1987 TOYOTA CELICA Service Repair Manual

ENGINE MECHANICAL - Cylinder Head
EM-63
(c) Install the intake chamber with connector, and
vacuum transmitting pipes with the two nuts and five
bolts.
Torque: 180 kg-cm (13 f&lb, 18 N-m)
(d) Connect the engine wire to the clamps of the intake
chamber.
(e) install new gaskets and cold start injector tube.
Torque: .To delivery pipe
300 kg-cm (22 f&lb, 29. N-m)
io cold start injector
(f) (w/ EG& 180 kg-cm (I 3 ft-lb; ‘I8 N:m)
Install the EGR vacuum modulator to the bracket.
(g) (7M-GE)
Install the air intake connector bracket mounting
bolts.
(h) (7M-GE)
Install the throttle body bracket(s).
(i) (7M-GTE)
Install the ISC pipe and connect the hoses.

-.
,y. ,. P > .: (i) install the EGR
pipe mounting bolts.
:i
(k) Install the manifold ‘stay mounting bolt.
(I) Connect following hoses:
. 47M-GE)
No.3 water by-pass hose to throttle body
(‘IM-GTE)
0 Auxiliary air pipe hose to vacuum transmitting pipe ’
l No.1 water by-pass hose to ISC valve .
(m) Connect following hoses: .,
. (7M-GE)
Diaphragm hose
0 VSWfor fuel. pressure up)hoses
l Pressure regulator hose
0 EGR hoses to throttle body and vacuum transmit-
ting pipe.
0 Vacuum transmitting pipe hose to intake chamber
-I
0 BVSV hose to throttle body
(r-r) Connect following wires:
0 ISC valve connector
0 Throttle position sensor connector
0 (‘/M-GE)
Cold start injector connector.
(01 Install the PCV pipe.
16. (‘IM-GTE)
INSTALL CAM POSITION SENSOR
(See steps 1, 2 on page 10-26)
17. (7M-GTE)
INSTALL PS RESERVOIR TANK
Install the PS reservoir tank with bracket.
18. INSTALL ALTERNATOR AND ADJUSTING BAR
(a) Install the alternator and adjusting bar.
(b) Install the drive belt.
(See page EM-361
(c) Connect the No.3 PCV pipe.

ENGINE MECHANICAL 7 Cylinder Block
7.
CYLINDER BLOCK
COMPONENTS
EM.-6$-
Piston
Piston - + Snap Ring
Connecting Rod Bushing
Connecting Rod Bearing
+ Gasket
t.
Connecting Rod Cap I + Oi! Seal
Rear Oil Seal Retainer
W-Oil Nozzle (7M-GTE)
I
260 (18. 261 I
Crr;;k;aft Thrust
Oil Pump

EM-66 ENGINE MECHANICAL - Cylinder Block
_. DISASSEMBLY OF CYLINDER BLOCK
(See page EM-651
1. REMOVE FLYWHEEL OR DRIVE PLATE AND REAR
END PLATE
2. INSTALL ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIMING BELT
(See steps 2 to 8 and 10 to 18 on pages EM-28 to 31)
4. REMOVE CYLINDER HEAD .I
(See steps 1 to 15 and 18 on pages EM-39 to 43)
5. REMOVE WATER BY-PASS PIPE AND H&ES
(a) Remove. the two nuts from the timing belt case.
(b) Remove.the three bolts from the cylinder block and
the water by-pass pipe and hose with gasket.
__” r
6. REMOVE GROUND STRAP FROlV&Y~l~tiER BLOkK
7. (7M-GE) -
REMOVE VACUUM CONTROL VALVE SET
8. REMOVE FUEL RETURN PIPE SUPPORT
Remove the two nuts, fuel pipe support and insulator.
9. REMOVE ENGINE MOUNTING BRACKETS
10. (‘IM-GE)
REMOVE OIL FILTER
(See page LU-6)
(7M-GTE)
REMOVE OIL FILTER BRACKET
(See step 1 on page LU-18)
11.
12.
13. (7M-GE w/ C#l cooler)
REMOVE OIL HOLE COVER PLATE
(7M-GE w/o Oil cooler)
REMOVE OIL HOLE COVER PLATE
REMOVE PS PUMP BRACKET
REMOVE OIL.PAN
(See page LU-9)
14. REMOVE TIMING BELT CASE WITH WATER PUMP
Remove the seven bolts and three nuts, and r!move the
timing belt case and gaskets.

ENGINE MECHANICAL - Cylinder Block
EM-67
15. REMOVE OIL PUMP DRIVE SHAFT
(a)
Remove the bolt and oil pump drive shaft.
(b) While turning oil pump drive shaft, slowly pull out so
as not to damage the bearing.
16. REMOVE OIL PUMP /
(a) Loosen the union nut.
(b)
Remove the two bolts and oil pump.
17. REMOVE REAR OIL SEAL RETAINER
Remove the five bolts, rear oil seal retainer and gasket.
18. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while
moving the rod back and forth.
Standard thrust clearance:
0.160 - 0.296 mm
(0.0063 - .0.0117 in.)
Maximum thrust clearance:
0.3 mm (0.012 in.)
If clearance is greater than maximum, replace the connect-
ing rod assembly. If necessary, replace the crankshaft.
19. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
Ia) Using a punch or numbering stamp, place the
matchmarks on the rod and cap to ensure correct
reassembly.

EM-68 . ENGINE MECHANICAL - ,Cylinder Block
EM39
J ,32
(b) Remove the connecting rod cap nuts.
(c) Using a plastic-faced hammer, lightly tap the con-
necting rod bolts and lift off the connecting rod cap.
NOTE: Keep the lower bearing inserted with the con-
necting rod cap.
(d) Cover the connecting rod bolts with a short piece of
,hose to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for. pitting and
scratches.
If the crank pin or bearing are damaged, replace the bear-
ings. If necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.

ENGINE MECHANICAL L- ,Cylinder -Block . . . /
., .
. . ,. ~.,, ;-.^ j, _,. @&#J~
. .
(h) Install the connecting rod cap.
(See step 7 on page EM-901
EM33
Torque: 650 kg-cm (47 f&lb, 64 N-m)
NOTE: Do not turn the crankshaft.
(iI Remove the connecting rod cap.
(i) Measure the Plastigage at its widest point.
Standard oil clearance: 0.021 - 0,063 mm
(0.0008 - 0.0021 In.)
Maximum oil clearance: 0.07 mm (0.0028 In.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, grind or replace the crankshaft.
Undersized bearing: U/S 0,25
(k) Completely remove the plastigage.
NOTE: If using a standard size bearing, replace with one
having the same number. If the number of the bearing can-
not be determined, select a bearing fromthe table below
according to the numbers imprinted on the connecting rod
cap and crankshaft. There are five sizes of standard bear-
ings, marked “I”, I’?“, “3”, “4” and “5”.
Number marked
Rod cap
lI1/2111213/21313
1 Crankshaft l0l1I01211101211121
Bearing )I-l-212) 3)313)4)415)
Example: Rod cap “Z”, Crankshaft “1” = Bearing “3”
(Refererjce)
mm (in.1
I vlark Big End inner
Diameter Crank Pin
Diameter Bearlng Centsr
Wall Thicknese
-
0 51.993 52.000 2/0472) - (2.0470 -
55.015
- 55.025 51.985
- 51.992
1.490 - 1
1.495
(2.1859 - 2.1663) (2.0446 - 2.0469) (0.0587 - 0.0589)
- 2 55.026
- 55.035 51.976
- 51.984
1.496 1.500
(2.1664 - 2.1667) (2.0463 - 2.0466)
(0.0589 - 0.0591)
55.036
- 3 55.045
I.501 - 1.505 -
(2.1668 - 2.1671) (0.0591 - 0.05931
1
I
1.506 - 1.510
(0.0593 - 0.0594)
I
,. ..__ 1” -..-.*

EM-70 ENGINE MECHANICAL - Cylinder Block
c Front
1 2 3 4 5 6
EM147: 3
20. REMOVE PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Remove all the carbon from the top of the cylinder.
(b) Cover the rod bolts with a short piece of hose to pro-
tect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and the
upper bearing through the top of the cylinder block.
NOTE:
0 Keep the bearing insert with the connecting rod and
cap.
l Arrange the piston and connecting rod assemblies in
order.
21. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance: 0.05 - 0.25 mm
(0.0020 - 0.0098 in.)*
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
STD size 2.925 - 2.975 mm
(0.1152 - 0.1171 in.)
O/S 0.125 2.988 - 3.038 mm
(0.1176 - 0.1196 in.)
22. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the main bearing cap
bolts in several passes, in the sequence shown.