1987 TOYOTA CELICA check engine

IN-4 Identification Information,
INTRODUCTION - General Repair Instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
Seal Lock Adhesive
GENERAL REPAIR INSTRUCTIONS
1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2.
3. During disassembly, keep parts in order to facilitate
reassembly.
Observe the following:
(a)
(b) Before performing electrical work, disconnect ‘the
negative (-1 cable from the battery terminal.
If it is necessary to disconnect the battery for inspec-
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi-
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
(e)
(f) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
Be sure the cover for the positive (+I terminal is pro-
perly in place.
4.
5. Check hose and wiring connectors to make sure that they
are secure and correct.
Non-reusable parts
(a)’ Always replace cotter pins gaskets, O-rings, oil seals,
etc. with new ones.
(b) Non-reusable parts are indicated in the component
illustrations by the “+” symbol.
6. Precoated Parts
Precoated parts are the bolts, nuts, etc. which are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused
to move in any way, it must be recoated with the
specified adhesive.

CH-2 CHARGING SY&EM - Precautions, Troubleshooting
._
: PRECAUTIONS
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery is
given a quick charge.
3. Do not perform tests with a high voltage insulation
resistance tester.
4. Never disconnect the battery while the engine is run-
ning.
Discharge warning
light does not light
with ignition ON and
engine not ‘running
Problem
Discharge warning
light does not go out
with engine running
(battery requires fre-
quent recharging
Possible cause
Fuse blown
Light burned out
Wiring connection loose
IC regulator faulty
TROUBLESHOOTING
Remedy
Check “CHG” and
“IGN” fuses
Replace light
Tighten loose connections
Replace IC regulator
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
IC regulator or alternator faulty
Wiring faulty Adjust or replace drive belt
Repair or replace cables
Check “ENG” fuse
Replace fusible link
Check charging system
Repair wiring
Page
CH-7
CH-4
CH-3

. COOLING SYSTEM - Description
co;3
RESERVOIR TANK
The reservoir tank is used to catch coolant
which overflows the cooling systein as a result of
volumetric expansion when the coolant is heated.
The coolant in the reservoir tank returns to the
radiator when the coolant temperature drops, thus
keeping the radiator full at all times and avoiding
needless coolant loss. Check the reservoir tank
level to learn if the coolant needs to be rep-
lenished.
WATER PUMP
The water pump is used for forced circulation of
coolant through the cooling system. It is mounted
on the front of the cylinder block and driven by a
V-ribbed belt,
THERMOSTAT I The cooling system is composed of the water
jacket (inside the cylinder block and cylinder head),
radiator, water pump, thermostat, cooling fan,
hoses and other components.
Coolant which is heated in the water
jacket is
pumped to the radiator, through which a cooling
fan blows air to cool the coolant as it passes
through. Coolant which has been cooled is then
sent back to the engine by the water pump, where
it cools the engine.
The water jacket is a network of channels in the
shell of the cylinder block and cylinder head
through which coolant passes. It is designed to
provide adequate cooling of the cylinders are com-
bustion chambers which become the hottest dur-
ing engine operation.
F(/ “ IATOR
The radiator performs the function of cooling
the coolant which has passed through the water
jacket and become hot, and is mounted in the front
of the vehicle. The radiator consists of an upper
tank and ‘lower tank, and a core which connects
the two tanks. The upper tank contains the inlet for
coolant from the water jacket and the filter inlet. It
also has a hose attached through which excess
coolant or steam can flow. The lower tank contains
the outlet for coolant and the drain cock. The core
contains many tubes through which coolant flows
from the upper tank to the lower tank as well as
cooling fins which radiate heat away from the coo-
lant in the tubes. The air sucked through the radia-
tor by cooling fan, as well as the wind generated
by the vehicle’s travel, passes through the radia-
tor, cooling it. Models with automatic transmission
incrl*-le an automatic transmission fluid cooler built
in:.
.le lower tank of the radiator.
RADIATOR CAP
The radiator cap is a pressure type can which
seals the radiator, resulting in pressurization of the
radiator as the coolant expands. The pressuriza-
tion prevents the coolant from boiling even when
the coolant temperature exceeds 100°C. A relief
valve (pressurization valve) and a vacuum valve
(negative pressure valve) are built into the radiator
zap. The relief valve opens and lets steam escape
:hrough the overflow pipe when the pressure
3enerated inside the cooling system exceeds the
imit (coolant temperature:
110 - 1 20°C, (230
- 248”F), pressure; 0.3 - 1 .O kg/cmz, (4.3 - 14.2
)si, 29.4 - 98.1 kPa). The vacuum valve opens to
3ljeviate the vacuum which develops in the coolant
system after the engine is stopped and the coolant
emperature drops. The valve’s opening allows the
)ressure in the cooling system to return to the
Qclant in the reservoir tank. The thermostat has a wax type and is mounted
in the. water outlet housing. The thermostat
includes a type of automatic valve operated by
fluctuations in the coolant temperature. This valve
closes when the coolant temperature drops, pre-
venting the circulation of coolant through the
engine and thus permitting the engine to warm up
rapidly. The valve opens when the coolant tem-
perature has risen, allowing the circulation of coo-
lant. Wax inside the thermostat expands when
heated and contracts when cooled. Heating the
wax thus generates pressure which overpowers
the force of the spring which keeps the valve
closed, thus opening the valve. When the wax
cools, its contraction causes the force of the
spring to take effect once more, closing the valve.
The thermostat in this engine operates at a tem-
perature of 88”C(19O”F).
I
I

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
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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.

Circuit
Opening
Relay Fuel Pump Relay
“CHECK 1 f-- 1 ] : :
llll II :
: :
ENGINE”
Warning
Light ECU
I iIll
+-,llllllllllll
Electronic
Load Air Temp. Sensor
Check Connector 1 1 1 / 1 1 1 1 1 1 1 1
:uator
Igniter w/r-:’ ’
A/C Compressor
& 1 wTwy 1 To Charcoal Canister
Neutral Start
Switch (A/T)

1-6 EFI SYSTEM - System Description
‘he .EFI system is composed of 3 basic sub
;ystems; Fuel Induction, Air Induction and
Ziectronic Control.
FUEL SYSTEM
An electric fuel pump supplies sufficient fuel,
under a constant pressure, to the injectors. These
injectors inject a metered quantity of fuel into the
intake manifold in accordance with signals from
the ECU (Electronic Control Unit).
AIR INDUCTION SYSTEM
The air induction system provides sufficient air for
engine operation.
[3: ‘I
i&TRONIC CONTROL SYSTEM
The 7M-GE, 7M-GTE engines are equipped wifh a
Toyota Computer Control System (TCCS) which
centrally controls the EFI, ESA, Diagnosis systems,
etc. by means of an Electronic Control Unit (ECU -
for-merly EFI computer) employing a microcom-
puter.
By means of the ECU, the TCCS controls the
following functions:
1. Electronic Fuel injection (EFI)
The ECU receivers signals from,various sen-
sors indicating changing engine operating
conditions such as:
Exhaust oxygen content (w/ TWC)
Intake air volume
i Intake air temperature
Coolant temperature
Engine rpm
Vehicle speed
Acceleration/deceleration etc.
These signals are utilized by the ECU to
determine the injection duration necessary for
an optimum air-fuel ratio.
2. Electronic Spark Advance (ESA)
The ECU is programmed with data for
optimum ignition timing under any and all
operating conditions. Using data provided by
sensors which monitor various engine func-
tions (rpm, A/C signal, coolant temperature,
etc.), the microcomputer (ECU) triggers the
spark at precisely the right instant. (See IG
section) 3. Idle Speed Control (IX)
The ECU is programmed with, target idling
speed values to respond to different engine
conditions (coolant temperature, air condi-
tioner on/off, etc.). Sensors transmit signals
to the ECU which control the flow of air
through the bypass of the throttle valve and
adjust idle speed to the target value.
(See pages FI-53, 7 1, 108) ’
4. Diagnosis
The ECU detects any malfunctions or abnor-
malities in the sensor network and tights the
“CHECK ENGINE” warning light on the instru-
ment panel. At the same time, the trouble is
identified and a diagnostic code is recorded
by the ECU.
5. Fail-Safe Function ’
In the event of computer malfunction, a back-
up circuit will take over to provide minimal
drivability. Simultaneously, the “CHECK
ENGINE” warning light will come on.