drain TOYOTA TERCEL 1996 Service User Guide

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

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

SF1PX-01
(a)
(b)
(a)
(b)
(c)(d)(e)
MF-28
- MFITHROTTLE BODY
1996 TERCEL (RM440U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP
3. DISCONNECT CONTROL CABLES FROM THROTTLE
BODY
(a) Disconnect the accelerator cable
(b) Disconnect the A/T throttle cable.
4. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector and
wire clamp.
(b) Disconnect the IAC valve connector.
(c) Disconnect the vacuum hose (from upper port of TVV of
EVAP) from port ºPº of throttle body.
(d) Disconnect the vacuum hose (from port ºPº of EGR vacu-
um modulator) from port ºEº of throttle body.
(e) Disconnect the vacuum hose (from port ºRº of EGR vacu-
um modulator) from port ºRº of throttle body.
(f) Remove the 2 nuts and 2 bolts.
Torque: 19.5 N´m (195 kgf´cm, 14 ft´lbf)
(g) Disconnect the throttle body from the intake manifold.
(h) Remove the gasket.
HINT:
At the time of installation, plaese refer to the following items. At-
tach a new gasket to the intake manifold, facing the protrusion
downward.

SF0XQ-05
Z02917
Ohmmeter
Resistance kW
Temperature °C (°F) Acceptable MF-44
- MFIENGINE COOLANT TEMPERATURE (ECT) SENSOR
1996 TERCEL (RM440U)
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SENSOR
3. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
4. REINSTALL ECT SENSOR
5. REFILL WITH ENGINE COOLANT

CO0HR-04
P20196
Drain Plug
Drain Plug
CO-2
- COOLINGCOOLANT
1996 TERCEL (RM440U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the right side of the ra-
diator lower tank) and engine drain plug (on the left front
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use a good brand of ethylene-glycol base coolant
and mix it according to the manufacturer's direc-
tions.

Using coolant which includes more than 50 % ethyl-
ene-glycol (but not more than 70 %) is recom-
mended.
NOTICE:

Do not use an alcohol type coolant.

The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T4.9 liters (5.2 US qts, 4.3 lmp. qts)
A/T5.3 liters (5.6 US qts, 4.7 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
ºFULLº line.
3. CHECK ENGINE COOLANT FOR LEAKS

CO0HT-04
P21028
(b)
(c)
(a)
P21132
(2)(1)(b)
(a)
P21130
P21029
CO-4
- COOLINGWATER PUMP
1996 TERCEL (RM440U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE GENERATOR
3. REMOVE INTAKE MANIFOLD STAY
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
4. REMOVE WATER INLET PIPE
(a) Disconnect the water inlet hose.
(b) Disconnect the heater inlet hose.
(c) Disconnect the water bypass hose.
(d) Remove the bolt, water inlet pipe and O-ring.
5. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
(a) Disconnect the engine wire clamp.
(b) Disconnect the connector clamp for crankshaft position
sensor.
(c) Remove the oil dipstick.
(d) Remove the mounting bolt of the dipstick guide clamp and
generator adjusting bar.
(e) Pull out the dipstick guide. Plug the guide installation hole
of the oil pump.
(f) Remove the O-ring from the dipstick guide.
6. REMOVE WATER PUMP
Remove the bolt, 2 nuts and water pump.

CO0HX-01
- COOLINGTHERMOSTAT
CO-9
1996 TERCEL (RM440U)
REMOVAL
NOTICE:
Do not remove the thermostat unless absolutely necessary.
HINT:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. REMOVE AIR CLEANER INLET
2. DRAIN ENGINE COOLANT
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, water inlet and thermostat from the water inlet housing.
(b) Remove the gasket from the thermostat.

CO0Y2-02
(b)
(a)
P20609
(c)(d)
P20754
Plug
(e)
P20755
A/T
(A)
P20610
Radiator Lower Hose
Radiator Lower Support CO-16
- COOLINGRADIATOR
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY
4. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 cooling fan connector.
(b) w/ A/C:
Disconnect the No.2 cooling fan connector.
(c) Disconnect the radiator upper hose from the radiator.
(d) Disconnect the radiator lower hose from the water inlet.
(e) Disconnect the 2 A/T oil cooler hoses from the radiator.
HINT:
Plug the hose to prevent oil from escaping.
(f) Remove the 2 bolts and 2 upper radiator supports.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
HINT:
(A/T only):
After installation, check that the rubber cushion (A) of the sup-
port is not depressed.
(g) Remove the radiator assembly.
(h) Remove the 2 radiator lower supports and the lower ra-
diator hose.

P21775
H
P21097
SST
CO0766
Clearance
Lock
Plate
O-Ring
- COOLINGRADIATOR
CO-21
1996 TERCEL (RM440U)
(b) Check the lock plate height (H) after completing the caulk-
ing.
Plate height: 7.75 - 8.25 mm (0.305 - 0.325 in.)
If not within the specified height, adjust the stopper bolt of the
handle again and perform the caulking again.
6. INSPECT FOR WATER LEAKS
(a) Tighten the drain plug.
(b) Plug the inlet and outlet pipes of the radiator with SST.
SST 09230-01010
(c) Using a radiator cap tester, apply pressure to the radiator.
Test pressure: 177 kPa (1.8 kgf/cm
2, 26 psi)
(d) Inspect for leaks.
HINT:
On radiators with resin tanks, there is a clearance between the
tank and lock plate where a minute amount of air will remain,
giving the appearance of an air leak when the radiator is sub-
merged in water. Therefore, before performing the water leak
test, first move radiator around in the water until all air bubbles
disappear.
7. PAINT LOCK PLATES
HINT:
If the water leak test checks out okay, allow the radiator to com-
pletely dry and then paint the lock plates.

CO0I9-04
P20884
CO-28
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE NO.1 COOLING FAN
(a) Remove the engine under covers.
(b) Drain the engine coolant.
(c) Remove the air cleaner inlet.
(d) Remove the reservoir tank assembly.
(e) Remove the No.1 cooling fan.
(1) Disconnect the upper radiator hose from the radia-
tor.
(2) Disconnect the cooling fan connector.
(3) Remove the 2 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
2. REMOVE NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Remove the 3 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)