510 TOYOTA TERCEL 1996 Service Repair Manual

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015

SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf

FI6510FI6642A07134
Knock signal waveform
0.5V/
Division
0V
0V5 m sec./Division
100 m sec./Division 0.5V/
Division
- DIAGNOSTICSENGINE
DI-59
1996 TERCEL (RM440U)
Reference: INSPECTION USING OSCILLOSCOPE

With the engine racing (4,000 rpm) measure between ter-
minal KNK of ECM and body ground.
HINT:
The correct waveform is as shown.

Spread the time on the horizontal axis, and confirm that
period of the wave is 123 m sec.
(Normal mode vibration frequency of knock sensor: 8.1
KHz.)
HINT:
If normal mode vibration frequency is not 8.1 KHz, the sensor
is malfunctioning.

A15717
- DIAGNOSTICSENGINE
DI-81
1996 TERCEL (RM440U)
DTC P0510 Closed Throttle Position Switch Malfunction
CIRCUIT DESCRIPTION
Refer to DTC P0120 on page DI-33.
DTC No.DTC Detection ConditionTrouble Area
P0510Closed throttle position switch does not turn ON even once
when vehicle is driven (2 trip detection logic)
Open in closed throttle position switch circuit

Closed throttle position switch

ECM
HINT:
After confirming DTC P0510, use the TOYOTA hand-held tester to confirm the closed throttle position switch
signal from the CURRENT DATA.
Throttle ValveClosed Throttle Position Switch SignalMalfunction
Fully closedOFFOpen circuit
Fully openONShort circuit
WIRING DIAGRAM
Refer to DTC P0120 on page DI-33.
INSPECTION PROCEDURE
HINT:
If DTCs P0110, P0115 and P0120 are output simultaneously, E2 (sensor ground) may be open.
TOYOTA hand-held tester:
1 Check for open in harness or ECM.
PREPARATION:
(a) Connect the TOYOTA hand-held tester to the DLC3.
(b) Disconnect the throttle position sensor connector.
(c) Connect the sensor wire harness terminals between ter-
minals 3 and 4.
(d) Turn the ignition switch ON.
CHECK:
Read thg CTP switch signal on the TOYOTA hand-held tester.
OK:
CTP switch signal: ON
OK Confirm good connection at sensor. If OK, re-
place throttle position sensor.
NG
DI95R-01

DI4M4-01
Vehicle Brought to Workshop
Customer Problem Analysis
Warning Light Check
DTC Check and Recording
Malfunction Code Clearance DI-148
DI-151
Circuit Inspection
Remains on
Malfunction Code
Symptom Simulation
DTC Check
DI-155
Identification of Problem
Normal Code
Confirmation Test
Does Not Light Up
END
1
2
3
4
7
Repair 856
Step
:Diagnostic steps permitting the use
of the TOYOTA hand-held tester.
DI-147
DI-148
DI-148
DI-148
DI-148
Malfunction Code
DTC Chart
DI-151
DTC Check and Recording
129
DI-148 Malfunction Code Clearance
10
11
Normal Code
Normal
Code
Malfunction CodeNormal
Code
,, , , , , 345101112
Malfunction Code
DI-146
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
320 Author
: Date
:
1996 TERCEL (RM440U)
SUPPLEMENTAL RESTRAINT SYSTEM
HOW TO PROCEED WITH TROUBLESHOOTING
Perform troubleshooting in accordance with the procedure on the following pages.

EM1OE-01
P20743
P20742
P20744
P20390SST
P20915
Timing Mark
SST
Installation
Mark
- ENGINE MECHANICALTIMING BELT
EM-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the rotor side of the
crankshaft position sensor inward.
2. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING
(a) Install the tension spring to the idler pulley.
(b) Align the bracket pin hole with the pivot pin.
(c) Install the idler pulley with the bolt. Do not tighten the bolt
yet.
(d) Pry the idler pulley toward the left as far as it will go and
temporarily tighten the bolt.
(e) Check that the idler pulley moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
(b) Check that the idler pulley moves smoothly.
4. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove on
the pulley side with the 5E mark, and slide on the timing
pulley.
(b) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, align the hole of the camshaft timing pulley on
the side with the 5E mark with the timing mark of the bear-
ing cap.
SST 09960-10010 (09962-01000, 09963-01000)

EM0K1-03
P20388
SST
P20383
Both intake and exhaust
Bushing bore diameter
mm (in.)Bushing size
11.000 - 11.027
(0.4331 - 0.4342)
11.050 - 11.077
(0.4350 - 0.4361)Use STD
Use O/S 0.05
P20387
SST
12.7 -
13.1 mm
EM5935
IntakeExhaust
38.5 mm
(1.516 in.)40.5 mm
(1.594 in.) EM-40
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS
(a) Using SST and a hammer, tap out the guide bushing.
SST 09201-10000 (09201-01060),
09550-10012 (09252-10010)
(b) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(c) Select a new guide bushing (STD size or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to the follow-
ing dimension:
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(d) Using SST and a hammer, tap in a new guide bushing to
where there is 12.7 - 13.1 mm (0.500 - 0.510 in.) left pro-
truding from the cylinder head.
SST 09201-70010
HINT:
Different bushings are used for the intake and exhaust.

P20410
P20366
8
6
13 4
2
57
9 10
P20369
Timing Mark
EXIN
Other Timing Mark
P20557
P20363
EM-48
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(v) Place the No.1 bearing cap in its proper location. When
doing this, check that there is no gap between the cylinder
head and the contact surface of bearing cap.
(w) Temporarily tighten the bearing cap bolts, alternately
tightening the left and right bolts uniformly.
(x) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(y) Turn the camshaft 1 revolution and check that the timing
marks of the camshaft gears are aligned.
5. CHECK AND ADJUST VALVE CLEARANCE (See page
EM-4)
6. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove on
the pulley side with the 5E mark, and slide the pulley.
(b) Secure the hexagonal portion of the camshaft, and install
and torque the bolt.
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
7. INSTALL NO.2 IDLER PULLEY
Install the idler pulley with the bolt. Torque the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
HINT:
Remove any oil or water on the idler pulley and keep it clean.

ST086-01
P25503
Terminal C
Terminal 50
P25510
Disconnect
P25511
Disconnect
P25512
ST-28
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO PULL-IN TEST
(a) Disconnect the field coil lead from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
If the clutch pinion gear does not move, replace the magnetic
switch.
2. DO HOLD-IN TEST
While connected as above with the clutch pinion gear out, dis-
connect the negative (-) lead from terminal C. Check that the
clutch pinion gear remains out.
If the clutch pinion gear returns inward, replace the magnetic
switch.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body. Check
that the clutch pinion gear returns inward.
If the clutch pinion gear does not return, replace the magnetic
switch.
4. INSPECT CLUTCH PINION GEAR CLEARANCE
(a) Connect the battery to the magnetic switch as shown.

MX07L-01
Q06510
Needle Roller Bearing
Synchronizer Ring
No.2 Clutch HubInput Shaft
Needle Roller Bearing
4th Gear No.2 Hub Sleeve
3rd Gear
Shifting Key
Shifting Key Spring
Synchronizer Ring
Snap Ring
Rear Ball Bearing Snap Ring
MX-20
- MANUAL TRANSAXLEINPUT SHAFT
732 Author
: Date
:
1996 TERCEL (RM440U)
INPUT SHAFT
COMPONENTS