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. •¿
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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