TOYOTA TERCEL 1996 Service Repair Manual

CO0HY-03
CO1230
CO1234
CO1233
Valve Lift CO-10
- COOLINGTHERMOSTAT
1996 TERCEL (RM440U)
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water, and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature: 80 - 84°C (176 - 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

CO0HZ-03
CO1225
Jiggle Valve
Protrusion
- COOLINGTHERMOSTAT
CO-1 1
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Place a new gasket onto the thermostat.
(b) Align the thermostat jiggle valve with the protrusion of the
water inlet, and insert the thermostat in the water inlet.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 5.0 N´m (50 kgf´cm, 43 in.´lbf)
3. INSTALL AIR CLEANER INLET
4. REFILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS

CO0I0-01
CO-12
- COOLINGRADIATOR
592 Author
: Date
:
1996 TERCEL (RM440U)
RADIATOR
ON-VEHICLE CLEANING
CLEAN RADIATOR
Using water or a steam cleaner, remove any mud or dirt from the radiator core.
NOTICE:
If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. (i.e. Main-
tain a distance between the cleaner nozzle and radiator core.)

CO18A-01
CO1242
Radiator Cap Tester
Radiator Cap
30° or More
- COOLINGRADIATOR
CO-13
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. REMOVE RADIATOR CAP
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
tester at an angle of over 30° above the horizontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 - 103 kPa (0.75 - 1.05 kgf/cm
2, 10.7 - 14.9 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

CO0I2-04
P20811
CO-14
- COOLINGRADIATOR
1996 TERCEL (RM440U)
COMPONENTS

P21089
Upper Tank

O-Ring
Lower Tank
Nut Oil Cooler Core

Non-reusable partPipe
Plate Washer
O-RingA/T

O-Ring
- COOLINGRADIATOR
CO-15
1996 TERCEL (RM440U)

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.

P20756
w/ A/C
P20757
- COOLINGRADIATOR
CO-17
1996 TERCEL (RM440U)
5. w/ A/C:
REMOVE NO.2 COOLING FAN FROM RADIATOR
Remove the 3 bolts and cooling fan.
6. REMOVE NO.1 COOLING FAN FROM RADIATOR
Remove the 2 bolts and cooling fan.

CO18B-01
CO1205
Dimension B
Stopper Bolt
Overhaul HandlePart A
ClawSST
P21090
Lock
Plate
Stopper BoltTank
P21091
CO-18
- COOLINGRADIATOR
1996 TERCEL (RM440U)
DISASSEMBLY
1. ASSEMBLE SST
SST 09230-01010
(a) Install the claw to the overhaul handle, inserting it in the
hole in part A as shown in the diagram.
(b) While gripping the handle, adjust the stopper bolt so that
dimension B is as shown in the diagram is 0.2 - 0.5 mm
(0.008 - 0.020 in.).
NOTICE:
If this adjustment is not performed, the claw may be dam-
aged.
2. UNCAULK LOCK PLATES
Using SST to release the caulking, squeeze the handle until
stopped by the stopper bolt.
SST 09230-01010
3. REMOVE TANKS AND O-RINGS
Lightly tap the radiator hose inlet (or outlet) with a soft-faced
hammer, and remove the tank.
Remove the O-ring.
4. A/T:
REMOVE OIL COOLER FROM LOWER TANK
(a) Remove the 2 nuts, spring washers, plate washers and oil
cooler.
(b) Remove the O-ring from the oil cooler.

CO0Y3-02
P21092
A
B
C
CO1267
Lock PlateLock Plate
Core
N00305
CORRECTWRONG
WRONG
P21093
CORRECT
WRONGTank
Lock
Plate
- COOLINGRADIATOR
CO-19
1996 TERCEL (RM440U)
REASSEMBLY
1. A/T:
INSTALL OIL COOLER TO LOWER TANK
(a) Clean the O-ring contact surface of the lower tank and oil
cooler.
(b) Install new O rings to the oil cooler.
(c) Install the oil cooler with the O-rings to the lower tank.
(d) Install the plate washers, spring washers and nuts.
Torque:
Nut A: 15 N´m (150 kgf´cm, 11 ft´lbf)
Nut B and C: 8.5 N´m (85 kgf´cm, 75 in.´lbf)
2. INSPECT LOCK PLATE
Inspect the lock plate for damage.
HINT:

If the sides of the lock plate groove are deformed, reas-
sembly of the tank will be impossible.

Therefore, first correct any deformation with pliers or like
object. Water leakage will result if the bottom of the lock
plate groove is damaged or dented or dented. There fore,
repair or replace if necessary.
3. INSTALL NEW O-RINGS AND TANKS
(a) After checking that there are no foreign objects in the lock
plate groove, install a new O-ring without twisting it.
HINT:
When cleaning the lock plate groove, lightly rub it with sand pa-
per without scratching it.
(b) Install the tank without damaging the O-ring.
(c) Tap the lock plate with a soft-faced hammer so that there
is no gap between it and the tank.