1987 TOYOTA CELICA Service Repair Manual

I7M-Gb 7M-GTE-
I Front Mark
Froht Mark
1 (Delta)
(Arrow)
Front Mark
(Protrusion) Front Mark
(Protrusion)
EM454
ASSEMBLY OF PISTON AND CONNECTlp?q:,:-a:
ROD __ . . . .
; *’
(See page EM-651 .._
.’
1. ASSEMBLE PISTON AND CONNECTING ROD
j
(a) Install a new snap ring on one side of the piston pin,
hole.
(b) Gradually heat the piston to approx. 60°C (140°F).
(c) Coat the piston pin with engine oil.
IdI Align the front marks of the piston and the connect-
ing rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the pin
hole.
2.
INSTALL q&TON RINGS
(a) Install the oil ring expander and two side rails by
hand.
(b) Using a piston ring expander, install the two com-
pression rings with the code mark facing upward.

EM-88 ENGINE MECHANICAL - Cylinder Block
r
Upper Side Compression1
Front
4-- R&i
Ring No. 2 Rail EM464

No. 1 Ex. No. 1
fqJiiJ;;;;B
25 mm (0.98 in.) 22 mm (0.87 in.) EM0771
(c) Position the piston rings so that the ring ends are as
shown.
CAUTION: Do not align the ends.
3. .INSTALL BEARINGS
(a) Align the bearing claw with th,e claw groove of the
connecting.rod or connecting rod cap.
(b) Install the bearing in the con’necting rod and rod cap.
CAUTION: Install the bearings with the oil hole in the;
connecting rod.
ASFEMBLY OF CYLINDER BLOCK
(See page EM-651
NOTE:
l Thoroughly clean all parts to be assembled.
l Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
l Replace all gaskets, O-rings and oil seals with new
parts.
1. (7M-GTE)
INSTALL OIL NOZZLES
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
2. INSTALL MAIN BEARINGS
NOTE: Different the bearing are used for the No. 1 and
ex. No. 1.

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

EM-90 ENdIM IV~ECHAN~CAL - Cylinder Block
6. INSTALL PISTON AND CONNECTING ROD
ASSEMBLIES
(a) Cover the-connecting rod bolts with a short piece of
-
hose to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly
numbered piston and connecting rod assemblies into
each cylinder with the front mark (delta for 7M-GE
and arrow for 7M-GTE) of the piston facing forward.
EM384
EM383.
EM482
7. INSTALL CONNECTING ROD CAPS
(a) Match the numbered cap with the numbered con-
necting rod.
(b) Install the cap with the protrusion facing forward.
(c) Install and alternately tighten the cap nuts in several
passes.
Torque: 650 kg-cm (47 ft-lb, 64 N-m) .
(d) Check that the crankshaft turns smoothly.
(e) Check the connecting rod thrust clearance.
(See step 18 on page EM-671
6. JNSTALL OIL PUMP ASSEMBLY
(a) Clean the oil pump.
(b) Install the oil pump with the two bolts and union nut.
Torque the bolt and union nut.
Torque: Bolt (A) 220 kg-cm (16 ft-lb, 22 N*m)
Bolt (B) 60 kg-cm (52 in.-lb, 5.9 Nom)
Union nut 350 kg-cm (25 ft-lb, 34 Nmrn)

ENGINE MECHANICAL - Cylinder Block
Qy g&
.
e. .-. .a ,j .a. VI ,... :~.~.**-.-. ),
9. INSTALL OIL PUMP DRIVE SHAFT
(a) While turning the drive shaft, insert slowly to avoid
damaging the drive shaft bearing.
(b) Install the bolt.
Torque:
145 kg-cm (10 ft-lb, 14 N*m)
10. INSTALL REAR OIL SEAL RETAINER
Install
a new gasket and rear oil seal retainer with the five
bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)
11. INSTALL TIMING BELT CASE WITH WATER PUMP
(a) Position new
gaskets on the cylinder block.
(b) Apply sealant to two or three threads of the 10 mm
bolt end.
Sealant: Part No. 08833-00070, THREE BOND 1324
or equivalent
(c) Install the timing belt case with the seven bolts and
three nuts.
12. INSTALL OIL PAN
(See page LU-14)
.13. INSTALL PS PUMP BRACKET

EM-92 _. ENGINE MECHANICAL +’ Cylinder Block
-..
: .
;,,
“.’
‘i4. (7M-GE w/ Oil Cooler)
INSTALL Oil.. REGULATOR
Install a new gasket and oil regulator with. the two bolts.
(7M-GE w/o Oil Cooler and.7M-GTE)
INSTALL OIL HOLE COVER PLATE
Install a new gasket and oil hole cover plate with the two .
bolts.
15. (7M-GE)
INSTALL NEW OIL FILTER
(See page LU-6)
16. INSTALL ENGlNE MOUNTING BRACKETS
17. INSTALL FUEL RETURN PIPE SUPPORT
Install a new insulator and fuel pipe support with the two
nuts. :
Torque: 130 kg-cm (69 ft-lb, ‘1.3 N&l
18. (7M-GE)
INSTALL VACUUM CONTROL VALVE SET
19. INSTALL GROUND STRAP TO CYLI’NDER BLOCK
20. lN,STALL WATER BY- PASS PIPE
(a) “Install a new gasket and water by-pass pipe to the
timing belt case with the two nuts.
Torque: 140 kg-cm (IO ft-!b, 14 N-m)
(b) Install the water by-pass pipe tqthe cylinder block
with the three bolts.
Torque: 130 kg-cm (9 ft-lb, 13 N-m)
21. INSTALL CYLINDER HEAD
(See steps 1 and 4 to 18 on pages EM-59 to 64)
22. INSTALL TIMING BELT
(See step 1 to 8 and 10 to 15 on pages EM33 to 36)
23. REMOVE ENGiNE STAND
24. INSTALL REAR END PLATE
Torque: 130. kg-cm (9 ft-lb, 13 N.m)
25. INSTALL FLYWHEEL OR DRIVE PLATE ON
CRANKSHAFT
(a) Install the flywheel or drive plate on crankshaft.
(b) Install and uniformly tighten the bolts in several
passes, in the sequence shown.
Torque: 750 kg-cm (54 ft-lb, 74 N*m)

. .
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1.1 .I.. -I ““... _.. ____ ,,_
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_-
IGNiiid’N SYSTEM
PRECAUTIONS Page
................................
16-2
TROUBLESHOOTING
............................
IG-3
IGNITION SYSTEM CIRCUIT
....................
ON-VEHICLE INSPkTlON (7M-GE) IO-4
............. IO-5
ON-VEHICLE INSPECTION (7M-GTE)
............ IO-1 2
DISTRIBUTOR (7M-GE)
.........................
IO-19
CAM POSITION SENSOR (7M-GTE)
............. 16-23

16-2 IGNITION SYSTEM - precautions
-.
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.