engine assembly TOYOTA TERCEL 1996 Service Owner's Manual

FI2553
SST
FI4429
Plug MF-2
- MFIMFI SYSTEM
526 Author
: Date
:
1996 TERCEL (RM440U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (-) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all MFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and contact with terminals
can cause further trouble.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent the entry of water. Also, when washing the engine
compartment, prevent water from getting on the MFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) When inspecting a connector with a volt/ohmmeter.
(l) Carefully take off the water-proofing rubber if it is a wa-
ter-proof type connector.
(m) Insert the tester probe into the connector from the wiring
side when checking the continuity, amperage or voltage.
(n) Do not apply unnecessary force to the terminal.
(o) After checking, install the water-proofing rubber securely
on the connector.
(p) Use SST for inspecting or testing the injector or its wiring
connector.
SST 09842-30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(7) Reconnect the fuel pump connector.

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.

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)

Q06532
SST
Engine Side
Q06533
SST
Socket Wrench
N00174
SST
SST
Q06514
x5 MX-12
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
HINT:

Install the No.3 clutch hub and shifting keys to the hub
sleeve.

Install the shifting key springs under the shifting keys.
NOTICE:
At the time of reassembly, position the key springs so that
their end gaps are not in line.

Support the tip of the input shaft with a spacer or such
to raise the transaxle assembly.

Using SST and a hammer, drive in the No.3 hub sleeve
assembly with the No.3 shift fork.
SST 09612-2201 1
NOTICE:
At the time of reassembly, align the synchronizer ring slots
with the shifting keys.
13. C151:
REMOVE 5TH DRIVEN GEAR
Using SST and a socket wrench, remove the 5th driven gear.
SST 09950-40010
HINT:
At the time of reassembly, please refer to the following item.
Using SST, install the 5th driven gear.
SST 09309-12020
14. REMOVE REAR BEARING RETAINER
Remove the 5 bolts and retainer.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
15. REMOVE BEARING SNAP RING
Using a snap ring expander, remove the 2 snap rings.
HINT:
If it is difficult to remove and install the snap rings, pull up the
shafts.

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

AX08M-03
Q07634
RH Drive Shaft

Snap
RingSpeedometer
Cable
Rear Engine
Mounting InsulatorAir Cleaner
Assembly

Snap RingTie Rod End
LH Drive Shaft
Nut Cap Plug for Governor Pressure Test
Oxygen Sensor
Front Exhaust Pipe Torque Converter
Clutch
Clip
Control Cable

Gasket
Compression Spring
Engine Under Cover
Cotter Pin Starter

Gasket
Clamp x 6
Plug for Line
Pressure Test

Non-reusable partx 5
Converter
Cover
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-25
777 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AX08N-03
Q06547
Q06548
Q07635
Q08079
AX-26
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE UPPER SIDE MOUNTING BOLTS
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
5. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. REMOVE GROUND CABLES AND BRACKET
7. INSTALL ENGINE SUPPORT FIXTURE
8. RAISE VEHICLE
9. REMOVE ENGINE UNDER COVER
10. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
11. DISCONNECT SPEEDOMETER CABLE
12. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
13. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)

AX086-04
Q07636
RH Drive ShaftStarterAir Cleaner
Assembly
Speedometer Cable
Rear Engine Mounting Insulator
Plug for Governor
Pressure Test
Tie Rod End

Snap Ring
LH Drive Shaft

Gasket
Clamp
Nut Cap

Cotter Pin O/D Solenoid
Connector
Snap
Ring
x6
Hole Plug
Torque Converter
Clutch
Clip
Control
Cable
Plug for Line Pressure Test
Oxygen Sensor

Gasket
Front Exhaust Pipe
Compression Spring
Engine Under Cover

Non-reusable part
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-29
811 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AX087-03
Q06569
Q06548
Q06571
Q06572
AX-30
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE GROUND CABLES
5. REMOVE UPPER SIDE MOUNTING BOLTS
(a) Remove the 2 upper side mounting bolts.
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
(b) Remove the upper side starter bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. INSTALL ENGINE SUPPORT FIXTURE
7. RAISE VEHICLE
8. REMOVE UNDER COVER
9. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
10. DISCONNECT SPEEDOMETER CABLE
11. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
12. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
13. DISCONNECT O/D SOLENOID CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the bolt.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)