TOYOTA TERCEL 1996 Service Repair Manual

P20572
A132 LA/T
A242 LA/T
P20577
P20292
P20164
- ENGINE MECHANICALENGINE UNIT
EM-59
1996 TERCEL (RM440U)
17. A/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the 2 bolts from the LH engine mounting bracket.
18. w/ PS:
REMOVE PS PUMP 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.
19. w/ A/C:
REMOVE A/C COMPRESSOR
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put aside the compressor, and suspend it.
20. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor.
(b) Remove the 2 bolts, compression springs and disconnect
the exhaust pipe.
(c) Remove the bolts and rear clamp.
(d) Disconnect the 2 rings and remove the front exhaust pipe.
21. REMOVE DRIVE SHAFTS (See page SA-18)

P20246
P20336
P20153
Ground Strap
P20285
M/T
P20002
A132L A/T EM-60
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
22. REMOVE ENGINE WITH TRANSAXLE FROM VE-
HICLE
(a) Install the No.1 engine hanger in the correct direction.
Part No.:
No.1 engine hanger 12281-11031
Bolt 91642-80825
(b) Attach the engine sling device to the engine hangers.
(c) Remove the rear engine mounting insulator through bolt.
(d) Remove the bolt and disconnect the ground strap.
(e) Remove the through bolt, 2 bolts, nut and RH engine
mounting insulator.
(f) M/T:
Remove the bolt and disconnect the ground strap.
(g) Remove the 5 bolts and LH engine mounting bracket.
(h) A132L A/T:
Remove the bolt and disconnect the ground strap.
(i) Remove the 5 bolts and LH engine mounting bracket.

Z14321
A242L A/T
P20255
Lift
P20167
P20161
P20245
A/T only
- ENGINE MECHANICALENGINE UNIT
EM-61
1996 TERCEL (RM440U)
(j) A242L A/T:
Remove the bolt and disconnect the ground strap.
(k) Remove the 5 bolts and LH engine mounting bracket.
(l) Lift the engine out of the vehicle slowly and carefully.
HINT:
Clear the battery carrier support while lowering the transaxle.
(m) Place the engine with the transaxle onto the stand.
23. w/PS:
REMOVE PS PUMP ADJUSTING STRUT
Remove the 2 bolts and PS pump adjusting strut.
24. w/A/C:
REMOVE A/C COMPRESSOR MOUNTING BRACKET
Remove the 4 bolts and compressor mounting bracket.
25. A/T only:
REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the engine rear end plate hole cover.
(b) Turn the crankshaft to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench.
(d) Remove the 6 bolts.
26. REMOVE STARTER (See page ST-3 and ST-16)
27. SEPARATE ENGINE AND TRANSAXLE

EM1OI-01
P20245
A/T only
P20161
P20167
P20256
Lower EM-62
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
M/T: (See page MX-4)
A132L A/T: (See page AX-26)
A242L A/T: (See page AX-30)
2. INSTALL STARTER
(See page ST-14 and ST-30)
3. A/T only:
INSTALL TORQUE CONVERTER CLUTCH MOUNTING
BOLTS
(a) First, install the gray bolt and then 5 bolts.
(b) Tighten the bolts evenly.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
(c) Install the engine rear end plate hole cover.
4. w/A/C:
INSTALL A/C COMPRESSOR MOUNTING BRACKET
Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
5. w/PS:
INSTALL PS PUMP ADJUSTING STRUT
Install the PS pump adjusting strut with the 2 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
6. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Lower the engine into the engine compartment.
(c) Tilt the transaxle downward, lower the engine and clear
the LH engine mounting.
NOTICE:
Be careful not to hit the PS gear housing, park/neutral posi-
tion switch and throttle position switch.

P20246
P00352
P20285
M/T
P20866
A132L A/T
A242L A/T
- ENGINE MECHANICALENGINE UNIT
EM-63
1996 TERCEL (RM440U)
(d) Keep the engine level, and align RH and LH engine
mountings with the body bracket.
(e) Attach the RH engine mounting insulator to the mounting
bracket and body, and temporarily install the through bolt,
2 bolts and nut.
(f) Install the LH engine mounting bracket to the transaxle
and mounting insulator with the 5 bolts. Torque the bolts.
Torque:
Bracket to transaxle (bolt head: NT)
65 N´m (650 kgf´cm, 47 ft´lbf)
Bracket to insulator (bolt head: 7T)
49 N´m (490 kgf´cm, 35 ft´lbf)
(g) Connect the ground strap with the bolt.
Torque: 49 N´m (490 kgf´cm, 35 ft´lbf)

P20336
P00356
P20164
P20292
EM-64
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
(h) Install and torque the rear engine mounting insulator
through bolt.
Torque: 65 N´m (650 kgf´cm, 47 ft´lbf)
(i) Remove the engine sling device from the engine.
(j) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Bolt and nut
64 N´m (650 kgf´cm, 47 ft´lbf)
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
(k) Connect the ground strap with the bolt.
7. INSTALL DRIVE SHAFTS (See page SA-18)
8. INSTALL FRONT EXHAUST PIPE
(a) Connect the 2 rings to the front exhaust pipe.
(b) Place a new gasket on the exhaust pipe.
(c) Connect the exhaust pipe to the exhaust manifold with 2
compression springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(d) Install the exhaust pipe to the tail pipe with the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(e) Install the heated oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
HINT:

Before installing the heated oxygen sensor, twist the sen-
sor wire counterclockwise 3 and 1/2 turns.

After installing the heated oxygen sensor, check that the
sensor wire is not twisted. If it is twisted, remove the
heated oxygen sensor and reinstall it.
9. w/ A/C:
INSTALL A/C COMPRESSOR
(a) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Connect A/C compressor connector.

P20577
P20565
M/T
P21044
A132L A/T
P21045
A242L A/T
S06150
M/T only
- ENGINE MECHANICALENGINE UNIT
EM-65
1996 TERCEL (RM440U)
10. w/ PS:
INSTALL PS PUMP
(a) Install the PS pump and drive belt with the 2 bolts.
(b) Adjust the drive belt tension (See page SR-3).
11. M/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the retainer to the cable.
(b) Connect the linkage with the plate washer and clip.
12. A132L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
13. A242L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
14. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder, tube and ground strap with the 3
bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

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.

- ENGINE MECHANICALENGINE UNIT
EM-67
1996 TERCEL (RM440U)
19. INSTALL CHARCOAL CANISTER
(a) Install the charcoal canister to the bracket.
(b) Connect the canister hoses.
20. CONNECT FUEL HOSE
Connect the fuel inlet hose with the union bolt and 2 new gas-
kets.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
21. CONNECT ACCELERATOR CABLE, AND ADJUST IT
22. INSTALL RADIATOR (See page CO-22)
23. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
24. FILL WITH TRANSAXLE OIL (FLUID)
25. FILL WITH ENGINE COOLANT
26. INSTALL ENGINE UNDER COVERS
27. INSTALL HOOD
28. START ENGINE AND CHECK FOR LEAKS
29. PERFORM ENGINE ADJUSTMENT
30. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
31. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

EM0JP-05
EM-68
- ENGINE MECHANICALCYLINDER BLOCK
489 Author
: Date
:
1996 TERCEL (RM440U)
CYLINDER BLOCK
COMPONENTS