TOYOTA TERCEL 1996 Service Repair Manual

CO0Y7-02
CO-30
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page CO-29).

CO0Y8-02
- COOLINGELECTRIC COOLING FAN
CO-31
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CO-28).

P21098
ECT SwitchCO0ID-04
P05962
Ohmmeter CO-32
- COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
612 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE COOLANT
TEMPERATURE (ECT) SWITCH
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SWITCH
3. INSPECT ECT SWITCH
(a) Using an ohmmeter, check that there is no continuity be-
tween the terminals when the coolant temperature is
above 94°C (201°F).
If there is continuity, replace the switch.
(b) Using an ohmmeter, check that there is continuity be-
tween the terminals when the coolant temperature is be-
low 83°C (181°F).
If there is no continuity, replace the switch.
4. REINSTALL ECT SWITCH
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR COOLANT LEAKS

P20319
Engine
Main Relay
CO0IE-05
BE0075
Ohmmeter
Continuity Ohmmeter Continuity
2
1
5
4 3No
Continuity
Ohmmeter
BE0076
OhmmeterOhmmeter
2
1
5
4 3 BatteryNo
Continuity
Continuity
- COOLINGENGINE MAIN RELAY
CO-33
613 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE ENGINE MAIN RELAY (Marking: EG MAIN)
3. INSPECT ENGINE MAIN RELAY
(a) Inspect the relay continuity
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 3.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
2 and 4.
(3) Check that there is no continuity between terminals
4 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation
(1) Apply battery positive voltage across terminals 1
and 3.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 4 and 5.
If there is no continuity, replace the relay.
(3) Check that there is no continuity between terminals
2 and 4.
If there is continuity, replace the relay.
4. REINSTALL ENGINE MAIN RELAY

P20321
No.1 Cooling
Fan Relay
CO0IF-05
Z14238
Ohmmeter
ContinuityOhmmeter
Continuity87a 86
30
85
Z14239
No
Continuity Ohmmeter
Battery 87a 86
30
85
P20322
No.2 Cooling
Fan Relay
P20030No ContinuityContinuity87 30 Ohmmeter
85Ohmmeter
86
Ohmmeter87a CO-34
- COOLINGCOOLING FAN RELAY
614 Author
: Date
:
1996 TERCEL (RM440U)
COOLING FAN RELAY
INSPECTION
1. INSPECT NO.1 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.1 cooling fan relay (Marking: FAN NO.1).
(c) Inspect the No.1 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is continuity between terminals 30
and 87a.
If there is continuity, replace the relay.
(d) Inspect the No.1 cooling fan relay operation.
(1) Apply battery voltage across terminals 85 and 86.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 30 and 87a.
If there is continuity, replace the relay.
(e) Reinstall the No.1 cooling fan relay.
2. w/ A/C:
INSPECT NO.2 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.2 cooling fan relay (Marking: FAN NO.2).
(c) Inspect the No.2 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is continuity between terminals 30
and 87a.
If there is no continuity, replace the relay.
(3) Check that there is no continuity between terminals
30 and 87.
If there is continuity, replace the relay.

P20031
Ohmmeter
Continuity85 3087a 86
Battery No
Continuity
87
P20323
No.3 Cooling
Fan Relay
Z14237
Ohmmeter No
ContinuityContinuity Ohmmeter
87 86
30
85
Z14236
Ohmmeter
Continuity
Battery 87 86
30
85
- COOLINGCOOLING FAN RELAY
CO-35
615 Author
: Date
:
1996 TERCEL (RM440U)
(d) Inspect the No.2 cooling fan relay operation.
(1) Apply battery voltage across terminals 85 and 86.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 30 and 87.
If there is continuity, replace the relay.
(3) Using an ohmmeter, check that there is continuity
between terminals 30 and 87.
If there is no continuity, replace the relay.
(e) Reinstall the No.2 cooling fan relay.
3. INSPECT NO.3 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.3 cooling fan relay. (Marking: FAN NO.3)
(c) Inspect the No.3 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
30 and 87.
If there is continuity, replace the relay.
(d) Inspect the No.3 cooling fan relay operation.
(1) Apply battery positive voltage across terminals 85
and 86.
(2) Using an ohmmeter, check that there is continuity
between terminals 30 and 87.
If there is no continuity, replace the relay.
(e) Reinstall the No.3 cooling fan relay.

LU08A-06
LU1169
Oil Pressure Gauge
Oil Pressure Switch
LU1107
Adhesive
- LUBRICATIONOIL AND FILTER
LU-1
616 Author
: Date
:
1996 TERCEL (RM440U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the oil quality is visibly poor, replace it.
Oil grade:
API grade or SH Energy-Conserving II or ILSAC multi-
grade engine oil. Recommended viscosity is as
shown in the illustration, with SAE 5W-30 being the
prefferred engine oil.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ºLº and ºFº marks on the dip-
stick.
If low, check for leakage and add oil up to the ºFº mark.
3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL
PRESSURE GAUGE
(a) Remove the bolt and air intake connector.
(b) M/T only
Remove the 3 bolts, release cylinder and tube from the
transaxle.
(c) Remove the oil pressure switch.
(d) Install the oil pressure gauge.
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle speed
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 - 490 kPa (2.5 - 5.0 kgf/cm
2, 36 - 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or eqivalent
(c) Reinstall the oil pressure switch.

LU-2
- LUBRICATIONOIL AND FILTER
617 Author
: Date
:
1996 TERCEL (RM440U)
(d) M/T only
Install the release cylinder and tube with the 3 bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(e) Install the air intake connector with the bolt.
7. START ENGINE AND CHECK FOR LEAKS

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