engine coolant TOYOTA TERCEL 1996 Service Owner's Manual

DI-52
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the
MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detection ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any particular
200 or 1,000 revolutions
Ignition system


Injector
P0301
P0302
For any particular 200 revolutions of the engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)

Injector

Fuel line pressure

Compression pressure

Valve clearance not to specification
P0302
P0303
P0304For any particular 1,000 revolutions of the engine, misfiring is
detected which causes a deterioration in emissions
(2 trip detection logic)
Valve clearance not to s ecification

Valve timing

Manifold absolute pressure sensor

Engine coolant temp. sensor
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI39Y-04

DI-56
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
OK
6 Check EGR system (See page EC-8).
NG Replace injector.
OK
7 Check manifold absolute pressure sensor and engine coolant temp. sensor (See
page DI-41 and DI-45).
NG Repair or replace.
OK
Check compression pressure (See page EM-3), valve clearance (See page EM-4) and valve tim-
ing (See page EM-17).

FI7132
Engine Speed
2,500 - 3,000 rpm
Idling
IG SW OFF
Warmed up3 min. or soCheckTime (a)(c)
(d)
(b)
FI6514
OX Signal Waveform (Oscilloscope)
1.0 V
0 V
200 m sec. /Division
DI-74
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
CONFIRMATION ENGINE RACING PATTERN
(a) Connect the TOYOTA hand-held tester to the DLC3, or connect the probe of the oscilloscope between
terminals OX1, OX2 and E1 of ECM.
(b) Start engine and warm it up with all accessories switched OFF until engine coolant temperature is
stable.
(c) Race the engine at 2,500 - 3,000 rpm for about 3 minutes.
(d) After confirming that the waveform of the oxygen sensor, bank 1 sensor 1 (OX1), oscillate around 0.5
V during feedback to the ECM, check the waveform of the heated oxygen sensor, bank 1 sensor 2
(OX2).
HINT:
If there is a malfunction in the system, the waveform of the
heated oxygen sensor, bank 1 sensor 2 (OX2), is almost the
same as that of the oxygen sensor, bank 1 sensor 1 (OX1), on
the left.
There are some cases where, even though a malfunction ex-
ists, the MIL may either light up or not light up.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0420) being output?
YES Go to relevant DTC chart.
NO
2 Check heated oxygen sensor (bank 1 sensor 2) (See page DI-44).

EM18U-02
P19776
CO/HC Meter
- ENGINE MECHANICALCO/HC
EM-1
422 Author
: Date
:
1996 TERCEL (RM440U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
(i) CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.

EM18V-02
EM-10
- ENGINE MECHANICALIDLE SPEED
431 Author
: Date
:
1996 TERCEL (RM440U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed:
750 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral position)
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

P20160
EM1OF-01
P20577
P20290
- ENGINE MECHANICALCYLINDER HEAD
EM-23
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT FRONT EXHAUST PIPE
Remove the 2 bolts and 2 compression springs, and disconnect
the front exhaust pipe.
4. A/T:
DISCONNECT THROTTLE CABLE
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
7. DISCONNECT FUEL HOSE
Remove the union bolt and gaskets, and disconnect the fuel in-
let hose.
NOTICE:
Catch leaking fuel in a container.
8. w/ PS:
REMOVE PS PUMP AND PUMP BRACKET WITHOUT
DISCONNECTING HOSES
(a) Loosen the 2 bolts, and remove the PS drive belt.
(b) Remove the 2 bolts, and disconnect the PS pump from
the engine.
HINT:
Put aside the PS pump, and suspend it.
(c) Remove the 3 bolts and PS pump bracket.

P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

P20160
EM-54
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
32. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with
the 2 compression spring and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
33. INSTALL RH ENGINE UNDER COVER
34. FILL WITH ENGINE COOLANT (See page CO-2)
35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT
37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
38. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

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