The 1986 Toyota Corolla SR5 equipped with the 4AC engine is a reliable compact vehicle known for its fuel efficiency and durability. This repair manual covers comprehensive maintenance, troubleshooting, and repair procedures for the 4AC 1.6L SOHC engine, 5-speed manual transmission, braking system, suspension, electrical systems, and other critical components. Below are essential sections for maintenance schedules, engine repair, transmission service, electrical systems, and troubleshooting.
Regular maintenance intervals for optimal performance and longevity.
| Interval | Service Required |
|---|---|
| Every 3,000 miles | Oil and filter change |
| Every 7,500 miles | Rotate tires, inspect brakes |
| Every 15,000 miles | Replace air filter, fuel filter |
| Every 30,000 miles | Replace spark plugs, check timing |
| Every 60,000 miles | Replace timing belt, coolant flush |
| Every 100,000 miles | Transmission fluid change, inspect clutch |
Technical details for the 4AC 1.6L engine.
Step-by-step instructions for common engine repairs.
WARNING! Always disconnect battery before working on engine. Use proper safety equipment.
Manual transmission maintenance and repair procedures.
Clutch Replacement: Remove transmission, replace clutch disc, pressure plate, and throwout bearing. Resurface flywheel.
Brake system specifications and service procedures.
| Component | Specification |
|---|---|
| Front Brakes | Disc, 9.0" diameter |
| Rear Brakes | Drum, 7.9" diameter |
| Master Cylinder | 15/16" bore |
| Brake Fluid | DOT 3 |
| Parking Brake | Mechanical, rear wheels |
Brake Pad Replacement: Remove caliper, replace pads, compress piston, reassemble.
Suspension components and steering system maintenance.
Strut Replacement: Support vehicle, remove wheel, disconnect strut mounts, install new strut assembly.
Wiring diagrams and electrical component service.
Alternator Replacement: Disconnect battery, remove drive belt, disconnect wiring, remove mounting bolts.
Carburetor and fuel delivery system service.
Carburetor Rebuild: Disassemble, clean all passages, replace gaskets and accelerator pump, reassemble with proper adjustments.
Radiator and cooling system maintenance.
| Component | Specification |
|---|---|
| Radiator Cap | 0.9 bar (13 psi) |
| Thermostat | Opens at 180°F (82°C) |
| Coolant Capacity | 5.8 quarts (with heater) |
| Coolant Type | Ethylene glycol 50/50 mix |
| Water Pump | Centrifugal, belt-driven |
Thermostat Replacement: Drain coolant, remove housing, replace thermostat and gasket, refill system.
Exhaust components and replacement procedures.
Exhaust Manifold Replacement: Remove heat shield, disconnect oxygen sensor, remove mounting nuts, install new manifold with gasket.
Common problems and solutions for the 1986 Corolla SR5 4AC.
| Symptom | Possible Cause | Corrective Action |
|---|---|---|
| Hard starting | Weak fuel pump, dirty carburetor | Check fuel pressure, clean carburetor jets |
| Engine misfire | Worn spark plugs, bad ignition wires | Replace plugs and wires, check distributor cap |
| Overheating | Low coolant, stuck thermostat | Check coolant level, replace thermostat |
| Poor fuel economy | Dirty air filter, misadjusted carburetor | Replace air filter, adjust carburetor mixture |
| Brake pedal soft | Air in lines, worn brake pads | Bleed brake system, inspect brake components |
| Clutch slipping | Worn clutch disc, improper adjustment | Adjust clutch free play, replace clutch if necessary |
Emergency Procedures: Always carry basic tools: screwdrivers, pliers, wrench set, jumper cables.
Technical Support: Refer to Toyota factory service manual for detailed specifications.