heater TOYOTA CELICA 1987 Service Repair Manual

. .
co-2 COOLING SYSTEM - Description
,- I . . .
DESCRlqTlON
This engine utilizes a pressurized water forced circulation cooling system which includes a thermostat equip-
ped mounted on the outlet side.
5 7M-GE
Throttle Body
ISC Valve
/
To Radiator
RHD
/
From Heater
rM-GTE
/
To Heater From Heat: ISC Valve
To Radiator
COGS
COOF

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

COOLING SYSTEM i Check and Replacement of Engine Coolant
co-5
._
CHECK AND REPLACEMENT OF
ENGINE COOLANT
1. CHECK ENGINE COOLANT LEVEL AT RESERVE TANK
The coolant level should be between the “LOW” and
“FULL” lines.
If low, check for leaks and add coolant up to the “FULL”
line. .,>‘
2. CHECK ENGINE COOLANT QUALITY
There should not be any excessive deposits of rust or
scales around the radiator cap or radiator filler hole, and
the coolant should also be free from oil.
lf excessively dirty, replace the coolant.
3. REPLACE ENGINE COOLANT
(a) Remove the radiator cap.
(b) Drain the coolant from radiator and engine drain
cocks.(Engine drain is at right rear of cylinder block.)
(cl Close the drain cocks.
(d) Fill system with coolant.
Use a good brand of. ethylene-glycol base coolant, mixed
according to manufactuer’s directions.
Capacity:
MA
w/ Heater or air conditioner
M/T 8.1 liters (8.5 US qts. 7.1 Imp. qts)
A/T 8.0 liters (8.5 US qts, 7.0 Imp. qts)
w/o Heater or air conditioner
M/T 7.5 liters (7.9 US qts, 6.6
Imp. qts)
A/T 7.4 liters (7.8 US qts, 6.5 Imp. qts)
MS
w/ Heater or air conditioner
GCC Countries*
8.5 liters (9.0 US qts, 7.5 Imp. qts)
Others
7.8 liters (8.2 US qts, 6.7 Imp. qts)
w/o Heater or air conditioner
GCC Countries*
7.8 liters (8.2 US qts, 6.7 Imp. qts)
Others
7.1 liters (7.5 US qts, 6.2 Imp. qts)
(e) Install the radiator cap.
(f) Start the engine and check for leaks.
(g) Recheck the coolant level and refill as necessary.
l GCC Countries: Saudi Arabia, Sultanate of Oman,
Bahrain, United Arab Emirates, Qatar, Kuwait.

COOLING SYSTEM - Radiator
-,... ~‘e:,.,,’ _,
CLEANING OF RADIATOR _ ---w..w- -...,.
Using water or steam cleaner, remove mud and dirt from
the radiator core.
CAUTION: If using’ high-pressure, type cleaner, be
careful not to deform the fins of the radiator core. Keep
a distance of more than 40 - 50 cm (15.75 - 19.69 in.)
between the radiator core and cleaner nozzle when
the cleaner nozzle pressure is 30 - 35 kg/cm2 (427 -
1
498 psi, 2,942 - 3,432 kPa1.
I lNSPECTlON.OF RADIATOR
t 1. CHECK RADIATOR CAP
Using a radiator cap tester, pump tester until relief valve
opens. Check that valve opens between 0.75 kg/cm2
(10.7 psi, 74 kPa) and 1.05 kg/cm2 (14.9 psi, 103 kPa).
Check that pressure gauge does not drop rapidly when
pressure on cap is below 0.6 kg/cm2 (8.5 psi, 59 kPa).
!J If either check is not within limits, replace cap.
1 2. CHECK COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 1.2 kg/cm2 117.1 psi, 118 kPa), check
that pressure does not drop.
If the pressure drops, check for leaks from the hoses,
radiator or water pump. If no external
leaks are found,
check the heater core, cylinder block
and head.

FI-124 EFI SYSTEM - Electronic Control System
-.
Ohmmeter 3. (‘IM-GTE)
INSPECT HEATERAESISiANCE OF OXYGEN
SENSOR
Using an ohmmeter, measure the resistance between the
terminals 2 and 3.
R8SiStaflC8:, 3.0 - 3.6 n
If the resistance is not as specified, replace the sensor.

EM-38
ENGINE MECHANICAL - Cylinder Head
COMPONENT? (Cont’d)
7M-GTE -.
No. 2
Cylinder Head Cover
Heater Hose Clamp
w
No. 3 Cylinder Head-
Cover
Turbocharoer
Oil Seal t
Camshaft Bearing Cap
-No. 2 Engine Hanger
Exhaust
Manifold
Stary
Water .Outlet
Housing
No.
Belt
+ Gasket
Chamber
with Connector
kg-cm (ft-lb, N-ml : Specified torque
+ Non-reusable part Intake Manifold
EM35

ENGINE MECHANICAL -- Cylinder Head
I

15. REMOVE CYLINDER HEAD COVERS
(a) (LHD)
Remove the accelerator link.
(b) (MA)
Remove the heater hose clamp.
(c) Remove the No.1 and No.2 cylinder head covers.
(d) Using SST, remove the No.3 cylinder head cover.
SST 09923-00010
16. REMOVE SPARK PLUGS
(See page 16-7)
17. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS
(See steps 4 and 6 to 9 on pages’ EM-28 to 30)
18. REMOVE CYLINDER HEAD $g!!$
_I -
(a) Using SST, uniformly loosen and remove thecylinder
head bolts in several passes, in the sequence shown.
SST 09043-38100
CAUTION: Head warpage or cracking could result
from removing in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block.
(c) Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a
screwdriver between the cylinder head and block projec-
tion.
CAUTION :
l Be careful not to damage the cylinder head and
block surface on the cylinder and head gasket side.
l Be careful not to damage the VSV.

EM2921
DISASSEMBLY OF CYLiNDER HEAD
(See pages EM-3.7,. 36)
1. REMOVE NO.2 TItiING BELT COVER
2. REMOVE ALTEPNATOR BRACKET
3. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the three bolts, and then remove the delivery
pipe with the injectors.
NOTE: When removing the delivery pipe, be careful not
to drop the injectors.
(b) Remove the six insulators and three spacers from the
cylinder head.
4. REMOVE INTAKE MANIFOLD
(w/ EGR)
Remove the four nuts, seven bolts, EGR valve, VSV, intake
manifold and gasket.
(w/o EGR)
Remove the four nuts, seven bolts, VSV, intake manifold
and gasket.
5. REMOVE NO.2 ENGINE HANGER AND GROUND
STRAP
6.
REMOVE HEATER UNION
7.
(wl EGR)
REMOVE EGR COOLER
6. REMOVE BEARING CAPS AND CAMSHAFTS
(a) Uniformly loosen and remove the bearing cap bolts in
several passes, in the sequence shown.
(b) Remove the camshaft bearing caps, oil seal and
camshaft.

ENGINE MECHANICAL - Cylinder Head
EM-67
EM302
EM2921
(i) Tighten the No.3 and No.7 bearing cap bolts a little at
a time and in the sequence shown in the figure.
Torque:
20.0 kg-c* (14 ft-lb, 20 N-ml
(i) Torque each bearing cap bolt a little at a time and in
the sequence shown in the figure.
Torque : 200 kg-cm (14 ft-lb, 20 N-m)
(k) Check the camshaft thrust clearance.
4.
(w/ EGR)
INSTALL EGR COOLER
Install a new gasket and EGR cooler with the eight bolts.
Torque :
140 kg-cm (IO ft-lb, 14 Nmrn)
(w/o EGR)
INSTALL EGR HOLE PLATE
Install a new gasket and EGR hole plate with the two bolts.
5. INSTALL HEATER UNION
(a) Install a new gasket, union, another gasket and union
bolt to the cylinder head.
(b) Torque the union bolt.
Torque:
600 kg-cm (43 ft-lb, 59 N-m)
6. INSTALL NO.2 ENGINE HANGER AND GROUND
STRAP
Torque:
400 kg-cm (29 ft-lb, 39 N-m)
7. INSTALL INTAKE MANIFOLD
(a) Position a new gasket on the cylinder head.
(b) (w/ EGR)
0 Install the intake manifold and VSV with the two
nuts and seven bolts.
l Install the EGR valve with the two nuts.
l Torque the bolts and nuts.
Torque: 180 kg-cm (13 ft-lb, 18 Nnrn)

ENGINE MECHANICAL - CylinderHead
EM&Q
C Front
EX
EM300’
:
‘INSTALLATl.QN’OF CYLINDER
(See pages EM-37, 38)
1. INSTALL CYLINDER HEAD
(a) Apply seal packing to the two i
Seal packing: Part No. 08826-00080 or equiyafent
(b) Place a new cylinder head gasket on the cylinder
block.
CAUTION: Be careful of the’installation direction.
!
(c) Place the cylinder head on the cylinder head gasket,
and connect the No.5 water by-pass hose to the
union.
Id) Apply a light coat of the.,engine oil on the threads and
under the cylinder head ‘bolts.
(e) Using SST, install and uniformity tighten the fourteen
cylinder head bolts. in several passes and in the
sequence shown.
SST 09043-38 100
Torque: >800 kg-cm (E8 ft-lb, 78 N=m)
2.
3.
4. INSTALL CAMSHAFT TIMING PULLEYS AND TIMING
BELT ’
(See steps 8 to 12 and 14 on pages EM-34 to 36)
INSTALL SPARK PLUGS
(See page 16-71 ~
INSTALL CYLINDER HEAD COVERS
(a) Using SST, install the No.3 cylinder head cover and
heater hose clamp.
SST 09923-00010 in.
Torque: 180 kg-cm (13 ft-lb, 18 N.m)