1987 TOYOTA CELICA Service Repair Manual

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.

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

CO-8 -. COOLING SYSTEM L Thermostat
._
Valve Lift
i
t-
THERMOSTAT
REMOVAL OF THERMOSTAT
REMOVE WATER OUTLET AND THERMOSTAT
(a) Remove two bolts, water outlet and thermostat with
gasket from the water outlet, housing.
(b) Remove the gasket from the thermostat.
INSPECTION OF THERMOSTAT
NOTE: Thermostat is numbered according to the valve
opening temperature.
(a)
Immerse the thermostat in water and heat the water
gradually.
(b)
Check the valve opening temperature.
Valve opening temperature:
86 - 90°C (187
- 194°F)
If the valve opening temperature is not within specifica-
tion, replace the thermostat.
(c) Check the vatve lift.
Valve lift:
8 mm (0.31 in.) or more at
100°C (212°F)
If the valve lift is less than specification, replace the ther-
mostat.
(d) Check that the valve spring is tight when the ther-
mostat is fully closed.
If necessary, replace the thermostat.
INSTALLATION OF THERMOSTAT
INSTALL THERMOSTAT AND WATER OUTLET
(a) Place a new gasket to the thermostat.
(b) Install the thermostat with the jiggle valve facin
upward as shown in the illustration, and water outlc
with the two bolts.
,

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.

CO-IO
-.
COOLING SYSTEM - Radiatpr
. .
COMPONENTS
IA (A/T)
MS (A/T)
+ O-Ring
I
Oil Cooler Pipe
I
1
Upper Tank
-+ Tank Plate
,+ 0-Rina
I I I I
I I I I I I I I I I I ICore
Lower
Tank
+ Non-reusable part
coo55
SST - I
DISASSEMBLY OF RADIATOR
1. REMOVE TANK PLATE
(a)
Raise the claws of the tank plates with SST in tt-
numerical order shown in the figure.
SST 09230-00010
NOTE:
Be careful not to damage the core plate.

COOLING SYSTEM - Radhtor co-11
Tank
O-Ring
Core
(b) Pull the tank plates outward.
2.
REMOVE TANi( AND O-RING
(a) Pull the tank upward.
(b) Remove the O-ring.
3. (A/T)
REMOVE OIL COOLER FROM LOWER TANK
(a) (MS)
Remove the pipes.
NOTE:
Make a note of the direction the pipes face.
(b) Remove the nuts, plate washers and oil cooler.
(c) Remove the O-rings from the oil cooler.
ASSEMBLY OF RADIATOR
(See page CO-lo)
1. (MA with A/T)
INSTALL OIL COOLER TO LOWER TANK
(a) Clean the O-ring contact surface of the lower tank
and oil cooler. _
(b) Install new O-rings (1) to the oil cooler (2).
(c) Install the oil cooler (2) with O-rings (1) to the lower
tank (3).
(d) Install the plate washers (4). and nuts (5). Torque the
nuts (5).
Torque: 220 kg-cm (16 f&lb, 22 Nqn)

-.
COOLING SYSTEM - Radiator
.
ore
Plate
Core plate
XTwisteq
XTwistedl
- 2755:
2. (MS with A/T)
INSTALL OIL COOLER TO LOWER TANK
(a)
Clean the O-ring contact surface of the
lower: tank
and oil cooler.
(b) Install new O-rings (1) to the oil cooler (2).
(c) Install the oil cooler (2) with the O-rings (1) to the
lower tank (3).
(d) Install the plate washers (41, spring washers (5) and
nuts (6). Torque the nuts (6).
Torque: 220 kg-cm (16 ft-lb, 22 N*m)
(e) Install the pipes (7).
Torque: 150 kg-cm (11 ft-lb, 15 N.mI
NOTE: Face the pipes in the same direction they were
before disassembly.
INSPECT CORE PLATE
Inspect the core plate for damage.
NOTE:
l If the sides of the core plate groove are deformed,
reassembly of the tank will be impossible. Therefore,
first correct any deformation with pliers.
0 Water leakage will result if the bottom of the core plate
groove is damaged or dented. Therefore, repair or re-
place if damaged.
3. INSTALL NEW O-RING AND TANK
NOTE:
l Clean the tank and core plate.
l Inspect the O-ring for twists.