1987 TOYOTA CELICA Service Repair Manual

ENGINE MECHANICAL Y Cylinder Block-
. . ,., ,,
..“./.. E”Q+‘J.g
. . . “h,. ,<_ .,., aa* _
. . . . . . . ..I. C/~ a....,,.?._.h, j
’ (b) Using the removed main bearing cap bo~t&?&gg~~
the cap back and forth,.and remove the caps, lower
bearings an! lower thrust washers (No. 4 cap only).
., NOTE: :
0 Keep the lower bearing inserted-with the cap.
0 Arrange the caps and lower thrust washers in correct
order.
9
(c) Lift out the crankshaft. “j ,
NOTE: Keep the upper bearings and upper thrust
washers insert with the cylinder block.
(d) Clean each journal and bearing.
(e) Check each journal and bearing for pitting and
scratches.
If the jounial.or bearing is damaged, replace the bearings.
If necessary, grind or replace the crankshaft,
(f)- Place the crankshaft on the cylinder block.
Cg) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps. (See step 5 on page
EM-891
Torque: 1,040 kg-&n (75 ft-lb, 102 N*m)
NOTE: Do not turn the crankshaft.
(i) Remove the main bearing caps.
(i) Measure the Plastigage at its widest point.
Standard oil clearance: . 0.030 - 0.048 mm
(0.0012 - q.0019 in.)
Maximum oil clearance: 0.07 mm ((i.0026’in.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, replace the crankshaft ,: .‘-
Under size bearing: U/S 0.25 :-.
(k) Completely remove the Plastigage. i
,^ -_ _ . j” ,,I, ,. .a”*+% -,..: :,.-__, ,-,--se. .j.z,.

EM-72 ENGINE MECHANICAL - Cylinder-Block
No.
0, 1 or 2
No. 1, No. 2 Journal
Mark
1,2,3,4or5
NO. 5 - N,o. 7 Journal Mark
1, 2, or 3
Journal
-I 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 from the table below
according to the numbers imprinted on the cylinder block
and crankshaft.
There are five sizes of, standard bearings, marked “I”,
“2”s “3 It,‘“4” and “5”.
Example:
Cylinder Block “2”, Crankshaft “I” = Bearing “3”
(Reference) ,
mm (in.)
Lower EM3831
EM41 3
I I
Mark Cylinder Block Main
I Main Journal Bearing Center
Journal Bore Diameter Wall Thickness
I I 0 60.007 - 60.012
(2.3625 - 2.3627)
I
-
- - 1 64.024 64.030 60.001 60.006 1.988 1.991
(2.5206 - 2.5209) (2.3622 - 2.3624) (0.0783
- 0.0784)
f
I 2 I (2.5209 64.031 - - 84.036 2.5211)
(2.3620 59,994 - - 60.000 2.3822) (0.0784 1.992 - - 0.0785) 1.994
-
- 3 64.037 64.042
1.995 1.997
(2.5211 - 2.5213)
(0.0785 - 0.0786)
4
‘- 1.998 - 2.000
(0.0787 - 0.0787)
t
I
I I 5 I
2.001 - 2.003
(0.0788 - 0.0789)
u/s 64.022
- 64.046 59.730 - 59.740 2.123
- 2.133
0.25 (2.5205 - 2.5215) (2.3516 -
2.3520) (0.0086 - 0.0840)
23. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust
washers.
NOTE:
0 Arrange the caps, bearings and thrust washers in cor-
rect order.
0 The pilot bearing in the crankshaft rear end is perma-
nently lubricated and requires no cleaning or lubrication.
24. (7M-GTE)
REMOVE OIL NOZZLES

ENGINE MECHANICAL --‘Cylinder Block.
. &#.&
./ 1 .,_. . . .,~..“._~__,_Y_
._
INSPECTION OF CYLINDER BiOCk ~. -.,. ;;.. i*
I
.
Front 0 Thrust
Direction
0 Axial
Direction
IOmm
(0.39 in.)
Middle 1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove ail the gasket material
from the cylinder block surface.
2. CLEAN CYLINDER BLOCK
Using a soft brush and solvent, clean the block.
3. INWCT TOP OF CYLINDER BLOC’K FOR FLATNESS
Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cylinder head gasket,
for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
I’f warpage is greater than maximum, replace the cylinder
block.
4. INSPECT CYLINDERS FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all six cylinders. If
necessary, replace the cylinder block.
5. INSPECT CYLINDER BORE DIAMETER
Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and axial
directions.
c
Standard diameter:
STD size 82.99 - 83.04 mm
(3.2873 - 3.2893 in.)
Maximum diameter:
STD size 83.24 mm (3.2772 in.)
O/S 0.50 83.74 mm (3.2988 in.)
If the diameter is greater than maximum, rebore ali six
cylinders. If necessary, replace the cylinder block.

EN’GINE &lECHANlCAL - Cylinder Block
1 33
6. REMOVE CYLINDER RIDGES
If the wear is less than 0.2 mm (0.008 in.), use a ridge
reamer to machine the top of the cylinder.
DISASSEMBLY OF PISTON AND
CONNECTING. ROD ASSEMBLIES
(See page EM-65)
1. CHECK FIT BETWEEN PlSTdN AND PIN :
Try to move the piston back
and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
2. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the compres-
sion rings.
(b) Remove the two side rails and oil ring expander by
hand.
NOTE: Arrange the rings in correct order.
3.
DISCONNECT CONNECTING ROD FROM PISTON
(a) Using needle-nose pliers, remove the snap rings from
the piston.

I 2 /3
4 .5 6 EM454
. . ..L.. -~.--,i -._- -*.,**
(b)
.Gradually heat the’ piston toapprox., 60°C ,(j,4-
I /..
,,: _A.
I,.
i . .
(cl Using a plastic-faced hammer and brass bar, light;?
tap out the piston pin and remove the connecting
rod.
NOTE:
0 The piston and pin are a matched set.
..
l Arrange the pistons, pins, rings, connecting rods‘ and
bearings in correct order.
‘INSPEi=TION OF PliiTON AND CbNNECTING
: riOD ,&&EMBLIES
1. C&EATv PISTONS
(a) ., - Using a gasket scraper, remove the carbon from the
piston top.
(b) Using a groove cleaning tool or broken ring, clean the
ring grooves.

EM-76
ENGINE MECHANICAL - Cylinder Block
(c) Using a soft brush and solvent, thoroughly clean the
piston. -_
CAUTION:
Do not damage the piston.
linder
rface 3. INSPECT PISTON DIAMETER AND OIL CLEARANCE
(a) Using a micrometer, measure the piston diameter at a
right angle to the piston pin hole center line, 22 mm
(0.87 in.) from the piston head.
Standard diameter:
,
7M-GE STD size 62.00 -
62.96 mm
(3.2636
- 3.2666 in.)
O/S O.SO 63.40 - 63.4s mm
(3.263S - 3.2664 in.)
7M-GTE STD size 62.91 - 62.96 mm
(3.2642 - 3.2661 in.)
O/S 0.50 83.41 - 63.46 mm
(3.2639 - 3.2658 in.)
(b) Measure the cylinder bore diameter in thrust direc-
tions.
(See step 5 on page EM-731
(c) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance:
7M-GE 0.08 - 0.10 mm (0.0031 - 0.0039 in.)
7M-GTE 0.07 - 0.09 mm (0.0026 - 0.0035 in.)
Maximum oil clearance: 0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace the
piston. If’necessary, rebore all six cylinders and replace all
six pistons. If necessary, replace the cylinder block.
INSPECT CLEARANCE BETWEEN WALL OF RING
GROOVE AND NEW PISTON RING
Using a thickness gauge, measure the clearance between
new piston ring and the wall of the piston ring groove.
Ring groove clearance: No. 1
0.03 - 0.07 mm
(0.0012 - 0.0026 in.)
No. 2 0.02 - 0.06 mm
(0.0006 - 0.0024 in.)
If the clearance is not within specification, replace the
piston.
4. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b)
Using a piston, push the piston ring a little beyond
the bottom of the ring travel.
(I 10 mm (4.33 in.) from top surface of cylinder
block)

ENGINE MECHANICAL -. Cylinder Block
E,M.+$ i
-.
:
:
. . .
. .
‘,’
‘.
:
t‘,
::
,c ;
‘:
:‘
::
;
. .
:
,i
(c) Using a thickness gauge, measure the end ‘g&p,‘“--’ .‘:
.Standerd enb gap:
No. 1
7M-GE (w/o TWC) and 7M-GTE
0.29 - 0.44 mm (0.0114 - 0.0173 in.)
7M-GE (w/ TWC) .
0.23 - 0.38 mm (0.0091 - 0.0150 in.)
No. 2 0.25 - 0.53 mm (0.0098 - 0.0209 in.)
Oil (Side rail)
7M-GE (w/o TWC) and +M-GTE
0.10 -’ 0.44 mm (O.dO3g - 0.0173 in.)
7M-GE (w/ TWC)
0.10 - 0.40 mm (0.0039 - 0.0157 in.)
Maximum end gap:
No. 1
7M-GE (w/o T&Z) and ‘7M-GTE
0.74 mm (0.0291 in.)
7&l-GE (w/ TWC)
* 0.88 mm IO.0268 in.)
No. 2 1.13 mm (0.0445 in.)
Oil (Side rail)
7M-GE (w/o TWC) and 7M-GTE
1.04 mm (0.0409 in.)
7M-GE (w/ TWC)
1.00 mm (0.0394 in.)
If the gap is greater than maximum, replace the piston
ring.‘lf the gap is greater than maximum, even with a new
piston ring, rebore the cylinder and use an O/S piston ring.
5. CHECK PISTON PIN FIT
At 60°C (14OOF) you should be.able to push the pin into
the piston with your thumb.
If the pin can be installed at a lower temperature, replace
the piston.
8. INSPECT CONNECTING RODS
(a)
Using a rod aligner and thickness gauge, check the
connecting rod alignment.
0 Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting
rod’ assembly.

EM-78 ENGINE MECHANICAL - Cylinder Block
ml0269 EM029 OJ
EM0226
SST 0 Check fortwist.
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting
rod assembly.
(b) Inspect the oil clearance between the rod bushing
and piston pin.
0 Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
BuShing inside diameter: 22.005 - 22.017 mm
IO.8663 - 0.8668 in.)
l Using a micrometer, measure the piston pin
diameter.
Piston pin diameter: 21.996 - 22.009 mm
(0.8660 - 0.8665 in.)
l Subtract the piston pin diameter measurement
from the bushing inside diameter measurement.
Standard oil clearance: 0.005 - 0.011 mm
(0.0002 - 0.0004 in.)
Maximum oil clearance: 0.02 mm (0.0008 in.)
If the oil clearance is greater than maximum, replace the
bushing. If necessary, replace the piston and piston pin
assembly.
7. IF NECESSARY, REPLACE CONNECTING ROD
BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222-30010
.B