TOYOTA TERCEL 1996 Service Repair Manual

EM9966
P20476
12 mm
Hexagon
Wrench
P00496
Adhesive
P20479
SST
- ENGINE MECHANICALCYLINDER BLOCK
EM-89
1996 TERCEL (RM440U)
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 4 bolts.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
11. INSTALL OIL FILTER UNION
Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
12. INSTALL OIL PUMP AND PRESSURE REGULATOR
VA LV E
13. INSTALL OIL PRESSURE SWITCH
(a) Clean the switch threads and cylinder block switch holes
of any sealer, oil or foreign materials. Remove any oil with
kerosene or gasoline.
(b) Apply adhesive to 2 or 3 threads of the switch end.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, install the oil pressure switch.
SST 09816-30010
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
14. INSTALL OIL FILTER (See page LU-1)

P20750
P20480
SST
P20545
EM9412
EM7333
EM-90
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
15. INSTALL RH ENGINE MOUNTING BRACKET
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
16. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816-30010
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
17. INSTALL GENERATOR BRACKET
Torque: 24 N´m (240 kgf´cm, 18 ft´lbf)
18. INSTALL WATER PUMP WITH WATER INLET PIPE
19. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
20. INSTALL CYLINDER HEAD
21. INSTALL TIMING BELT AND PULLEYS
22. REMOVE ENGINE STAND
23. INSTALL REAR END PLATE
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
24. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of new mounting bolt
end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent

EM9410
1
2 3
45
6
- ENGINE MECHANICALCYLINDER BLOCK
EM-91
1996 TERCEL (RM440U)
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the mounting bolts, in several
passes, in the sequence shown.
Torque: 90 N´m (900 kgf´cm, 65 ft´lbf)
25. A/T:
INSTALL DRIVE PLATE (See step 24)
26. M/T:
INSTALL CLUTCH DISC AND COVER

EM1OC-01
EM-92
- ENGINE MECHANICALEXHAUST SYSTEM
513 Author
: Date
:
1996 TERCEL (RM440U)
EXHAUST SYSTEM
COMPONENTS

EC079-03
- EMISSION CONTROLEMISSION CONTROL SYSTEM
EC-1
514 Author
: Date
:
1996 TERCEL (RM440U)
EMISSION CONTROL SYSTEM
PURPOSE
The emission control systems are installed to reduce the amount of HC, CO and NOx exhausted from the
engine ((3) and (4)), to prevent the atmospheric release of blow-by gas-containing HC (1) and evaporated
fuel containing HC being released from the fuel tank (2).
The function of each system is shown in the following table.
SystemAbbreviationFunction
(1) Positive Crankcase Ventilation
(2) Evaporative Emission Control
(3) Exhaust Gas Recirculation
(3) Three-Way Catalytic Converter
(4) Sequential Multiport Fuel Injection *PCV
EVAP
TWC
SFIReduces HC
Reduces evaporated HC
Reduces NOx
Reduces HC, CO and NOx
Injects a precisely timed, optimum amout of fuel for reduced exhaust
emissions
Remark: * For inspection and repair of the SFI system, refer to the SFI section this manual.

EC07E-05
EC-2
- EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
515 Author
: Date
:
1996 TERCEL (RM440U)
PARTS LAYOUT AND SCHEMATIC DRAWING
LOCATION

EC07F-03
- EMISSION CONTROLPARTS LAYOUT AND SCHEMATIC DRAWING
EC-3
1996 TERCEL (RM440U)
DRAWING

EC1228
Cylinder Head Side
Clean Hose
EC07D-03
EC1229
Intake Manifold Side
Clean Hose
EC3648
EC-4- EMISSION CONTROLPOSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
517 Author
: Date
:
1996 TERCEL (RM440U)
POSITIVE CRANKCASE
VENTILATION (PCV) SYSTEM
INSPECTION
1. REMOVE PCV VALVE
2. ATTACH CLEAN HOSE TO PCV VALVE
3. BLOW AIR FROM CYLINDER HEAD SIDE
Check that air passes through easily.
NOTICE:

Do not suck air through the valve.

Petroleum substances inside the valve are harmful.
4. BLOW AIR FROM INTAKE MANIFOLD SIDE
Check that air passes through with difficulty.
If the PCV valve fails either of the checks, replace it.
5. REINSTALL PCV VALVE
6. VISUALLY INSPECT HOSES, CONNECTIONS AND
GASKETS
Check for cracks, leaks or damage.

EC0JN-01
EC3070
Gasket
Check Valve
(Vacuum Valve)
- EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC-5
518 Author
: Date
:
1996 TERCEL (RM440U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loosen connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.
3. VISUALLY INSPECT FUEL TANK CAP
Check if the cap and or gasket are deformed or damaged.
If necessary, repair or replace the cap.
4. REMOVE CHARCOAL CANISTER
5. REMOVE CAP FROM CHARCOAL CANISTER
6. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
7. INSPECT FOR CLOGGED FILTER AND STUCK
CHECK VALVE
(a) Using low pressure compressed air4.71 kPa (48 gf/cm
2,
0.68 psi), blow into port A and check that air flows from the
other ports.
If operation is not as specified, replace the charcoal canister.
(b) Blow air 4.71 kPa (48 gf/cm
2, 0.68 psi) into port B and
check that air does not flow from the other ports.

Port B
Port C
(a)
(b)
P05838
EC-6
- EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
519 Author
: Date
:
1996 TERCEL (RM440U)
(c) Clean the filter by blowing 294 kPa (3 kgf/cm2,
43 psi) of
compressed air into port A while holding port B closed.
NOTICE:

Do not attempt to wash the canister.

No activated carbon shold come out.
8. REINSTALL CAP TO CHARCOAL CANISTER
9. REINSTALL CHARCOAL CANISTER
10. DRAIN ENGINE COOLANT
11. REMOVE TVV FROM WATER INLET AND OUTLET
HOUSING
(a) Disconnect the vacuum hose from the throttle body.
(b) Disconnect the vacuum hose from the charcoal canister.
(c) Remove the TVV.
12. VISUALLY INSPECT TVV OPERATION
(a) Cool the TVV to below 50°C (122°F) with cool water.
(b) Below air into the upper port and check that the TVV is
closed.
(c) Cool the TVV to above 65°C (149°F) with hot water.
(d) Blow air into the upper port and check that the TVV is
open.
If operation is not as specified, replace the TVV.
13. REINSTALL TVV
(a) Apply sealant to the thread of the TVV and reinstall it.
Sealant:
Part No. 08833-00070, THREE BOND 1324 or equiva-
lent
Torque:35 N´m (350 kgf´cm, 26 ft´lbf)
(b) Reconnect 2 vacuum hoses.
14. REFILL WITH ENGINE COOLANT