engine TOYOTA TERCEL 1996 Service Repair Manual

LU08B-04
P20919
SST
LU0490
SST
- LUBRICATIONOIL AND FILTER
LU-3
1996 TERCEL (RM440U)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Ade-
quate means of skin protection and washing facilities
should be provided.

Care should be taken, therefore, when changing en-
gine oil, to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves, that cannot be penetrated by oil,
should be worn. Wash your skin throughly with soap
and water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline, thinners, or
solvents.

In order to preserve the environment, used oil must
be disposed of only at designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-06501
(b) Clean the filter contact surface on the filter mounting.
(c) Lubricate the filter rubber gasket with engine oil.
(d) Tighten filter until the gasket contacts seat of the filter
mounting. Then using SST, give it an additional 3/4 turn
to seat the filter.
SST 09228-06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Fill the engine with new oil.
Oil grade: See step 1 in oil oressure check
Oil capacity:
Drain and refill w/ Oil filter change
w/o Oil filter change2.8 liters (3.0 US qts, 2.5 lmp. qts)
2.6 liters (2.7 US qts, 2.3 lmp. qts)
Dry fill3.7 liters (3.9 US qts, 3.3 lmp. qts)

LU-4
- LUBRICATIONOIL AND FILTER
1996 TERCEL (RM440U)
4. START ENGINE AND CHECK FOR LEAKS
5. CHECK ENGINE OIL LEVEL

LU08D-05
P20907
EM9278
EM9755
P20160
- LUBRICATIONOIL PUMP
LU-7
1996 TERCEL (RM440U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE HOOD
2. REMOVE OIL DIPSTICK
3. DRAIN ENGINE OIL
4. REMOVE TIMING BELT (See page EM-12)
5. SUSPEND ENGINE WITH ENGINE SLING DEVICE
6. REMOVE CRANKSHAFT TIMING PULLEY(See page
EM-12)
7. w/ A/C:
REMOVE A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put a side compressor, and suspend it.
(c) Remove the 4 bolts and compressor mounting
bracket.
8. DISCONNECT FRONT EXHAUST PIPE
(a) Remove the 2 bolts and the 2 compresson springs.
(b) Disconnect the exhaust pipe.

LU08F-04
LU0144
P21820
P21819
LU1165
- LUBRICATIONOIL PUMP
LU-1 1
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT PRESSURE REGULATOR VALVE
Coat the valve piston with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If necessary, replace the valve.
2. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driv-
en rotor and pump body.
Standard clearance:
0.10 - 0.16 mm (0.0039 - 0.0063 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.
3. INSPECT TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set.
4. INSPECT SIDE CLEARANCE
Using a feeler gauge and flat block, measure the side clearance
as shown.
Standard clearance:
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
Minimum clearance:
2.90 mm (0.1142 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.

Z14807
Oil Pump
Oil PanFIPG
A' - A
Front
Seal Diameter
a: 7mm
b: 4mm
c: 5mmB' - B C' - C ab
bc
B'
BC'
C
- LUBRICATIONOIL PUMP
LU-15
1996 TERCEL (RM440U)

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(f) Place a new O-ring into the cylinder block side groove.
(g) Install the oil pump and tension spring bracket with the 9
bolts.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
2. INSTALL PRESSURE REGULATOR VALVE
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
3. INSTALL OIL STRAINER
(a) Apply a little engine oil to a new O-ring.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
4. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pan,
oil pump, rear oil seal retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the contact sur-
faces.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pump, rear oil seal retainer
and oil pan as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Seal diameter:
7 mm ( 0.28 in.) for a
4 mm ( 0.16 in.) for b
5 mm ( 0.17 in.) for c

Install a nozzle that has been cut to a 4 mm ( 0.16
in.) or 7 mm (0.28 in.) or 5 mm (0.17 in.) opening.
HINT:
Avoid applying an excess amount to the surface.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap after use.
(c) Install the oil pan with the 10 bolts.
Torque: 13 N´m (130 kgf´cm, 10 ft´lbf)
5. CONNECT FRONT EXHAUST PIPE

LU-16
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with 2
compresson springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
6. w/ A/C:
INSTALL A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (270 kgf´cm, 20 ft´lbf)
(b) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Connect the A/C compressor connector.
7. INSTALL CRANKSHAFT TIMING PULLEY (See page
EM-17)
8. INSTALL TIMING BELT (See page EM-17)
9. INSTALL OIL DIPSTICK
10. FILL WITH ENGINE OIL
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK ENGINE OIL LEVEL
13. INSTALL HOOD

IG08E-06
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
SPARK TEST
Replace the camshaft position sensor.
CHECK RESISTANCE OF HIGH-TENSION
CORD (See step 2)
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL
(See step 4) 1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL IGNITER
Resistance: Cold Hot
Secondary
9.3 - 16.0 kW
11.7 - 18.8 kW
CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
(See step 5)
Resistance:Cold Hot
985 - 1,600 W1,265 - 1,890 W
CHECK IGT SIGNAL FROM ECM
(See page
DI-84)
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
(See step 6)
Resistance:Cold
Hot
TRY ANOTHER IGNITERReplace the crankshaft position sensor. Replace the ignition coil. Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
NO
OK OK
OK
OK
OK
OKBAD
BAD
BAD
BAD
BAD
BAD
BAD
Primary
0.67 - 1.05 kW0.85 - 1.23 kW
985 - 1,600 W1,265 - 1,890 W
- IGNITIONIGNITION SYSTEM
IG-1
632 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in following sentences express the tem-
perature of the coils themselves. ºColdº is from -10°C
(14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to
100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high-tension cord from the spark
plug.
(2) Remove the spark plugs.
(3) Install the spark plugs to the high-tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time. If the spark done not occur, do the test as fol-
lows:

IG08M-04
P21254
Connector Clamp
P21034
- IGNITIONCRANKSHAFT POSITION SENSOR
IG-13
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR AND CLAMP
2. REMOVE RH ENGINE UNDER COVER
3. REMOVE NO.2 TIMING BELT COVER (See page
EM-12)
4. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and disconnect the crankshaft position sensor.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)

ST081-01
P21028
Z193254A/T M/T
3A/T ST-16
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE AIR CLEANER HOSE
2. REMOVE INTAKE MANIFOLD STAY
(a) Disconnect the engine wire clamps from intake
manifold stay.
(b) Remove the bolt, nut and intake manifold stay.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
3. REMOVE STARTER
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter wire.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
(c) Remove the 2 bolts, wire clamp and starter.
Torque: 37 N´m (370 kgf´cm, 27 ft´lbf)

CH065-01
- CHARGINGCHARGING SYSTEM
CH-1
677 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING SYSTEM
PRECAUTION

Check that the battery cables are connected to the correct terminals.

Disconnect the battery cables when the battery is given a quick charge.

Do not perform tests with a high voltage insulation resistance tester.

Never disconnect the battery while the engine is running.