sensor TOYOTA TERCEL 1996 Service Repair Manual

EG0023
EM-24
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. w/ A/C and w/o PS:
REMOVE IDLER PULLEY BRACKET
(a) Loosen the idler pulley mounting nut and adjusting bolt,
and remove the drive belt.
(b) Remove the 3 bolts and idler pulley bracket.
10. REMOVE IGNITION COILS AND SPARK PLUGS
11. DISCONNECT VACUUM HASES
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the 3 vacuum hoses from the throttle body.
(c) Disconnect the vacuum hose from the TVV (to charcoal
canister).
(d) Disconnect the vacuum hose from the TVV (to throttle
body).
(e) Disconnect the vacuum hose from the EGR VSV.
12. REMOVE THROTTLE BODY (See page MF-28)
13. REMOVE EGR PIIPE
Loosen the union nut, and remove the 2 nuts, EGR pipe and
gasket.
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt and disconnect the vacuum modulator.
(b) Remove the 2 nuts, EGR valve, EGR vacuum modulator
with the bracket and gasket.
15. REMOVE EGR VSV AND CAMSHAFT POSITION SEN-
SOR
(a) Disconnect the EGR VSV and camshaft position sensor
connector.
(b) Remove the bbolt and EGR VSV.
(c) Remove the bolt, camshaft position sensor and O-ring.

P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

EM1OH-01
- ENGINE MECHANICALENGINE UNIT
EM-57
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN TRANSAXLE OIL (FLUID)
6. REMOVE AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
7. REMOVE RADIATOR (See page CO-16)
8. DISCONNECT ACCELERATOR CABLE
9. DISCONNECT FUEL HOSE
Remove the union bolt and gaskets, and disconnect the fuel in-
let hose.
NOTICE:
Catch leaking fuel in a container.
10. REMOVE CHARCOAL CANISTER
(a) Disconnect the canister hoses.
(b) Remove the charcoal canister.
11. DISCONNECT HOSES
(a) Disconnect the brake booster vacuum hose.
(b) Disconnect the MAP sensor hose.
(c) Disconnect the heater hoses.
12. DISCONNECT SPEEDOMETER CABLE FROM
TRANSAXLE
13. w/ PS:
DISCONNECT IDLE-UP AIR HOSES FROM AIR CON-
TROL VALVE
14. DISCONNECT ENGINE WIRE HARNESS
Disconnect these connectors and wires:

Main heated oxygen sensor connector

Oil pressure switch connector

P20565
M/T EM-58
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)

Engine coolant temperature sender gauge connec-
tor

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
15. M/T only:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
(a) Remove the 3 bolts, release cylinder and tube from the
transaxle.
(b) Disconnect the ground strap.
16. M/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.

P20572
A132 LA/T
A242 LA/T
P20577
P20292
P20164
- ENGINE MECHANICALENGINE UNIT
EM-59
1996 TERCEL (RM440U)
17. A/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the 2 bolts from the LH engine mounting bracket.
18. w/ PS:
REMOVE PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Loosen the 2 bolts, and remove the PS drive belt.
(b) Remove the 2 bolts, and disconnect the PS pump from
the engine.
HINT:
Put aside the PS pump, and suspend it.
19. w/ A/C:
REMOVE A/C COMPRESSOR
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put aside the compressor, and suspend it.
20. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor.
(b) Remove the 2 bolts, compression springs and disconnect
the exhaust pipe.
(c) Remove the bolts and rear clamp.
(d) Disconnect the 2 rings and remove the front exhaust pipe.
21. REMOVE DRIVE SHAFTS (See page SA-18)

P20336
P00356
P20164
P20292
EM-64
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
(h) Install and torque the rear engine mounting insulator
through bolt.
Torque: 65 N´m (650 kgf´cm, 47 ft´lbf)
(i) Remove the engine sling device from the engine.
(j) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Bolt and nut
64 N´m (650 kgf´cm, 47 ft´lbf)
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
(k) Connect the ground strap with the bolt.
7. INSTALL DRIVE SHAFTS (See page SA-18)
8. INSTALL FRONT EXHAUST PIPE
(a) Connect the 2 rings to the front exhaust pipe.
(b) Place a new gasket on the exhaust pipe.
(c) Connect the exhaust pipe to the exhaust manifold with 2
compression springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(d) Install the exhaust pipe to the tail pipe with the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(e) Install the heated oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
HINT:

Before installing the heated oxygen sensor, twist the sen-
sor wire counterclockwise 3 and 1/2 turns.

After installing the heated oxygen sensor, check that the
sensor wire is not twisted. If it is twisted, remove the
heated oxygen sensor and reinstall it.
9. w/ A/C:
INSTALL A/C COMPRESSOR
(a) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Connect A/C compressor connector.

EM-66
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
15. CONNECT ENGINE WIRE HARNESS
Connect these connectors and wires:

Main heated oxygen sensor connector

Oil pressure switch connector

Engine coolant temperature sender gauge
connector

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
16. w/ PS:
CONNECT IDLE-UP AIR HOSES TO AIR CONTROL
VA LV E
17. CONNECT SPEEDOMETER CABLE
18. CONNECT HOSES
(a) Connect the brake booster vacuum hose.
(b) Connect the MAP sensor hose.
(c) Connect the heater hoses.

EM0JQ-06
EM9411
EM9412
P20480
SST
P20478
SST
P20477
12 mm
Hexagon
Wrench EM-70
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
DISASSEMBLY
1. M/T:
REMOVE CLUTCH COVER AND DISC
2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
8. REMOVE WATER PUMP WITH WATER INLET PIPE
9. REMOVE GENERATOR BRACKET
10. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816-30010
11. REMOVE RH ENGINE MOUNTING BRACKET
12. REMOVE OIL FILTER
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
14. REMOVE OIL PUMP AND PRESSURE REGULATOR
VA LV E
15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.

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