check engine TOYOTA TERCEL 1996 Service Repair Manual

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

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

LU08F-04
LU0144
P21820
P21819
LU1165
- LUBRICATIONOIL PUMP
LU-1 1
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT PRESSURE REGULATOR VALVE
Coat the valve piston with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If necessary, replace the valve.
2. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driv-
en rotor and pump body.
Standard clearance:
0.10 - 0.16 mm (0.0039 - 0.0063 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.
3. INSPECT TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set.
4. INSPECT SIDE CLEARANCE
Using a feeler gauge and flat block, measure the side clearance
as shown.
Standard clearance:
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
Minimum clearance:
2.90 mm (0.1142 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.

LU-16
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with 2
compresson springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
6. w/ A/C:
INSTALL A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (270 kgf´cm, 20 ft´lbf)
(b) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Connect the A/C compressor connector.
7. INSTALL CRANKSHAFT TIMING PULLEY (See page
EM-17)
8. INSTALL TIMING BELT (See page EM-17)
9. INSTALL OIL DIPSTICK
10. FILL WITH ENGINE OIL
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK ENGINE OIL LEVEL
13. INSTALL HOOD

IG08E-06
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
SPARK TEST
Replace the camshaft position sensor.
CHECK RESISTANCE OF HIGH-TENSION
CORD (See step 2)
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL
(See step 4) 1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL IGNITER
Resistance: Cold Hot
Secondary
9.3 - 16.0 kW
11.7 - 18.8 kW
CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
(See step 5)
Resistance:Cold Hot
985 - 1,600 W1,265 - 1,890 W
CHECK IGT SIGNAL FROM ECM
(See page
DI-84)
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
(See step 6)
Resistance:Cold
Hot
TRY ANOTHER IGNITERReplace the crankshaft position sensor. Replace the ignition coil. Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
NO
OK OK
OK
OK
OK
OKBAD
BAD
BAD
BAD
BAD
BAD
BAD
Primary
0.67 - 1.05 kW0.85 - 1.23 kW
985 - 1,600 W1,265 - 1,890 W
- IGNITIONIGNITION SYSTEM
IG-1
632 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in following sentences express the tem-
perature of the coils themselves. ºColdº is from -10°C
(14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to
100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high-tension cord from the spark
plug.
(2) Remove the spark plugs.
(3) Install the spark plugs to the high-tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time. If the spark done not occur, do the test as fol-
lows:

CH065-01
- CHARGINGCHARGING SYSTEM
CH-1
677 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING SYSTEM
PRECAUTION

Check that the battery cables are connected to the correct terminals.

Disconnect the battery cables when the battery is given a quick charge.

Do not perform tests with a high voltage insulation resistance tester.

Never disconnect the battery while the engine is running.

N00280
DENSO
Borroughs
CH0087
CORRECTWRONG WRONG
P13685
CH0732
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter
B
- CHARGINGCHARGING SYSTEM
CH-3
1996 TERCEL (RM440U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooved.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
4. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
5. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the charge warn-
ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the generator
and connect it to the negative (-) tester probe of the
ammeter.