TOYOTA TERCEL 1996 Service Repair Manual

CO1206
Dimension B
Punch Assembly
Overhaul HandleStopper BoltPartSST
P21094
8 7
65
43
2
1
P21095
Stopper
BoltSSTTank
Lock
Plate
P21096
RibBracket
Claw
Z15037
CO-20
- COOLINGRADIATOR
1996 TERCEL (RM440U)
4. ASSEMBLE SST
SST 09230-01010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part A as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension B shown in the diagram is 7.7 mm (0.30 in.)
5. CAULK LOCK PLATE
(a) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST 09230-01010
HINT:

Do not stake the areas protruding around the ports,brack-
et or tank ribs.

The oil cooler (A/T only) and the points attowed in the il-
lustlation cannot be staked with the SST. Use a plier or like
object and be careful not to damage the core plates.

P21775
H
P21097
SST
CO0766
Clearance
Lock
Plate
O-Ring
- COOLINGRADIATOR
CO-21
1996 TERCEL (RM440U)
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height: 7.75 - 8.25 mm (0.305 - 0.325 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and perform the caulking again.
6. INSPECT FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm
2, 26 psi)
(d) Inspect for leaks.
HINT:
On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
merged in water. Therefore, before performing the water leak
test, first move radiator around in the water until all air bubbles
disappear.
7. PAINT LOCK PLATES
HINT:
If the water leak test checks out okay, allow the radiator to com-
pletely dry and then paint the lock plates.

CO0Y4-02
CO-22
- COOLINGRADIATOR
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CO-16).

CO0Y5-02
P20875
Above 94°C
P20883
Ammeter
Battery
- COOLINGELECTRIC COOLING FAN
CO-23
603 Author
: Date
:
1996 TERCEL (RM440U)
ELECTRIC COOLING FAN
ON-VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the engine main relay, cooling fan relay, cooling
fan, fuses, and check for short circuit between the cooling fan
relay and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 94°C (201°F))
(a) Start the engine, and raise coolant temperature to above
94°C (201°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
M/T5.7 - 7.7 A
A/T8.6 - 11.6 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 6.4 - 7.4 A
(d) Reconnect the cooling fan connector.

CO0I8-04
P20876
Air Cleaner Inlet
RH Engine Under
CoverRadiator Tank
Assmbly
No.1 Cooling
Fan Connector
Radiator Upper Hose No.1 Cooling Fan
No.1 Cooling Fan
LH Engine Under Cover CO-24
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
COMPONENTS

P20878
FanFan Shroud
Fan Motor
Connector Holder No.1 Cooling Fan
- COOLINGELECTRIC COOLING FAN
CO-25
1996 TERCEL (RM440U)

P20882
Air Cleaner InletNo.2 Cooling
Fan Connector
No.2 Cooling Fan No.2 Cooling Fan CO-26
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)

P20947
FanConnector Holder
Fan Motor
Fan ShroudFan Motor Cover No. 2 Cooling Fan
- COOLINGELECTRIC COOLING FAN
CO-27
1996 TERCEL (RM440U)

CO0I9-04
P20884
CO-28
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE NO.1 COOLING FAN
(a) Remove the engine under covers.
(b) Drain the engine coolant.
(c) Remove the air cleaner inlet.
(d) Remove the reservoir tank assembly.
(e) Remove the No.1 cooling fan.
(1) Disconnect the upper radiator hose from the radia-
tor.
(2) Disconnect the cooling fan connector.
(3) Remove the 2 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
2. REMOVE NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Remove the 3 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)

CO0Y6-01
P20880
P20886
P20887
- COOLINGELECTRIC COOLING FAN
CO-29
1996 TERCEL (RM440U)
DISASSEMBLY
1. DISASSEMBLE NO.1 COOLING FAN
(a) Remove the nut and fan.
(b) Remove the fan motor.
(1) Disconnect the wire and connector holder from the
fan shroud.
(2) Remove the 3 screws and fan motor.
2. DISASSEMBLE NO.2 COOLING FAN
(a) Remove the 3 screws and fan.
(b) Remove the screw and fan motor cover.
(c) Remove the fan motor.
(1) Disconnect the wire and connector from the fan
shroud.
(2) Remove the 3 screws and fan motor.