TOYOTA TERCEL 1996 Service Repair Manual

SS0N7-04
- SERVICE SPECIFICATIONSMFI
SS-1 1
141 Author
: Date
:
1996 TERCEL (RM440U)
MFI
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum281 - 287 kPa (2.87 - 2.93 kgf/cm2, 40.8 - 41.7 psi)
Fuel pumpResistance at 20°C (68°F)0.2 - 3.0 W
InjectorResistance at 20°C (68°F)
Injection volume
Difference between each cylinder
Fuel leakage13.4 - 14.2 W
39 - 49 cm3 (2.4 - 3.0 cu in.) per 15 sec.
5 cm3 (0.31 cu in.) or less
1 drop or less per 3 min.
Throttle bodyThrottle body fully closed angle6°
Throttle position
sensorResistance
0 mm (0 in.) VTA - E2
0.50 mm (0.020 in.)IDL - E2
0.70 mm (0.028 in.)IDL - E2
Throttle valve fully open VTA - E2
- VC - E2
0.2 - 5.7 kW
2.3 kW or less
Infinity
2.0 - 10.2 kW
2.5 - 5.9 kW
IAC valveResistance +B - RSO (or RSC)
Cold (-10°C (14°F) to 50°C (122°F))
Hot (50°C (122°F) to 100°C (212°F))
17.0 - 24.5 W
21.5 - 28.5 W
VSV for EGRResistance at 20°C (68°F)33 - 39 W
ECT sensor and
IAT sensorResistance at -20°C (-4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 - 20 kW
4 - 7 kW
2 - 3 kW
0.9 - 1.3 kW
0.4 - 0.7 kW
0.2 - 0.4 kW
MAP sensorPower source voltage4.5 - 5.5 V
Main heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Sub heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Fuel cut rpmFuel return rpm900 rpm

SS0N8-03
SS-12
- SERVICE SPECIFICATIONSMFI
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Fuel line Union bolt type
Flare nut type29
30290
30022
23
Fuel inlet hose x Fuel filter2929022
Fuel outlet pipe x Fuel pump bracket2929022
Fuel tank x Fuel pump set bolt3.43530 in.´lbf
Fuel pressure regulator x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Fuel pressure regulator2020014
Delivery pipe x Cylinder head1919014
Fuel inlet hose x Delivery pipe3030023
Fuel pump bracket x Fuel cut-off valve1.51513 in.´lbf
Fuel tank x Fuel tank filler pipe3.43530 in.´lbf
Fuel tank x Body3334025
Throttle body x Intake manifold19.519514
Main heated oxygen sensor x Exhaust manifold4444032
Sub heated oxygen sensor x Exhaust pipe4444032
Knock sensor x Cylinder block4545033

SS0N9-04
- SERVICE SPECIFICATIONSCOOLING
SS-13
143 Author
: Date
:
1996 TERCEL (RM440U)
COOLING
SERVICE DATA
ThermostatValve opening temperature
Valve lift at 95°C (203°F)80 - 84°C (176 - 183°F)
8 mm (0.31 in.) or more
Radiator capRelief valve opening pressure STD
Minimum74 - 103 kPa (0.75 - 1.05 kgf/cm2, 10.7 - 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)
No. 1 electric
cooling fanRotating amperage M/T
A/T5.7 - 7.7 A
8.6 - 11.6 A
No. 2 electric
cooling fanRotating amperage6.4 - 7.4 A

SS0NA-03
SS-14
- SERVICE SPECIFICATIONSCOOLING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug x Cylinder block2525018
Water pump x Cylinder block17.517513
Oil dipstick guide x RH engine mounting bracket18.518514
Water inlet pipe x Cylinder block7.57565 in.´lbf
Intake manifold stay x Cylinder block2020015
Water inlet x Water outlet housing5.05043 in.´lbf
Radiator upper support x Body121209
Oil cooler x Radiator lower tank Nut A
Nut B, C15.0
8.5150
8511
75 in.´lbf
No. 1 cooling fan x Radiator7.07061 in.´lbf
No. 2 cooling fan x Radiator7.07061 in.´lbf

SS0NB-01
- SERVICE SPECIFICATIONSLUBRICATION
SS-15
145 Author
: Date
:
1996 TERCEL (RM440U)
LUBRICATION
SERVICE DATA
Oil presuureat idle speed
at 3,000 rpm29 kPa (0.3 kgf/cm2, 43 psi) or more
245 - 490 kPa (2.5 - 5.0 kgf/cm2, 36 - 71 psi)
Oil pumpBody clearance STD
Maximum
Tip clearance STD
Maximum
Side clearance STD
Minimum0.10 - 0.16 mm (0.0039 - 0.0063 in.)
0.20 mm (0.0079 in.)
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
0.20 mm (0.0079 in.)
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
2.90 mm (0.1142 in.)

SS0NC-01
SS-16
- SERVICE SPECIFICATIONSLUBRICATION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch release cylinder x Transaxle case M/T only121209
Drain plug x Oil pan2525018
Oil pump x Oil pump pulley3737027
Oil pump x Cylinder block7.57565 in.´lbf
Pressure regulator valve x Cylinder block3030022
Oil strainer x Cylinder block101007
Oil pan x Cylinder block1313010
Oil pan x Oil pump1313010
Front exhaust pipe x Exhaust manifold6263046
Compressor mounting bracket x Cylinder block2727020
A/C compressor x Compressor mounting bracket2525018

SS0ND-04
- SERVICE SPECIFICATIONSIGNITION
SS-17
147 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION
SERVICE DATA
High-tension cordResistance Maximum25 kW per cord
Spark plugRecommended spark plug ND
NGK
Correct electrode gapK16TR11
BKR5EKB-1 1
1.1 mm (0.043 in.)
Ignition coilPrimary coil resistance at cold
at hot
Secondary coil resistance at cold
at hot0.67 - 1.05 W
0.85 - 1.23 W
9.3 - 16.0 kW
11.7 - 18.8 kW
Camshaft position
sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W
Crankshaft
position sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W

SS0NE-01
SS-18
- SERVICE SPECIFICATIONSIGNITION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Spark plug x Cylinder head1818013
Ignition coil x Cylinder head8.58575 in.´lbf
Camshaft position sensor x Cylinder head88069 in.´lbf
Crankshaft position sensor x Oil pump88069 in.´lbf

SS0NF-07
- SERVICE SPECIFICATIONSSTARTING
SS-19
149 Author
: Date
:
1996 TERCEL (RM440U)
STARTING
SERVICE DATA
Starter
(Planetary type)Rated voltage and output power
No-load characteristics Current
rpm
Center bearing oil clearance STD
Maximum
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum12 V 0.8 kW
At 11.5 V 90 A or less
3,000 rpm or more
0.03 mm (0.0012 in.)
0.1 mm (0.004 in.)
14.0 mm (0.551 in.)
9.0 mm (0.354 in.)
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
8.8 N (0.9 kgf, 2.0 lbf)
28.0 mm (1.102 in.)
27.0 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
Starter
(Reduction type)Rated voltage and output power
No-load characteristics Current
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum
Magnetic switch
Contact plate for wear Maximum12 V 1.0 kW
At 11.5 V 90 A or less
3,000 rpm or more
13.5 mm (0.531 in.)
8.5 mm (0.334 in.)
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
11.8 N (1.2 kgf, 2.6 lbf)
30.0 mm (1.181 in.)
29.0 mm (1.412 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

SS0NG-06
SS-20
- SERVICE SPECIFICATIONSSTARTING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
End cover x Brush holder1.51513 in.´lbf
End cover x Starter housing Planetary type
Reduction type5.9
9.360
9552 in.´lbf
82 in.´lbf
Magnetic switch x Starter housing Planetary type
Reduction type8.3
9.385
9573 in.´lbf
82 in.´lbf
Lead wire of field frame x Magnetic switch Planetary type
Reduction type9.8
5.9100
6087 in.´lbf
52 in.´lbf
Intake manifold x Intake manifold stay17.517513
Cylinder block x Intake manifold stay17.517513
Starter wire x Terminal 30 of starter8.89078 in.´lbf
Starter x Transaxle3737027
Terminal nut x Terminal C of starter1717312
Terminal nut x Terminal 30 of starter1717312
Magnetic switch end cover x Magnetic switch3.63632 in.´lbf