.
(c) Remove the four nuts, fluid coupling and wate,
w-w.
(d) Remove the fan from the fluid coupling.
2. REMOVE PS AIR PIPE
3. REMOVE WATER PUMP
Remove the eight bolts and two nuts, and remove wate
pump and gasket.

1.
2.
3.
.._ INSPECT WATER PUMP BODY AND TIMI+BELT
CASE ” ._
Check the water pump body and timing b&i case for
cracks and damaged gasket surfaces.
If necessary, replace the water pump or timing belt case,
INSPECT WATER PUMP BEARINQ
Turn the pulley and check that the water pump bearing
moves smoothly and quietly.
lf necessary, replace the water pump,
INSPECT FLUID COUPLING
Check that the fluid coupling is not damaged and that no
silicon oil leaks.
If necessary, replace the fluid coupling.
INSTALLATION OF WATER PUMP
(See page CO-6)
1. INSTALL WATER PUMP
install water pump on new gasket with the eight bolts and
two nuts.
Torque:
160 kg-cm (13 ft-lb, 18 N*mI
2. INSTALL PS AIR PIPE
3. INSTALL WATER PUMP PULLEY, FLUID COUPLING
AND ALTERNATOR DRIVE BELT
(al Install the water pump pulley and fluid coupling with
the four nuts.
(b)
(c) Place the drive belt on to each pulley.
Stretch the belt tight and tighten the four nuts.
4. ADJUST ALTERNATOR DRIVE BELT TENSION
(See page EM-361

EM-28
ENGINE MECliANICAL - Titiingj Belt.
TIMING B’ELT
-.
COMPONENTS
No. 3 Timing Belt Cover Camshaft Timing Pulley
I I ImIng oen
I
Crankshaft Pulley
kg-cm (ft-lb, N-ml : Specified torque
EM30f 31
REMOVAL OF TIMING BELT
1.
REMOVE SPARK PLUGS
2. REMOVE WATER OUTLET
Remove the two bolts, water outlet and thermostat with
. gasket.
3. .(with A/C)
REMOVE A/C BELT
4. REMOVE FAN AND ALTERNATOR DRIVE BELT
5.
REMOVE PS BELT

EM-36 ENGINE MECHANICAL - Timinn Belt
EM302
EM301
,
A
Alternator
1
EM3000
CORRECT WRONG
WRONG 14. INSTALL ALTERNATOR DRIVE BELT AND FAN
Torque: Fan 55 kg-cm (48 in.-lb, 6.4 N-m)
Adjusting bolt 130 kg-cm (9 ft-lb, 13 N*m)
15. (with A/C)
INSTALL A/C BELT
16. INSTALL WATER OUTLET
install the thermostat with a new gasket and water outlet
with the two bolts.
17. INSTALL SPARK PLUGS
(See page 10-7)
16. ADJUST DRIVE BELTS
Install and adjust the drive belts.
Drive belt deflection with 10 kg or 22 lb:
New belt
A 10 - 12 mm IO.39 - 0.47 in.)
B 7 - 8 mm (0.28 7 0.31 in.)
C MA 7 - 9.5 mm (0.28 - 0.374 in.)
MS 7.5 - 9.5 mm (0.296 - 0.374 in.1
Used belt
A 15 - 17 mm (0.59 - 0.67 in.1 ,
B 9 - 11 mm (0.35 - 0.43 in.)
C MA 10.5 - 12 mm (0.413 - 0.47 in.)
MS 10 - 13 mm (0.39 - 0.51 in.)
(Reference)
Using SST, check the drive belt tension.
SST A 09216-00020
SST B 09216-00030
Drive belt tension:
New belt A 70 - 80 kg
B 65 - 65 kg
C 53 - 77 kg
Used belt A 30 - 45 kg
B 25 - 40 kg
C 30 - 40 kg
NOTE:
0 “New belt” refers to a belt which has been used less
than 5 minutes on a running engine.
0 “Used belt” refers to a belt which has been used on a
running engine for 5 minutes or more.
0 After installing the drive belt, check that it fits properly
in the ribbed grooves. l Check by hand to confirm that the belt has not slipped
out of the groove on the bottom of the crank pulley.
l After installing the belt, run the engine for approx. 5
minutes and then recheck the deflection.

- ENGINE MECHANICAI, - Cylinder H&d
1
-.
CYLINDER HEAD
COMPONENTS _
7M-GE
No. 2 Cylinder
Cover
No. 3 Cylinder
Cover Head
PCV Pipe
-No. 1 Cylinder Head
Cover
q--Camshaft Bearing
Water Outlet
Housing
No. 2 Timing Belt
Cover , ’ @&-No. 2 Engine Hanger
II 1
400 (29. 20) 1
Air Intake Chamber
Alternator Bracket

ENGINE MECHANICAL - Cylinder Head
EM-&j
REMOVAL OF CYLINDER HEAD
1. (See pages EM-37, 38)
REMOVE AiiERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.
2.
3.
4. (7M-GTE)
REMOVE PS RESERVOIR TANK
Remove the two bolts, nut and, reservoir tank with bracket.
(‘IM-GTE),
REMOVE CAM POSITION SENSOR
REMOVE AIR INTAKE CHAMBER WITH CONNECTOR
(a) Remove the PCV pipe.
(b) Disconnect following connectors:
. (7M-GE)
Cold start injector connector
l Throttle position sensor connector
l ISC valve connector
(c) Disconnect following hoses: aI
l BVSV hose from throttle body
l EGR hoses from throttle.boby
l Vacuum transmitting p.ipe hose from intake cham-
ber
0 Pressure regulator hose
;, I
l VSV (for fuel pressure up) &es
. (7 M-GE)
Diaphragm hose
(d) Disconnect following hoses:
-
0 (7M-GTE)
Auxiliary air pipe hose from vacuum transmitting
pipe hose
l No.1 water by-pass hose from ISC valve
. (7M-GE)
No.3 water by-pass hose from throttle body ,
0 (-/M-GTE)
No.3 water by-pass hose from water by-pass pipe
(e) (w/ EGR)
Remove the EGR pipe mounting bolts.
(f) Remove the manifold stay mounting bolts.