check engine TOYOTA TERCEL 1996 Service Repair Manual

P20489
P20548
Z07984
SST SST
SST
SSTSSTPiston
Pin
SST
- ENGINE MECHANICALCYLINDER BLOCK
EM-77
1996 TERCEL (RM440U)
23. CHECK FIT BETWEEN PISTON AND PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
24. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the rings in the correct order only.
25. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using SST, press out the piston pin from the piston.
(b) Remove the connecting rod.
SST 09221-25024 (09221-00020, 09221-00030,
09221-00130, 09221-00140, 09221-00150)
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

P00393
EM0JR-04
Z07983
P00390
EM9429
Front
Cylinder Bore Size Mark (1,2 or 3) EM-78
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
(b) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(c) Clean the cylinder block.
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of the cylinder block.

P20540
P20527
Top of Cylinder Block
110 mm
(4.33 in.,)
EM7639
N00301
- ENGINE MECHANICALCYLINDER BLOCK
EM-81
1996 TERCEL (RM440U)
8. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the ring groove.
Ring groove clearance:
No.10.04 - 0.08 mm (0.0016 - 0.0031 in.)
No.20.03 - 0.07 mm (0.0012 - 0.0028 in.)
If the oil clearance is greater than maximum, replace the piston.
9. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.26 - 0.48 mm (0.0102 - 0.0189 in.)
No.20.36 - 0.57 mm (0.0142 - 0.0224 in.)
Oil (Side rail)0.13 - 0.50 mm (0.0051 - 0.0197 in.)
Maximum end gap:
No.11.07 mm (0.0421 in.)
No.21.02 mm (0.0402 in.)
Oil (Side rail)1.10 mm (0.0433 in.)
If the end gap is greater than maximum, replace the piston ring.
If necessary, replace the cylinder block.
10. INSPECT CONNECTING RODS
Using a rod aligner, check the connecting rod alignment.

Check for out-of-alignment.
Maximum out-of-alignment:
0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
If out-of-alignment is greater than maximum, replace the con-
necting rod assembly.

N00302
EM3208
N00295
EM-82
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)

Check for twist
Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
HINT:
If replacing the connection rods, replace the same number of
connecting rod bearings as that of new connecting rod caps.
11. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
12. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD49.985 - 50.000 mm (1.9679 - 1.9685 in.)
U/S 0.2549.745 - 49.755 mm (1.9585 - 1.9589 in.)
Crank pin diameter:
STD42.985 - 43.000 mm (1.6923 - 1.6929 in.)
U/S 0.2542.745 - 42.755 mm (1.6829 - 1.6833 in.)
If the diameter is not as specified, check the oil clearance (See
page EM-70).
If necessary, grind or replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-
of-round as shown.
Maximum taper:
0.08 mm (0.0031 in.)
Maximum out-of-round:
0.07 mm (0.0028 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
13. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
(a) Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure in step 2).
(b) Install new main journal and/or crank pin undersized
bearings.

EM0JT-05
P20471
Front Mark
(Cavity)
Front Mark
(Protrusion)
Z08055
SST
Piston Pin
SSTSST
SST
SST
SST SST
P20549
P20560
1R
2R
- ENGINE MECHANICALCYLINDER BLOCK
EM-85
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Coat the piston pin and pin holes of the piston with engine
oil.
(b) Align the cavity on the piston with the protrusion on the
connecting rod.
(c) Using SST, press in the piston pin.
SST 09221-25025 (09221-00020, 09221-00030,
09221-00130, 09221-00140, 09221-00150)
(d) After installing the piston pin, check that when the con-
necting rod is aligned with the center of the piston the
space between the piston and each end of the piston pin
are equal on the left and right sides.
HINT:
If the piston pin is off-center due to insufficient insertion pres-
sure on the piston pin, place a washer at the position indicated
by
in the illustration for (c). Then, while checking that the
space is equal at the ends of the piston pin on the left and right
sides, press in the washer.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code Mark:
No.11R
No.22R

P20551
P20530
Front
Z14291
1
2 3
45
6
7
89
10
EM3480
P20569
Front Mark
(Cavity)
FrontPush
- ENGINE MECHANICALCYLINDER BLOCK
EM-87
1996 TERCEL (RM440U)
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the oil grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing caps.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 58 N´m (580 kgf´cm, 42 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM-70).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.

EM3481
Front Mark
(Protrusion)
Front
EM3448
P20475
Seal Packing
A'B'
A
B
A - A' B - B' EM-88
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
9. INSTALL CONNECTING ROD CAPS
(a) Match the numbered connecting rod cap with the num-
bered connecting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
(c) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.
(d) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance (See page
EM-70).
10. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the rear oil
seal retainer and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the rear oil seal retainer as shown
in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

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

EC0JP-01
EC-8
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the stmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using 3 - way connector, connect a vacuum gauge to the EGR
valve vacuum hose as shown in the illustration.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. INSPECT OPERATION VSV WITH COLD ENGINE
(a) The engine coolant temperature shold be below 45°C
(113°F).
(b) Check that the vacuum gauge indicates zero at 2,500
rpm.
5. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 60°C (140°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,500 rpm.
(c) Check that the vacuum gauge indicates zero at idle.
(d) Disconnect the vacuum hose from port R of the EGR vac-
uum modulator and connect port R directley to the intake
manifold with another hose.
(e) Check that the vacuum gauge indicates high vacuum at
2,500 rpm.
HINT:
As a large amount of exhaust gas enters, the will misfire slghtly.
6. REMOVE VACUUM GAUGE
Remove the vacuum gauge and reconnect the vacuum hoses
to the proper locations.

(a)
(b)
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC-9
1996 TERCEL (RM440U)
7. INSPECT EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Apply vacuum directly to the EGR valve with the engine
idling.
(c) Check that the engine runs rough or dies.
(d) Reconnect the vacuum hoses to the proper locations.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
8. VSV ISPECTION (See page MF-42)
9. CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
(b) Block ports P and R with your finger.
(c) Bllow air into port Q, and check that the air passes through
to the air filter freely.
(d) Start the engine and maintain speed at 2,500 rpm.
(e) Repeat the above test. Check that there is a strong resis-
tans to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
(f) Reconnect the vacuum hoses to the proper locations.
10. REMOVE AIR CLEANER CAP
11. REMOVE EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the EGR hose from the vacuum modulator.
(c) Loosen the union nut.
(d) Remove the 4 nuts, EGR valve, pipe sleeve ball and the
2 gaskets.
12. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.
13. REINSTALL EGR VALVE
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300kgf´cm, 22ft´lbf)
(b) Install anew gasket, the EGR pipe, new sleeve ball with
the 2 nuts and union nut.
Torque:
Nut: 30 N´m (300kgf´cm, 22ft´lbf)
Union nut: 40 N´m (400kgf´cm, 30ft´lbf)
(c) Connect the vacuum hoses to the EGR valve.
(d) Connect the EGR hose to the vacuum modulator.
14. REINSTALL AIR CLEANER CAP