check engine light TOYOTA TERCEL 1996 Service Owner's Manual

P20556
P20558
P20535
Tension
P20555
EM-18
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
(b) Using the crankshaft pulley bolt, turn the crankshaft and
align the timing marks of the crankshaft timing pulley and
oil pump body.
6. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
HINT:
When re-using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
(a) Remove any oil or water on the pulleys, and keep them
clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
7. CHECK VALVE TIMING
(a) Loosen the No.1 idler pulley mount bolt, until the pulley is
moved slightly by the spring tension.

P03849
Overall Length
EM0255
P20367
45° Carbide Cutter
Z07819
Width
Z08336
45°
1.0 - 1.4 mm30° EM-34
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(d) Check the valve overall length.
Standard overall length:
Intake93.45 mm (3.6791 in.)
Exhaust93.89 mm (3.6768 in.)
Minimum overall length:
Intake92.95 mm (3.6594 in.)
Exhaust93.39 mm (3.6768 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
(c) Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(d) Check the valve face and seat for the following:
(1) If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Z14254
Painted
Black Painted Silver Intake Exhaust
P20416
SST
EM9933
- ENGINE MECHANICALCYLINDER HEAD
EM-43
1996 TERCEL (RM440U)
HINT:
The intake valve oil seal is silver and the exhaust valve oil seal
is black.
(b) Install the valve.
(c) Install the spring seat.
(d) Install the valve spring.
(e) Install the spring retainer.
(f) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70010
(g) Using a plastic-faced hammer, lightly tap the valve stem
tip to assure proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL STUD BOLT FOR CYLINDER HEAD COVER
5. INSTALL NO.2 ENGINE HANGER
Torque:
No. 1
21 N´m (210 kgf´cm, 15 ft´lbf)
No. 2
53 N´m (530 kgf´cm, 38 ft´lbf)

P20389
Gasket
EM1OG-01
P20419
EX
(A)
Bi-Hexagon Wrench
(B)IN
(B)
(A)(B)
(B)(B)
(B)
8
61 3
9
10 4 257
(A) (A) (A)(A) IN
EX
P20413
Painted Mark
90°
P20174
(b)(c)
(d)(e)
EM-44
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any cylinder head bolt is broken or deformed, replace
it.

There are 2 lengths of cylinder head bolts, long (A) and
short (B).
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) First, using a bi-hexagon wrench 8 mm, install and uni-
formly tighten the 10 cylinder head bolts, in several
passes, in the sequence shown.
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts 90° in the numerical or-
der shown.
(e) Check that the painted mark is now at a 90° angle to front.
3. ASSEMBLE INTAKE CAMSHAFT
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring.
(c) Install the camshaft sub-gear.
(d) Install the wave washer.
HINT:
Align the pins on the gears with the gear spring ends.

EM9988
EM3441
P20487
EM9392
EM3444
- ENGINE MECHANICALCYLINDER BLOCK
EM-71
1996 TERCEL (RM440U)
16. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the rod back and forth.
Standard thrust clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
Maximum thrust clearance:
0.45 mm (0.0177 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using a soft-faced hammer, lightly tap the connecting rod
bolt and lift the cap and lower bearing.
HINT:
Keep the lower bearing inserted with the connecting rod cap.

P20551
P20530
Front
Z14291
1
2 3
45
6
7
89
10
EM3480
P20569
Front Mark
(Cavity)
FrontPush
- ENGINE MECHANICALCYLINDER BLOCK
EM-87
1996 TERCEL (RM440U)
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the oil grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing caps.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 58 N´m (580 kgf´cm, 42 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM-70).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.

EM3481
Front Mark
(Protrusion)
Front
EM3448
P20475
Seal Packing
A'B'
A
B
A - A' B - B' EM-88
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
9. INSTALL CONNECTING ROD CAPS
(a) Match the numbered connecting rod cap with the num-
bered connecting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
(c) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.
(d) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance (See page
EM-70).
10. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the rear oil
seal retainer and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the rear oil seal retainer as shown
in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

SF0X4-05
FI3271
New
O-Ring
New Grommet
P00159
CORRECT
WRONG
InjectorDelivery Pipe GrommetO-Ring
WRONG
P20295
Spacer
Insulator
Connector MF-22
- MFIINJECTOR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to an O-ring, and install it
to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Place the 2 spacers and 4 insulators in position on the cyl-
inder head.
(e) Place the injectors together with the delivery pipe on the
cylinder head.
(f) Check that the injectors rotate smoothly.
HINT:
If the injectors do not rotate smoothly, the probable cause is in-
correct installation of O-rings. Replace the O-rings.
(g) Position the injector connector upward.
(h) Install the 2 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
2. CONNECT ENGINE WIRE
(a) Connect the 4 injector connectors.
(b) Connect the engine wire to the surge tank stay.
3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Install 2 new gaskets and the inlet hose with the union
bolt.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
(b) Connect the engine wire clamp to the No.2 engine hang-
er.
4. CONNECT FUEL RETURN HOSE TO FUEL RETURN
PIPE
5. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR

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.

P13734
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
at 25°C (77°F)13.9 - 15.1 V
at 115°C (239°F)13.5 - 14.3 V
If the voltmeter reading is greater than standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.