drain TOYOTA TERCEL 1996 Service Owner's Manual

P21098
ECT SwitchCO0ID-04
P05962
Ohmmeter CO-32
- COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
612 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE COOLANT
TEMPERATURE (ECT) SWITCH
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SWITCH
3. INSPECT ECT SWITCH
(a) Using an ohmmeter, check that there is no continuity be-
tween the terminals when the coolant temperature is
above 94°C (201°F).
If there is continuity, replace the switch.
(b) Using an ohmmeter, check that there is continuity be-
tween the terminals when the coolant temperature is be-
low 83°C (181°F).
If there is no continuity, replace the switch.
4. REINSTALL ECT SWITCH
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR COOLANT 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)

P21171
Tension Spring
Bracket
Drive Rotor
O-RingPressure Regulator
Valve Body
Piston
Drain PlugDrive Rotor
Oil Pump Bldy
Oil Pump Pulleyx 9

Non-reusable partOil Panx 10 Oil Strainer RetainerSpring
Snap Ring

O-Ring

Oil Seal

Gasket
LU-6
- LUBRICATIONOIL PUMP
621 Author
: Date
:
1996 TERCEL (RM440U)

LU08D-05
P20907
EM9278
EM9755
P20160
- LUBRICATIONOIL PUMP
LU-7
1996 TERCEL (RM440U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE HOOD
2. REMOVE OIL DIPSTICK
3. DRAIN ENGINE OIL
4. REMOVE TIMING BELT (See page EM-12)
5. SUSPEND ENGINE WITH ENGINE SLING DEVICE
6. REMOVE CRANKSHAFT TIMING PULLEY(See page
EM-12)
7. w/ A/C:
REMOVE A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put a side compressor, and suspend it.
(c) Remove the 4 bolts and compressor mounting
bracket.
8. DISCONNECT FRONT EXHAUST PIPE
(a) Remove the 2 bolts and the 2 compresson springs.
(b) Disconnect the exhaust pipe.

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

Z18912
Oil Receiver Pipe
Straight Screw Plug (C141)


Slotted Spring Pin (C151)
Outer Race
Plate Washer Reverse Restrict Pin (C151)
Oil Receiver Pipe
x13 Transmission Case
 Lock Ball Assembly (C151)


Back-Up Light Switch
Lock Bolt
Breather Plug
Shift and Select Lever
Shaft Assembly
Selecting Bellcrank Assembly
Oil Seal
x9
Transmission Case
Cover (C141) Drain Plug
 Non-reusable part

Precoated partTransmission Case
Cover (C151)
x9
Gasket Gasket
Filler Plug


Straight Screw Plug
Straight Screw Plug (C141)
Gasket MX-8
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
720 Author
: Date
:
1996 TERCEL (RM440U)

Q02129
AT2802
OK if hot
Add if hot
Q02558
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-3
1996 TERCEL (RM440U)
2. PRELIMINARY CHECK
(a) Check the fluid level.
HINT:
The vehicle mjst have been driven so that the engine and trans-
saxle are at normaloperating temperature.
ATF temperature: 70 - 80 °C (158 - 176 °F)
(1) Park the vehicle on the level surface and set the
parking brake.
(2) With the engine idling, shift the selector into each
gear from the P to L position and return to the P
position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range. If the level is at the low side of the hot range,
add new fluid.
Fluid type: ATF DEXRON®ll
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
NOTICE:
Do not overfill.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF DEXRON®ll
Dry fill: 5.5 liters (5.8 US qts, 4.8 lmp.qts)
Drain and refill: 2.5 liters (2.6 US qts, 2.2 lmp.qts)

Z13623
RPMidle
AT5867Drain plug Filler plug
MT0613
Filler Hole
Fluid Level
0 - 5 mm
e
Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
BE1485
8 423
5 761
9 AX-4
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Start the engine and shift the selector into all posi-
tions from the P position through the L position and
then shift it into the P position.
(5) With the engine idling, check the fluid level. Add the
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 - 80 °C (158 - 176 °F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) If necessary, replace the differential fluid.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Remove the filler plug.
(4) Add new fluid until it begins to run out of the filler
hole.
Fluid type: ATF D-ll or DEXRON®lll (DEXRON®ll)
Capacity: 1.4 liters (1.5 US qts, 1.2 lmp.qts)
(e) Check the differential fluid level.
Remove the filler plug and check the differential fluid lev-
el.
(f) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(g) Inspect the park/neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-15).

Q02558
AX0RJ-02
Q04924
Z15675
A
B
C
AT4869
A
B
C
D
A
BC
D AX-12
- AUTOMATIC TRANSAXLE (A132L)VALVE BODY ASSEMBLY
764 Author
: Date
:
1996 TERCEL (RM440U)
VALVE BODY ASSEMBLY
ON-VEHICLE REPAIR
1. DRAIN TRANSAXLE FLUID
Using a hexagon wrench, remove the drain plug and drain the
fluid into the suitable container.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
2. REMOVE OIL PAN AND GASKET
NOTICE:
Some fluid will remain in the oil pan. Remove the oil pan
bolts, and carefully remove the oil pan assembly. Discard
the gasket.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
3. EXAMINE PARTICLES IN PAN
Remove the magnets and use then to collect any steel chips.
Look at the chips on the magnet carefully to anticipate what
type of wear you will find in the transaxle.
Steel (magnetic) ...... bearing, gear and plate wear
Brass (non-magnetic) ..... bushing wear
4. REMOVE OIL STRAINER
Remove the 3 bolts and the oil strainer.
NOTICE:
Be careful as some oil will come out of the strainer.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE OIL PIPES
(a) Remove the 2 bolts and pipe bracket.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
(b) Pry up the both pipe ends with a large screwdriver and re-
move the 4 pipes.
NOTICE:
Be careful not to bend or damage the pipes.

Q02129
AT3417
OK if hot
Add if hot
OR0028
Z13623
RPMidle
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-3
1996 TERCEL (RM440U)
2. PRELIMINARY CHECK
(a) Check the fluid level.
HINT:
The vehicle must have been driver so that the engine and trans-
axle are at normal operating.
ATF temperature: 70 - 80 °C (158 - 176 °F)
(1) Park the vehicle on the level surface and set the
parking brake.
(2) With the engine idling, shift the selector into each
gear from the P position to the L position and return
to the P position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range. If the level is at the low side of the hot range,
add new fluid.
Fluid type: ATF DEXRON®ll
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
NOTICE:
Do not overfill.
(1) Remove the drain plug and drain the fluid.
(2) Install the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF DEXRON®ll
Dry fill: 7.2 liters (7.6 US qts, 6.3 lmp.qts)
Drain and refill: 3.1 liters (3.3 US qts, 2.7 lmp.qts)
(4) Start the engine and shift the selector into all posi-
tions from the P position through the L position and
then shift it into the P position.
(5) With the engine idling, check the fluid level. Add the
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 - 80 °C (158 - 176 °F) and add as nec-
essary.