Toyota Tercel 1985 Operating instructions

FOREWORD

Thismanualcontainsmaintenanceandrepairproceduresfor

the1985Tercel.

Applicablemodels:AL21series

AL25series

Themanualisdividedinto21sectionsand5 appendixeswitha

thumbindexforeachsectionattheedgeofthepages.

Allinformationinthismanualisbasedonthelatestproduct

informationatthetimeofpublication.Howeverspecifications

andproceduresaresubjecttochangewithoutnotice.

.v . yf. .

TOYOTAMOTORCORPORATION

NOTE:Clickon"Bookmarks"ontheleftside

ofthispdfforeasynavigation.

Thismanualisfora 1985Tercelonly.

Itshouldbecompatiblewithothermodelyears.

Useatyourownrisk.

•¿

^j*^>

1985TOYOTATERCEL

REPAIRMANUAL

INTRODUCTION

MAINTENANCE

ENGINEMECHANICAL

EMISSIONCONTROLSYSTEM

FUELSYSTEM

COOLINGSYSTEM

LUBRICATIONSYSTEM

IGNITIONSYSTEM

STARTINGSYSTEM

CHARGINGSYSTEM

CLUTCH

MANUALTRANSAXLE

AUTOMATICTRANSAXLE

PROPELLERSHAFT

FRONTAXLEANDSUSPENSIÓN

REARAXLEANDSUSPENSIÓN

BRAKESYSTEM

STEERING

BODYELECTRICALSYSTEM

BODY

AIRCONDITIONINGSYSTEM

SERVICESPECIFICATIONS

STANDARDBOLTTORQUESPECIFICATIONS

SSTANDSSM

AUTOMATICTRANSMISSION

HYDRAULICCIRCUIT

ELECTRICALWIRINGDIAGRAMS

IN-1

INTRODUCTION

Page

HOWTOUSETHISMANUALIN-2

IDENTIFICATIONINFORMATIONIN-4

GENERALREPAIRINSTRUCTIONSIN-4

PRECAUTIONSFORVEHICLESEQUIPPEDWITH

CATALYTICCONVERTERIN-6

VEHICLELIFTANDSUPPORTLOCATIONSIN-7

ABBREVIATIONSUSEDINTHISMANUALIN-8

IN-2 INTRODUCTION- HowToUseThisManual

HOWTOUSETHISMANUAL

Toassistinfindingyourwaythroughthemanual,theSection

Titleandmajorheadingaregivenatthetopofeverypage.

AnINDEXisprovidedonthefirstpageofeachsectiontoguide

youtotheitemtoberepaired.

Atthebeginningofeachsection,PRECAUTIONSaregiven

thatpertaintoall repairoperationscontainedinthatsection.

Read these precautions befo re starting any repair task.

TROUBLESHQOTINGtablesareincludedforeachsystemto

helpyoudiagnosethesystemproblemandfindthecause.The

repairforeachpossiblecauseisreferencedintheremedycol-

umntoquicklyleadyoutothesolution.

REPAIRPROCEDURES

Mostrepairoperationsbeginwithanoverviewillustration.It

identifiesthecomponentsandshowshowthepartsfit

together.

Example:

1st1,850(134,181)

2nd300( 22,29),

430(31,42)

IntermedíateShaft

DustCover

Flange

HeightWasher

430

(31,

42)

CenterSupportBearing_ — —

—— -~""PropellerShaft

kg-cm(ft-lb,Nm)| : Tighteningtorque

•: Non-reusablepart

INTRODUCTION- HowToUseThisManual IN-3

Theproceduresarepresentedina step-by-stepformat:

•Thephotoorillustrationshowswhat todoandwhereto do

it.

•Thetaskheadingtellswhat todo.

•Thedetailedtexttellshow toperformthetaskandgives

otherinformationsuchasspeciÍFicationsandwarnings.

Example:

Photograph or illustration:

what to do and where

/Task heading: what to do

CONNECTPROPELLERSHAFTFLANGETO

COMPANIONFLANGEONDIFFEREIMTIAL

(a)Alignthemarksontheflangesandconnectthethem

withthefourboltsandnuts.„^^n t i H t

(b)Torquethenuts.. . . ..

^how to do it

Torque:430kg-cm{31ft-lb,42Nm)

Specification

Thisformatenablestheexperiencedtechniciantohavea FAST

TRACK.Hecanreadthetaskheadingsandonlyrefertothe

detailedtextwhenheneedsit.Importantspecificationsand

warningsalwaysstandoutinboldtype.

REFERENCES

Referenceshavebeenkepttoa mínimum.However,whenthey

arerequiredyouaregiventhepage togoto.

SPECIFICATIONS

Specificationsarepresentedinboldtypethroughoutthetextin

theapplicablestep.Youneverhavetoleavetheprocedureto

lookupyourspecs.

WARNINGS,CAUTIONS,NOTES:

•WARNINGSarepresentedinboldtype,andindícatethereis

apossibilityofinjurytoyouorotherpeople.

•CAUTIONSarealsopresentedinboldtype,andindícatethe

possibilityofdamagetothecomponentsbeingrepaired.

•NOTESareseparatedfromthetextbutdonotappearin

bold.Theyprovideadditionalinformationtohelpyoueffi-

cientlyperformtherepair.

IIM-4

INTRODUCTION— IdentificationInformation,GeneralRepairInstructions

IDENTIFICATIONINFORMATION

VEHICLEIDENTIFICATIONNUMBER

Thevehicleidentificationnumberisstampedonthefrontcowl

oftheenginecompartmentThisnumberisalsostampedon

topoftheinstrumentpanelandthedriver'sdoorpost.

ENGINESERIALNUMBER

Theengineserialnumberisstampedontheleftsideofthe

cylinderblock.

GENERALREPAIRINSTRUCTIONS

1.Usefender,seatandfloorcoverstokeepthevehicleclean

andpreventdamage.

2.Duringdisassembly,keeppartsinordertofacilítate

reassembly.

3.Observethefollowing:

(a)Beforeperformingelectricalwork,disconnectthe

cablefromthebatteryterminal.

(b)Ifitisnecessarytodisconnectthebatteryforinspec-

tionorrepair,alwaysdisconnectthecablefromthe

negative(-)terminalwhichisgroundedtothevehi-

clebody.

(c)Topreventdamagetothebatteryterminalpost,

loosentheterminalnutandraisethecablestraightup

withouttwistingitorpryingit.

(d)Cleanthebatteryterminalpostsandcableterminal

witha shoprag.Donotscrapethemwitha fileor

such.

(e)Installthecableterminaltothebatterypostwiththe

nutloóse,andtightenthenutafterinstallation.Do

notusea hammerorsuchtotaptheterminalonto

thepost.

(f)Besurethecoverforthepositive(+)terminalispro-

perlyinplace.

4.Checkhoseandwiringconnectorstomakesurethatthey

aresecureandcorrect.

5.Non-reusableParts

(a)Alwaysreplacecotterpins,gaskets,O-ringsandoil

seáisetc.Withnewones.

(b)Non-reusablepartsareindicatedinthecomponent

¡llustrationsbythesymbol"•".

INTRODUCTION— GeneralRepairInstructionslN-5

PrecoatedParts

Precoatedpartsarethebolts,nuts,etc.Whicharecoated

witha seallockadheasiveatthefactory.

(a)Ifa precoatedpartistightened,loosenedorcaused

tomoveinanyway,itmustberecoatedwiththe

specifiedadhesive.

RecoatingofPrecoatedParts

(b) Cleanofftheoídadhesivefromthebolts,nutor

installationpartthreads.

(2)Drywithcompressedair.

(3)Applythespecifiedseallockadhesivetothe

boltornutthreads.

(c)Precoatedpartsareindicatedinthecomponent

illustrationsbythesymbol"*".

7.Whennecessary,usea sealerongasketstopreventleaks.

8.Carefullyobserveallspecificationsforbolttighteningtor-

ques.Alwaysusea torquewrench.

9.Useofspecialservicetools(SST)andspecialservice

materials(SSM)mayberequired,dependingonthenature

oftherepair.BesuretouseSSTandSSMwherespecified

andfollowtheproperworkprocedure.A listofSSTand

SSMcanbefoundatthebackofthismanual.

10.Whenreplacingfuses,besurethenewfuseisthecorrect

amperagerating.DONOTexceedthefuseampratingor

useoneofa lowerrating.

11.Caremustbetakenwhenjackingupandsupportingthe

vehicle.Besuretoliftandsupportthevehicleatthe

properlocations(SeepageIN-7).

(a)Ifthevehicleistobejackeduponlyatthefrontor

rearend,besuretoblockthewheelsinorderto

ensuresafety.

(b)Afterthevehicleisjackedup,besuretosupportiton

stands.Itisextremelydangeroustodoanyworkon

thevehicleraisedonjackalone,evenfora smalljob

thatcanbefinishedquickly.

WRONG CORRECT

IN0001

12.Observethefollowingprecautionstoavoiddamageto

parts:

(a)Todisconnectvacuumhoses,pulíontheend,notthe

middleofthehose.

(b)Topulíapartelectricalconnectors,pulíonthecon-

nectoritself,notthewires.

(c)Becarefulnottodropelectricalcomponents,suchas

sensorsorrelays.Iftheyaredroppedona hardfloor,

theyshouldbereplacedandnotreused.

IN-6 INTRODUCTION— GeneralRepairInstructions

Example

INOO02

(d)Whensteamcieaninganengine,protecttheHA,air

filter,andVCVfromwater.

(e)Neveruseanimpactwrenchtoremoveorinstallther-

moswitchesorthermosensors.

(f)Whencheckingcontinuityatthewireconnector,

insertthetesterprobécarefullytopreventtermináis

frombending.

(g)Whenusinga vacuumgauge,neverforcéthehose

ontoa connectorthatistoolarge.Usea step-down

adapterinstead.Oncethehosehasbeenstretched,it

mayleak.

13.Taghosesbeforedisconnectingthem:

(a)Whendisconnectingvacuumhoses,usetagstoiden-

tifyhowtheyshouldbereconnected.

(b)Aftercompletinga job,doublecheckthatthe

vacuumhosesareproperlyconnected.A labelunder

thehoodshowstheproperlayout.

Canadá3A

HICHose

Plug

ASHose

14.Whenaircleanerisremoved,plugtheHIChoseandAS

hosetopreventroughidlingandleakageofexhaustgas.

INTRODUCTION— PrecautionsForVehiclesEquippedWithCatalyticConverterIN-7

PRECAUTIONSFORVEHICLESEQUIPPEDWITH

CATALYTICCONVERTER

WARNING:Iflargeamountsofunburnedgasolineflow

intotheconverter,itmayoverheatandcréatea firehazard.

Topreventthis,observethefollowingprecautionsand

explainthemtoyourcustomer.

1.Useonlyunleadedgasoline.

2.Avoidprolongedidling.

Avoidrunningtheengineatfast¡dlespeedformorethan

10minutesandat¡dlespeedformorethan20minutes.

3.Avoidsparkjumptest.

(a)Sparkjumptestonlywhenabsolutelynecessary.Per-

formthistestasrapidlyaspossible.

(b)Whiletesting,neverracetheengine.

4.Avoidprolongedenginecompressionmeasurement.

Enginecompressiontestsmustbemadeasrapidlyas

possible.

5.Donotrunenginewhenfueltankisnearlyempty.

Thismaycausetheenginetomisfireandcréateanextra

loadontheconverter.

6.Avoidcoastingwithignitionturnedoffandprolonged

braking.

7.Donotdisposeofusedcatalystalongwithpartscon-

taminatedwithgasolineoroil.

IN-8INTRODUCTION— VehicleLiftandSupportLocations

VEHICLELIFTANDSUPPORTLOCATIONS

FWD

4WD

JACKPOSITION

FrontCenterofcrossmember

RearRearfloorcrossmember(FWD)

Centerofrearaxiehousing(4WD)

PANTOGRAPHJACKPOSITIONQ

SUPPORTPOSITION

Safetystand

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