Block TOYOTA TERCEL 1996 Service Manual PDF

CO0Y1-02
P21031
CO1231 CORRECT WRONG
Seal Diameter
2 - 3 mm
(0.08 - 0.12 in.)
Seal Packing
P21131
New
O-Ring CO-6
- COOLINGWATER PUMP
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the contact
surfaces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water pump groove.
Seal packing:
Part No. 08826-00100, THREE BOND 1282B or
equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water pump with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 14 ft´lbf)
2. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide, and install it with the mounting
bolt of the generator adjusting bar and dipstick guide
clamp.
Torque: 18.5 N´m (185 kgf´cm, 14 ft´lbf)
(d) Install the oil dipstick.

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

P21179
N00279
SST
SST
P21172
P21103
P21100
LU-8
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
9. REMOVE OIL PAN
(a) Remove the 10 bolts.
(b) Insert the SST blade between the cylinder block and oil
pan, cut off applied sealer and then remove the oil pan.
SST 09032-00100
NOTICE:

Do not use SST for the oil pump body side and rear oil
seal retainer.

Be careful not to damage the oil pan flange.
10. REMOVE OIL STRAINER
Remove the 3 bolts and oil strainer with the O-ring.
11. REMOVE PRESSURE REGULATOR VALVE
12. REMOVE OIL PUMP AND OIL PUMP PULLY
(a) Remove the 9 bolts and tension spring bracket.

LU08F-04
LU0144
P21820
P21819
LU1165
- LUBRICATIONOIL PUMP
LU-1 1
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT PRESSURE REGULATOR VALVE
Coat the valve piston with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If necessary, replace the valve.
2. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driv-
en rotor and pump body.
Standard clearance:
0.10 - 0.16 mm (0.0039 - 0.0063 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.
3. INSPECT TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set.
4. INSPECT SIDE CLEARANCE
Using a feeler gauge and flat block, measure the side clearance
as shown.
Standard clearance:
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
Minimum clearance:
2.90 mm (0.1142 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.

LU08I-05
EG0099
P21101
Marks
P21885
EG0097
Seal Diameter
2 - 3 mm
(0.08 - 0.12 in.)
A - AB -B
A
AB
B LU-14
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the contact
surfaces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Place the driven rotors into the pump body with the marks
facing the front.
(c) Align the pully and oil pump drive shaft.
(d) Using a vise, install the oil pump pully and nut.
Torque: 37 N´m (370 kgf´cm, 27 ft´lbf)
(e) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Z14807
Oil Pump
Oil PanFIPG
A' - A
Front
Seal Diameter
a: 7mm
b: 4mm
c: 5mmB' - B C' - C ab
bc
B'
BC'
C
- LUBRICATIONOIL PUMP
LU-15
1996 TERCEL (RM440U)

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(f) Place a new O-ring into the cylinder block side groove.
(g) Install the oil pump and tension spring bracket with the 9
bolts.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
2. INSTALL PRESSURE REGULATOR VALVE
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
3. INSTALL OIL STRAINER
(a) Apply a little engine oil to a new O-ring.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
4. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pan,
oil pump, rear oil seal retainer and cylinder block.

Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the contact sur-
faces.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pump, rear oil seal retainer
and oil pan as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Seal diameter:
7 mm ( 0.28 in.) for a
4 mm ( 0.16 in.) for b
5 mm ( 0.17 in.) for c

Install a nozzle that has been cut to a 4 mm ( 0.16
in.) or 7 mm (0.28 in.) or 5 mm (0.17 in.) opening.
HINT:
Avoid applying an excess amount to the surface.

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 after use.
(c) Install the oil pan with the 10 bolts.
Torque: 13 N´m (130 kgf´cm, 10 ft´lbf)
5. CONNECT FRONT EXHAUST PIPE

ST0IY-01
P10584
Ohmmeter
Continuity
P10585
Ohmmeter
No Continuity
P10586
P10587
ST0040
ST-6
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT COMMUTATOR FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
2. INSPECT COMMUTATOR FOR GROUND
Using an ohmmeter, check that there is continuity between the
segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
3. INSPECT COMMUTATOR FOR DIRTY AND BURNT
SURFACE
If the surface is dirty or burnt, correct it with sandpaper (No.400)
or on a lathe.
4. INSPECT COMMUTATOR CIRCLE RUNOUT
(a) Place the commutator on V-blocks.
(b) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
5. INSPECT COMMUTATOR DIAMETER
Using a vernier caliper, measure the commutator diameter.
Standard diameter: 30.0 mm (1.181 in.)
Minimum undercut depth: 29.0 mm (1.412 in.)
If the diameter is less than minimum, replace the armature.
6. INSPECT UNDERCUT DEPTH
Check that the undercut depth is clean and free of foreign mate-
rials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.24 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

P25608
Wooden
Block
40 mm
37 mm
20 mmContact
Plate
V06796
P25609
SST
P25479
- STARTINGSTARTER (Reduction Type)
ST-1 1
1996 TERCEL (RM440U)
(f) Temporarily tighten the terminal nuts.
(g) Tighten the terminal nut.
(1) Put a wood block on the contact plate and press it
down with a hand press.
Dimensions of wood block:
20 x 37 x 40 mm (0.97 x 1.46 x 1.57 in.)
Press force:
981 N (100 kgf, 221 lbf)
NOTICE:

Check the diameter of the hand press ram. Then cal-
culate the gauge pressure of the press when 981 N
(100 kgf, 221 lbf) of force is applied.

If the contact plate is not pressed down with the spe-
cified pressure, the contact plate may tilt due to coil
deformation or the tightening of the nut.
(2) Using SST, tighten the nut to the specified torque.
SST 09810-38140
Torque: 17 N´m (173 kgf´cm, 12 ft´lbf)
NOTICE:
If the nut is over tightened, it may cause cracks on the in-
side of the insulator.
(h) Clean the contact surfaces of the contact plate and plung-
er.
Clean the contact surfaces of the remaining contact plate
and plunger with a dry shop rag.
(i) Reinstall the magnetic switch end cover.
Install the plunger, new gasket, end cover and lead clamp
with 3 bolts.
Torque: 3.6 N´m (36 kgf´cm, 32 in.´lbf)

ST083-07
ST0663
Continuity
ST0664No Continuity
Z03211
Z03209
ST0040
- STARTINGSTARTER (Planetary Type)
ST-19
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT ARMATURE COIL
(a) Check the commutator for open circuit.
Using an ohmmeter, check that there is continuity be-
tween the segments of the commutator.
If there is no continuity between any segment, replace the ar-
mature.
(b) Check the commutator for ground.
Using an ohmmeter, check that there is no continuity be-
tween the commutator and armature coil core.
If there is continuity, replace the armature.
(c) Check the commutator for dirty and burnt surface.
If the surface is dirty or burn, correct with sandpaper (No.400)
or a lathe.
(d) Check for the commutator circle runout.
(1) Place the commutator on V-blocks.
(2) Using a dial gauge, measure the circle runout.
Maximum circle runout: 0.05 mm (0.0020 in.)
If the circle runout is greater than maximum, correct it on a lathe.
(e) Using vernier calipers, measure the commutator diame-
ter.
Standard diameter: 28.0 mm (1.102 in.)
Minimum diameter: 27.0 mm (1.063 in.)
If the diameter is less than minimum, replace the armature.
(f) Check that the undercut depth is clean and free of foreign
materials. Smooth out the edge.
Standard undercut depth: 0.6 mm (0.024 in.)
Minimum undercut depth: 0.2 mm (0.008 in.)
If the undercut depth is less than minimum, correct it with a
hacksaw blade.

BR0RA-07
BR5038
BR5040
BR5039
BR3885
BR-4
- BRAKEBRAKE FLUID
878 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE FLUID
BLEEDING
HINT:
If any work is done on the brake system or air in the brake lines
is suspected, bleed the system of air.
NOTICE:
Do not let brake fluid remain on a painted surface. Wash it
off immediately.
1. FILL BRAKE RESERVOIR WITH BRAKE FLUID
Fluid: SAEJ1703 or FMVSS No.116 DOT3
2. BLEED MASTER CYLINDER
HINT:
If the master cylinder has been disassembled or the reservoir
becomes empty, bleed the master cylinder.
(a) Disconnect the brake lines from the master cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with your finger and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
3. BLEED BRAKE LINE
(a) Connect the vinyl tube to the brake caliper.
(b) Depress the brake pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) At the point when fluid stops coming out, tighten the
bleeder plug, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the fluid has been bled
out.
(e) Repeat the above procedure to bleed the air out of the
brake line for each wheel.