1986 Corolla SR5 Repair Manual

The 1986 Toyota Corolla SR5 is a compact sedan featuring front-engine, front-wheel drive layout with 1.6L 4A-C engine, 5-speed manual transmission, independent front suspension with MacPherson struts, rear leaf spring suspension, front disc/rear drum brakes, and comprehensive electrical system. Below are key sections for maintenance procedures, specifications, troubleshooting, and repair instructions.

1. Vehicle Specifications 2. Engine Maintenance 3. Transmission & Drivetrain 4. Brake System 5. Suspension & Steering 6. Electrical System 7. Fuel System 8. Cooling System 9. Exhaust System 10. Body & Interior 11. Troubleshooting Guide

Vehicle Specifications

Key technical data for 1986 Corolla SR5 model.

Component	Specification
Engine	1.6L 4A-C inline 4-cylinder
Displacement	1587 cc
Horsepower	74 hp @ 4800 rpm
Torque	88 lb-ft @ 2800 rpm
Transmission	5-speed manual
Fuel System	2-barrel carburetor
Fuel Capacity	13.2 gallons
Brakes Front	Ventilated discs
Brakes Rear	Drum brakes
Wheelbase	95.7 inches

Engine Maintenance

Routine maintenance procedures for 4A-C engine.

Oil Change: Drain and replace every 3,000 miles with 10W-30 oil.
Spark Plugs: Replace every 30,000 miles with NGK BPR5ES.
Timing Belt: Inspect every 60,000 miles; replace if worn.
Valve Adjustment: Check clearance every 15,000 miles.
Air Filter: Replace every 12,000 miles or as needed.

WARNING! Always disconnect battery before working on electrical components. Allow engine to cool before servicing.

Transmission & Drivetrain

Manual transmission service and clutch maintenance.

Transmission Fluid: Check level monthly; use 75W-90 GL-4 gear oil.
Clutch Adjustment: Check pedal free play (0.4-0.8 inches).
Shift Linkage: Lubricate every 15,000 miles.
CV Joints: Inspect boots for damage during oil changes.

CAUTION! Use jack stands when working under vehicle. Do not rely on hydraulic jack alone.

Brake System

Brake Pads: Replace when thickness below 1/8 inch.
Brake Fluid: DOT 3; replace every 2 years or 24,000 miles.
Rotor Thickness: Minimum 0.787 inches.
Drum Diameter: Maximum 7.87 inches.
Parking Brake: Adjust when lever travel exceeds 8-10 clicks.

Suspension & Steering

Front MacPherson struts and rear leaf spring maintenance.

Front Suspension: Strut replacement, ball joint inspection, control arm bushings.

Steering: Manual rack and pinion; check for play every oil change. Wheel Alignment: Toe-in 0±2mm, Camber 0°45'±45', Caster 1°20'±45'. Tire Rotation: Every 7,500 miles. Shock Absorbers: Replace if leaking or excessive bounce.

Electrical System

Battery, alternator, and wiring diagnostics.

Battery: 12V 45Ah; check terminals for corrosion monthly.
Alternator: Output 45A; test if battery not charging.
Starter: Draw should not exceed 180A.
Fuses: Located in driver's side kick panel and engine bay.

Tip: Use multimeter for electrical diagnostics. Always disconnect battery before repairs.

Fuel System

Carburetor service and fuel delivery system.

Carburetor Adjustment: Idle speed 750±50 rpm; mixture screw 2.5 turns out.
Fuel Filter: Replace every 15,000 miles.
Fuel Pump: Mechanical type; pressure 2.5-3.2 psi.
Choke: Check automatic choke operation in cold starts.
Fuel Lines: Inspect for cracks or leaks annually.

WARNING! No smoking or open flames when working on fuel system. Have fire extinguisher nearby.

Cooling System

Radiator, thermostat, and coolant maintenance.

Exhaust System

Manifold, catalytic converter, and muffler inspection.

CAUTION! Work in well-ventilated area. Carbon monoxide is deadly.

Body & Interior

1986 Corolla SR5 features: Cloth seats, AM/FM radio, analog gauges, rear-wheel drive configuration.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery/ignition/fuel	Check battery voltage; test spark; verify fuel delivery.
Poor acceleration	Clutch/carburetor	Check clutch slippage; clean carburetor; adjust timing.
Brake vibration	Warped rotors	Resurface or replace front brake rotors.
Overheating	Coolant/thermostat	Check coolant level; test thermostat; flush radiator.
Electrical issues	Alternator/grounds	Test alternator output; check ground connections.

Reset: Disconnect battery for 30 minutes to reset ECU.

Service: Refer to Toyota dealership for complex diagnostics.