oil pressure TOYOTA TERCEL 1996 Service User Guide

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

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

SS0LK-02
SS-28
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
158 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
186 - 265 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth0 ± 0.5 mm (0 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth19 mm (0.75 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
L position
Throttle valve fully closed 2 " 1
47 - 62 km/h (29 - 39 mph)
91 - 107 km/h (57 - 66 mph)
85 - 104 km/h (53 - 65 mph)
36 - 46 km/h (22 - 29 mph)
39 - 49 km/h (24 - 30 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
63 - 72 km/h (39 - 45 mph)
59 - 68 km/h (37 - 42 mph)

SS0LI-04
SS-30
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
160 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth LH side
RH side5.3 ± 0.5 mm (0.209 ± 0.020 in.)
3.1 ± 0.5 mm (0.122 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth25.0 mm (0.98 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
Throttle valve fully closed 3 O/D
L position
Throttle valve fully closed 2 " 1
45 - 61 km/h (28 - 38 mph)
89 - 106 km/h (55 - 66 mph)
83 - 102 km/h (52 - 63 mph)
83 - 43 km/h (19 - 27 mph)
19 - 33 km/h (12 - 21 mph)
44 - 56 km/h (27 - 35 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
65 - 76 km/h (40 - 47 mph)
61 - 72 km/h (38 - 45 mph)

SS0N1-03
SS-36
- SERVICE SPECIFICATIONSSTEERING
166 Author
: Date
:
1996 TERCEL (RM440U)
STEERING
SERVICE DATA
ON-VEHICLE INSPECTION
Steering wheel freeplayMaximum30 mm (1.18 in.)
Drive belt tension New belt140 - 180 lbf Drive belt tension New belt
Used belt
140 180 lbf
80 - 120 lbf
Maximum rise of oil level5 mm (0.20 in.)
Oil pressure at idle speed with valve closed Minimum6,374 kPa (65 kgf/cm2, 925 psi)
Steering effort at idle speedMaximum7.8 N´m (80 kgf´cm, 69 in.lbf)
PS VANE PUMP
Rotor shaft bushing oil clearance STD0.01 - 0.03 mm (0.0004 - 0.0012 in.) Rotor shaft bushing oil clearance STD
Maximum
0.01 0.03 mm (0.0004 0.0012 in.)
0.07 mm (0.0028 in.)
Vane plate heightMinimum8.0 mm (0.315 in.)
Vane plate thickness Minimum1.77 mm (0.0697 in.)
Vane plate lengthMinimum14.97 mm (0.5894 in.)
Vane plate to rotor groove clearanceMaximum0.03 mm (0.0012 in.)
Vane plate length Pump rotor and cam ring mark Vane late length Pum rotor and cam ring mark
None14.996 - 14.998 mm (0.59039 - 0.59047 in.)None
1
14.996 - 14.998 mm (0.59039 - 0.59047 in.)
14.994 - 14.996 mm (0.59032 - 0.59039 in.)1
2
14.994 14.996 mm (0.59032 0.59039 in.)
14.992 - 14.994 mm (0.59024 - 0.59032 in.)2
3
14.992 14.994 mm (0.59024 0.59032 in.)
14.990 - 14.992 mm (0.59016 - 0.59024 in.)3
4
14.990 14.992 mm (0.59016 0.59024 in.)
14.988 - 14.990 mm (0.59008 - 0.59016 in.)
Spring free length36 - 38 mm (1.42 - 1.49 in.)
Vane pump rotating torqueMaximum0.3 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
MANUAL STEERING GEAR
Steering rack runout Maximum0.30 mm (0.0118 in.)
Pinion preload Turning0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.lbf)
Total preload Turning0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
PS GEAR
Steering rack runout Maximum0.30 mm (0.0118 in.)
Measure oil clearance STD0.050 - 0.083 mm (0.00197 - 0.00327 in.) Measure oil clearance STD
Maximum
0.050 0.083 mm (0.00197 0.00327 in.)
0.125 mm (0.00492 in.)
Total preload Turning0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)

P25916
S00553
DI-10
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Remove the fuse cover on the instrument panel.
(d) Connect the TOYOTA hand-held tester to DLC3 on the
vehicle.
(e) Use ACTIVE TEST mode to operate the fuel pump.
(f) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page MF-1).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page MF-1 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high-tension cord from spark plug or re-
move the ignition coil.
(b) Remove spark plug.
(c) Install the spark plug to high-tension cord or ignition coil.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
NG Proceed to page IG-1 and continue to trouble-
shoot.
OK

EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.

If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.

If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS

EM0K0-05
P20381
P20380
P20350
P20353
EG0031
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1996 TERCEL (RM440U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high-pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Remove the gasket material.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Clean the combustion chambers.
(d) Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(e) Clean the valve guide bushings.
(f) Using a valve guide bushing brush and solvent, clean all
the guide bushings.

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

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.