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*^>
A^

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
MA
EM
MT
AT

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
(I
(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

INTRODUCTION— AbbreviationsUsedInThisManual IN-9
ABBREVIATIONSUSEDINTHISMANUAL
AAP
A/C
AS
ASV
A/T
BTDC
CALIF.
CB
CMH
EBCV
ECU
EGR
EL
EVAP
EX
Ex.
FED.
FWD
HAC
HAI
HIC
IG
HA
IN
in.
LH
MC
MP
M/T
OC
O/S
PCV
PS
RH
SSM
SST
STD
S/W
TDC
TP
TVSV
TWC
U/S
VSV
VTV
w/
w/o
4WD
AuxiliaryAccelerationPump
AirConditioner
AirSuction
AirSwitchingValve
AutomaticTransmission
BeforeTopDeadCenter
VehiclesSoldInCalifornia
ChokeBreaker
ColdMixtureHeater
ElectronicAirBleedControlValve
ElectronicControlUnit
ExhaustGasRecirculation
ExtraLow(Gear)
Evaporative(EmissionControl)
Exhaust(manifold,valve)
Except
VehiclesSoldInUSAExceptCalifornia
FrontWheelDrive
HighAltitudeCompensation
HotAirIntake
HotIdleCompensation
Ignition
IntegratedIgnitionAssembly
Intake(manifold,valve)
Inch
Left-hand
MixtureControl
Multipurpose
ManualTransmission
OxdationCatalyst
Oversized
PositiveCrankcaseVentilation
PowerSteering
Right-hand
SpecialServiceMaterials
SpecialServiceTools
Standard
Switch
TopDeadCenter
ThrottlePositioner
ThermostaticVacuumSwitchingValve
ThreeWayCatalyst
Undersized
VacuumSwitchingValve
VacuumTransmittingValve
With
Without
Four-WheelDrive

MA-1
MAINTENANCE
Page
MAINTENANCESCHEDULEMA-2
MAINTENANCEOPERATIONSMA-4
GENERALMAINTENANCEMA-19
GENERALNOTES:
•Everyserviceitemintheperiodicmaintenancelistmustbeper-
formed.
•Failuretodoevenoneitemcancausetheenginetorunpoorly
andincreaseexhaustemissions.

MA-2 MAINTENANCE— MaintenanceSchedule
MAINTENANCESCHEDULE
Maintenanceoperations: A= Checkand/oradjustifnecessary;
R= Replace,changeorlubrícate;
I= Inspectandcorrectorreplaceif
necessary
NORMALCONDITIONSCHEDULE
System
ENGINE
FUEL
IGNITION
EVAP
BRAKES
CHASSIS
\Serviceinterval
\(Odometerreading(
\months,whichever
\comesfirst)
Maintenanceitems
>r Maintenanceservicesbeyond60,000miles
(96,000km)shouldbeperformedatthesameintervals
shownineachmaintenanceschedule.
Milesx 1,000
Kmx 1,000
Months
Valveclearance**
DrivebeltsC) V-ribbedbelt(Alternator)
Conventionalbelt(PSandA/C)
Engineoilandoilfilter**
Enginecoolant(2)
Exhaustpipesandmountings
Idlespeedandfastidle
speed* 3A-Cengine<3)
3Aengine
Chokesystem**
Throttlepositionersystem* 3A-Cengine(3)
3Aengine
Airfilter**
Fuellineandconnections
Fuelfillercapgasket
Sparkplugs 3A-Cengine**
3Aengine*
Charcoalcanister
Brakelininganddrums
Brakepadsanddiscs
Brakelinepipesandhoses
Steeringlinkage
Driveshaftboots
Balljointsanddustcovers
Automatictransmission,manualtransmission,
differentialandsteeringgearhousingoil
Rearwheelbearinggrease(ex.wagón)W-)
Boltsandnutsonchassisandbody
10
16
12
R
15
24
18
A
A
A
A
I
R
I
20
32
24
R
30
48
36
A
I
R
I
A
I
I
R
I
R
R
40
64
48
R
45
72
54
A
A
I
R
R
I
50
80
60
R
60
96
72
A
I
I
R
R
I
A
I
I
R
I
R
R
R
I
I
I
I
I
I
I
I
Seepage
(itemNo.)
MA-8(item14)
MA-4(item1)
MA-4(item2)
MA-6(item7)
MA-6(item8)
MA-8(item12)
MA-9(item15)
MA-10(item16)
MA-8(item13)
MA-11(item17)
MA-12(item18)
MA-5(item4)
MA-7(item11)
MA-7(item10)
MA-5(item5)
MA-6(item9)
MA-13(item20)
MA-13(item21)
MA-13(item19)
MA-14(item22)
MA-14(item24)
MA-14(item25)
MA-14(item23)
MA-15(item26)
MA-17(item30)
MA-17(item31)
Maintenanceservicesindicatedbya star(*)orasterisk(*)arerequiredunderthetermsoftheEmissionControlSystems
Warranty.SeeOwner'sGuideforcompletewarrantyinformation.
•
ForvehiclessoldinCalifornia
ForvehiclessoldoutsideCalifornia
NOTE:
(1)After60,000miles(96,000km)or72months,inspectevery10,000miles(16,000km)or12months.
(2)After60,000miles(96,000km)or72months,replaceevery30,000miles(48,000km)or36months.
(3)After15,000miles(24,000km)or18months,adjustmentisnotnecessary.
(4)Changeevery45,000miles(72,000km)or54months.

MAINTENANCE— MaintenanceScheduleMA-3
Followthesevereconditionscheduleifvehicleisoperatedmainlyunderoneormoreofthefollowingsevereconditions:
•Pullinga trailer
•Repeatedshort trips
•Drivingonroughand/ormuddyroads
•Drivingondustyroads
•Drivinginextremelycoldweatherand/oronsaltedroads
SEVERECONDITIONSCHEDULE
System
ENGINE
FUEL
IGNITION
EVAP
BRAKES
CHASSIS
\Service¡nterval
\(Odometerreadingo
\months,whichever
\comesfirst)
\
r
\
Maintenanceservicesbeyond60,000miles
(96,000km)shouldbeperformedatthesameintervals
shownineachmaintenanceschedule.
Milesx 1,000
Kmx1,000
Months
Valveclearance*
DrivebeltsC) V-ribbedbelt(Alternator)
Conventionalbelt(PSandA/C)
Engineoilandoilfilter*
Enginecoolanr^)
Exhaustpipesandmountings
Idlespeedandfastidiespeed 3A-Cengine^)
3Aengine
Chokesystem*
Throttlepositionersystem 3A-Cengine^
3Aengine
Airfilter**(6)
Fuellineandconnections
Fuelfillercapgasket
Sparkplugs 3A-Cengine*
3Aengine
Ignitionwiringanddistributorcap*
Charcoalcanister
Brakelininganddrums
Brakepadsanddiscs
Brakelinepipesandhoses
Steeringlinkage^
Driveshaftboots
Balljointsanddustcovers
Automatictransmission,manualtransmission,
differentialandsteeringgearhousing(8)0¡|
Rearwheelbearinggrease(ex.wagón)(5)
Boltsandnutsonchassisandbody(7)
5
8
6
R
I
7.5
12
9
10
16
12
R
I
15
24
18
A
R
I
A
A
A
I
I
R
20
32
24
R
I
22.5
36
27
25
40
30
R
I
30
48
36
A
I
R
I
A
I
I
R
I
R
R
35
56
42
R
I
37.5
60
45
40
64
48
R
I
45
72
54
A
R
I
A
I
I
50
80
60
R
I
R
52.5
84
63
55
88
66
R
60
96
72
A
I
I
R
R
I
A
I
I
R
I
R
R
R
(4)
I
I
I
I
R
I
I
I
I
I
R
I
I
I
I
I
I
R
R
I
I
I
I
I
R
I
Seepage
(itemNo.)
MA-8(item14)
MA-4(item1)
MA-4(item2)
MA-6(item7)
MA-6(item8)
MA-8(item12)
MA-9(item15)
MA-10(item16)
MA-8(item13)
MA-11(ítem17)
MA-12(item18)
MA-5(ítem3,4)
MA-7(ítem11)
MA-7(item10)
MA-5(item5)
MA-6(item6)
MA-6(item9)
MA-13(ítem20)
MA-13(item21)
MA-13(item19)
MA-14(item22)
MA-14(item24)
MA-14(item25)
MA-14(item23)
MA-15(item27)
MA-16(item28)
MA-16(item29)
MA-17(item30)
MA-17(item31)
Maintenanceservicesindicatedbya star(*)orasterisk(*)arerequiredunderthetermsoftheEmissionControlSystems
Warranty.SeeOwner'sGuideforcompletewarrantyinformation.
*ForvehiclessoldinCalifornia
*ForvehiclessoldoutsideCalifornia
NOTE:
(1)After60,000miles(96,000km)or72months,inspectevery10,000miles(16,000km)or12months.
(2)After60,000miles(96,000km)or72months,replaceevery30,000miles(48,000km)or36months.
(3)After15,000miles(24,000km)or18months,adjustmentisnotnecessary.
(4)Ináreaswhereroadsaltisused,inspectandcleaneachyearjustafterthesnowseason.
(5)Changeevery45,000miles(72,000km)or54months.
(6)Applicablewhenoperatingmainlyondustyroads.Ifnot,followthenormalconditionschedule.
(7)Applicablewhenoperatingmainlyonroughand/ormuddyroads.Ifnot,followthenormalconditionschedule.
(8)Inspectthesteeringgearhousingforoilleakageonly.

MA-4 MAlNTENANCE— MaintenanceOperations
Nippondenso Borroughs
EC0003EC0004EC0001
CORRECTWRONGWRONG
CH0084
MAINTENANCEOPERATIONS
ENGINE
ColdEngineOperations
1.INSPECTV-RIBBEDTYPEDRIVEBELT
(ALTERNATOR)
(a)Visuallycheckthebeltforseparationoftheadhesive
rubberaboveandbelowthecore,coreseparation
fromthebeltside,severedcore,separationoftherib
fromtheadhesiverubber,crackingorseparationof
theribs,tomorwomribsorcracksintheinnerridges
oftheribs.
Ifnecessary,replacethedrivebelt.
(b)Usinga belttensióngauge,checkthedrivebeltten-
sión.
Belttensióngauge:
NippondensoBTG-20(95506-00020)or
BorroughsNo.BT-33-73F
Drivebelttensión:Usedbelt80± 20Ib
Newbelt125± 25Ib
Ifnecessary,adjustthedrivebelttensión.
NOTE:
•"Newbelt"referstoa brandnewbeltwhichhasnever
beenused.
•"Usedbelt"referstoa beltwhichhasbeenusedona
runningenginefor5 minutesormore.
•Afterreplacingthedrivebelt,checkthatiffitsproperly
intheribbedgrooves,especiallyintheplacesdifficult
tosee.
CORRECT
WRONG
Clearance
T iiiwmii
llllll'IMI
lllllllllll
mili
Illilllllll
lllllll
•miiuin MA0035
2.INSPECTCONVENTIONALTYPEDRIVEBELTS
(PSPUMPANDA/CCOMPRESSOR)
(a)Visuallycheckthedrivebeltforcracks,oilinessor
wear.Checkthatthebeltdoesnottouchthebottom
ofthepulleygroove.
Ifnecessary,replacethedrivebelt.
(b)Usinga belttensióngauge,checkthedrivebeltten-
sión.
Nippondenso Borroughs
EC00Q3EC0004EC0001
Belttensióngauge:
Nippondenso
Borroughs
Drivebelttensión
BTG-20(95506-00020)or
No.BT-33-73F
Usedbelt80± 20Ib
Newbelt125± 25Ib
Ifnecessary,adjustthedrivebelttensión.

MAINTENANCE— MaintenanceOperations MA-5
4.
INSPECTAIRFILTER
(a)Visuallycheckthattheaircleanerelementisnot
excessivelydirty,damagedoroily.
NOTE:Oilinessmayindícatea stuckPCVvalve.
Ifnecessary,replacetheaircleanerelement.
(b)Cleantheelementwithcompressedair.
Firstblowfrominsidethoroughiy,thenblowofftheout-
sideoftheelement.
REPLACEAIRFILTER
Replacetheusedaircleanerelementwitha newone.
WRONG
IG0002
REPLACESPARKPLUGS
(a)Disconnectthesparkplugwiresattheboot.
DONOTpulíonthewires.
(b)Removethesparkplugs.
(c)Setthegaponthenewplugs.
Gap:3A-C(ex.CanadáWagónM/T)
1.1mm(0.043in.)
3A& 3A-C(forCanadáWagónM/T)
0.8mm(0.031in.)
Recommendedsparkplugs:
Federal
NDW14EXR-U11orW16EXR-U11
NGKBPR4EY11orBPR5EY11
Calif.& Canadá3A-C(ex.WagónM/T)
NDW16EXR-U11
NGKBPR5EY11
3A& Canadá3A-C(forWagónM/T)
NDW14EXR-UorW16EXR-U
NGKBPR4EYorBPR5EY

MA-6 MAINTENANCE— MaintenanceOperations
/?N./
^—^__^^^ VU^—
\¿£
Q^SZffiA
/\T
MA0119
6.INSPECTIGNITIONWIRINGANDDISTRIBUTOR(IlA)
CAP
(a)Removethedistributor(HA)capwithwire.
(b)Cleanthedistributor(HA)capandwireswitha clean
cloth.
(c)Visuallyinspectthewiringforcracksordamage.
(d)Visuallyinspectthecapforcracks,carbóntracksor
wear.
NOTE:Ináreaswhereroadsaltisused,inspectionand
cleaningshouldbeperformedeachyearjustafterthe
snowseason.
7.REPLACEENGINEOILANDOILFILTER
(SeepageLU-3)
Engineoilgrade:
APIgradeSForSF/CC,multigradeviscosityand
fuel-efficientoil
Engineoilcapacity(Drainandrefillwithoilfilter
change):
3.3liters(3.5USqts,2.9Imp.qts)
DrainCocks
MA0100
3A-CEngine(Ex.CanadáWagónM/T)
iB,c
Airshouldflowthroughfreelyandno
charcoalshouldcomeout.ECH24
3A& 3A-C(CanadáWagónM/Tonly)
EngineB c
t
Airshouldflowthroughfreelyandno
charcoalshouldcomeout.
8.REPLACEENGINECOOLANT
(a)Drainthecoolantfromradiatorandenginedrain
cocks.(Enginedrainisontheleftnexttotheoilfilter.)
(b)Ciósethedraincocks.
(c)Fillsystemwithcoolant.
Coolantcapacity(w/heaterorairconditioner):
5.3liters(5.6USqts,4.7Imp.qts)
Usea goodbrandofethylene-glycolbasecoolant,mixed
accordingtothemanufacturéisinstructions.
9.INSPECTCHARCOALCANISTER
(a)Disconnectthehosestothecharcoalcanister.Label
hosesforcorrectinstallation.
(b)PlugpipeC andD (ex.CanadáWagónM/T)withyour
fingersandblowcompressedair(3kg/cm2,43psior
294kPa)throughpipeB (fueltankside).
•CheckthataircomesoutofthebottompipeA
withoutresistance.
•Checkthatnoactivatedcharcoalcomesout.
Ifnecessary,replacethecharcoalcanister.
NOTE:Donotattempttowashthecharcoal.
(c)Connectthehosestothecharcoalcanister.

MAINTENANCE— MaintenanceOperations MA-7
10.REPLACEGASKETINFUELFILLERCAP
(a)Removetheoídgasket(O-ring)fromthefuelfiller
cap.
Donotdamagethecap.
(b)Installthenewgasketbyhand.
(c)Inspectthecapfordamageorcracks.
(d)Installthecapandcheckthetorquelimiter.
USASedanandWagónFWD,
CanadáSedan(3A-CEngineonly)
andWagónFWDw/A/T
CharcoaiCanister
FuelTank
VSV
OVCV
Carburetor
FuelPump
FuelFilter
11.INSPECTFUELLINESANDCONNECTIONS
Visuallyinspectthefuellinesforcracks,Ieakage,loóse
connections,deformationortankbandlooseness.
CanadáSedan(3AEngine
andWagónFWDw/M/T
CharcoaiCanister
[}
Carburetor-Jow51
FuelPump^^A
FuelFilter(jJ
f)
only)
L
)
—FuelTank
^71Fuel
B}—hller
Cap
EC0434
USAWagón4WDand
CanadáWagón4WDw/A/T
VSV
OVCV
Carburetor
FuelPump
FuelFilter
CharcoaiCanister
FuelFiller
Cap
MA0269
CanadáWagón4WDw/M/T
Carbúrete
FuelPump
FuelFilter?
CharcoaiConister FuelFillerCap
FuelTank

MA-8 MAINTENANCE— MaintenanceOperations
12.INSPECTEXHAUSTPIPESANDMOUNTINGS
Visuallyinspectthepipes,hangersandconnectionsfor
severecorrosión,leaksordamage.
13.INSPECTCHOKESYSTEM
(a)Removetheaircleaner.
(b)Cleanthechokeshaftandlinkage.
•Spraycarburetor(orchoke)cleaneronthechoke
linkagetoremovedirtanddust.
•Spraycarburetor(orchoke)cleaneronbothends
ofthechokeshaftwhileopeningandclosingthe
chokevalvebyhand.
P,u9ASVHose
(exceptCanadá3A
andFederal3A-C)
Plug
ASHose
exceptFederal 3A-C)
MA0103
Front First
EXINn EX
HotEngineOperations
14.ADJUSTVALVECLEARANCE
NOTE:(Ifaircleanerisremoved)Beforestartingthe
engine,plugtheairsuction(AS)hosetopreventleakage
ofexhaustgasandtheHIChosetopreventroughidling.
(a)Warmuptheenginetonormaloperatingtem-
perature.
(b)Stoptheengineandremovethevalvecover.
(c)SetNo.1 cylindertoTDC/compression.
•Turnthecrankshaftwitha wrenchtoalignthetim-
ingmarksatTDC.Setthegrooveonthepulleyto
the0 position.
•CheckthattherockerarmsonNo.1 cylinderare
loóseandrockersonNo.4 aretight
Ifnot,turnthecrankshaftonecompleterevolutionand
alignmarksasábove.
(d)Adjusttheclearanceofhalfofthevalves.
•Adjustonlythosevalvesindicatedbyarrows.
Valveclearance:Intake0.20mm(0.008in.)
Exhaust0.30mm(0.012in.)

MAINTENANCE— MaintenanceOperations MA-9
Front Second
MA0270
(f)
(g)
•Usea feelergaugetomeasurebetweenthevalve
stemandrockerarm.Loosenthelocknutandtum
theadjustingscrewtosettheproperclearance.
Holdtheadjustingscrew¡npositionandtighten
thelocknut.
•Reckecktheclearance.Thefeelergaugeshould
movewitha veryslightdrag.
Tumthecrankshaftonecompleterevolution(360°)
andaligntimingmarksinthemannermentioned
above.Adjustonlythevalves¡ndicatedbyarrows.
Reinstallthevalvecover.
Reinstalltheaircleaner.
K*
RubberCapTachometer
ServiceConnectorMAOKM
15.ADJUSTIDLESPEED
(a)Preparation
•Aircleanerinstalled
•Chokevalvefullyopen
•Accessoriesswitchedoff
•Allvacuumlinesconnected(i.e.,AS,EGRsystems,
etc.)
•TransmissioninN range
•Engineidiingatnormaloperatingtemperature
•EnginecoolingfanOFF
(b)Connecta tachometertotheengine.
Removetherubbercapandconnectthetachometer
positive(+)terminaltotheserviceconnectorofthe
distributor(HA).
CAUTION:
1.NEVERallowtheignitioncoiltermináistotouch
groundasitcouldresultindamagetotheigniter
and/orignitioncoil.
2.Assometachometersarenotcompatiblewith
thisignitionsystem,itisrecommendedthatyou
consultwiththemanufacturer.