TOYOTA TERCEL 1996 Service Repair Manual

N12897
EB W-BEngine Room
Relay Block
(JUNCTION CONNECTOR)A
A
2 2Engine Hood
Courtesy Switch
12
LG-B12
IC2
LG-B14
T4 Theft Deterrent ECU
DSWH
E5
W-B DI-246
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
Engine Hood Courtesy Switch Circuit
CIRCUIT DESCRIPTION
The engine hood courtesy switch is built into the engine hood lock assembly and goes on when the engine
hood is opened and goes off when the engine hood is closed.
WIRING DIAGRAM
DI4NE-02

BE4061I00298I09784
1
2 Disconnect
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-247
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check engine hood courtesy switch.
PREPARATION:
(a) Remove engine hood lock assembly.
(b) Disconnect engine hood courtesy switch connector.
CHECK:
Check continuity between terminals 1 and 2 when engine hood
lock is locked and unlocked.
OK:
Engine hood lockTester connectionSpecified condition
LOCK-No continuity
UNLOCK1 - 2Continuity
NG Replace engine hood courtesy switch.
OK
2 Check harness and connector between theft deterrent ECU and switch, switch
and body ground (See page IN-26).
NG Repair or replace harness or connector.
OK
Check and replace theft deterrent ECU
(See
page
IN-26).

EM18U-02
P19776
CO/HC Meter
- ENGINE MECHANICALCO/HC
EM-1
422 Author
: Date
:
1996 TERCEL (RM440U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
(i) CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.

EM-2
- ENGINE MECHANICALCO/HC
423 Author
: Date
:
1996 TERCEL (RM440U)
If the CO/HC concentration does not comply with regulations,
troubleshoot according to the table below. Check and correct
the cause if necessary.

EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.

If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.

If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS

EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author
: Date
:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)

P19787
SST(A)
SST(B)
Spark Plug Side
Z07669
B
A
BB
A
B
- ENGINE MECHANICALVALVE CLEARANCE
EM-5
426 Author
: Date
:
1996 TERCEL (RM440U)
(b) Turn the crankshaft pulley 1 revolution (360°) and align
its groove with the timing mark º0º of the No.1 timing belt
cover.
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
6. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve points upward.
(2) Position the notch of the valve lifter so that the shim
can be removed with a small screwdriver as shown
in the illustration.
(3) Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter
flange. Remove SST (A).
SST 09248-55040 (09248-05410, 09248-05420)
HINT:

Apply SST (B) at slight angle on the side marked with º9º,
at the position shown in the illustration.

Set SST (A) at position A, if position A is too narrow, at
position B, as shown in the illustration.
(4) Remove the adjusting shim with a small screwdriver
and magnetic finger.

EM0494
P20156
SST(A)
SST(B)
EM-6
- ENGINE MECHANICALVALVE CLEARANCE
427 Author
: Date
:
1996 TERCEL (RM440U)
(b) Determine the replacement adjusting shim size by the fol-
lowing Formula or Charts on the next 2 pages:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N = T + (A - 0.20 mm (0.008 in.))
Exhaust:
N = T + (A - 0.36 mm (0.014 in.))
Select a new shim with a thickness as close as possible
to the calculated value.
HINT:
Shims are available in 17 increments of 0.05 mm (0.0020 in.),
from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
(1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248-55040 (09248-05410, 09248-05020)
(d) Recheck the valve clearance.
7. REINSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing:
Part No. 08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 5 seal washers and
cap nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install oil filler cap.
8. REINSTALL IGNITION COILS AND HIGH-TENSION
CORDS
9. RECONNECT EGR VACUUM MODULATOR
10. RECONNECT PCV HOSES TO CYLINDER HEAD COV-
ER

V03145
Adjusting Shim Selection Chart (Intake)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.24
shim.Intake valve clearance (Cold):
0.15 - 0.25 mm (0.006 - 0.010 in.)
2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299) Shim
No.ThicknessShim
No.Thickness
HINT: New shims have the thickness in millimeters
imprinted on the face.
New shim thickness
mm (in.)
02
04
06
08
10
12
14
1620
22
24
26
28
30
32
34
18
Installed shim thickness
Measured clearancemm (in.)
mm (in.)
- ENGINE MECHANICALVALVE CLEARANCE
EM-7
428 Author
: Date
:
1996 TERCEL (RM440U)

V03146 Installed shim thickness
Measured clearancemm (in.)
mm (in.)
Exhaust valve clearance (Cold):
0.31 - 0.41 mm (0.012 - 0.016 in.)
EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed,
and the measured clearance is 0.450 mm (0.0177 in.).
Replace the 2.800 mm (0.1102 in.) shim with a new No.18
shim.Adjusting Shim Selection Chart (Exhaust)
2.500 (0.0984)
2.550 (0.1004)
2.600 (0.1024)
2.650 (0.1043)
2.700 (0.1063)
2.750 (0.1083)
2.800 (0.1102)
2.850 (0.1122)
2.900 (0.1142)2.950 (0.1161)
3.000 (0.1181)
3.050 (0.1201)
3.100 (0.1220)
3.150 (0.1240)
3.200 (0.1260)
3.250 (0.1280)
3.300 (0.1299) Shim
No.ThicknessShim
No.Thickness
HINT: New shims have the thickness in millimeters
imprinted on the face.
New shim thickness
mm (in.)
02
04
06
08
10
12
14
1620
22
24
26
28
30
32
34
18
EM-8
- ENGINE MECHANICALVALVE CLEARANCE
429 Author
: Date
:
1996 TERCEL (RM440U)