cylinder TOYOTA TERCEL 1996 Service Repair Manual

IN00U-36
N17080
Filler Cap
Float
Reservoir
 Grommet
Clip
Slotted Spring Pin
: Specified torque
 Non-reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
- INTRODUCTIONHOW TO USE THIS MANUAL
IN-1
1 Author
: Date
:
1996 TERCEL (RM440U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN-16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

V08423 Knock Sensor 1
GRECM
KNK
E1 12
E6
WIRING DIAGRAM
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
DTC P0325Knock Sensor 1 Circuit Malfunction
CIRCUIT DESCRIPTION
Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which
generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine
knocking occurs, ignition timing is retarded to suppress it.
DTC No. DTC Detection Condition Trouble Area
P0325No knock sensor 1 signal to ECM with engine speed,
1,200 rpm or more.
Open or short in knock sensor1 circuit

Knock sensor 1 (looseness)

ECM
If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle
value is set to the maximum value.

Diagnostic Trouble Code No. and Detection Item

Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.

Indicates the diagnostic trouble code, diagnostic
trouble code set parameter and suspect area of
the problem.

IN-24
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TERCEL (RM440U)
6. CIRCUIT INSPECTION
How to read and use each page is shown below.

PP3IP-01
- PREPARATIONENGINE MECHANICAL
PP-5
1996 TERCEL (RM440U)
RECOMMENDED TOOLS
09040-0001 1Hexagon Wrench Set .Oil filter union
09043-50080Bi-hexagon Wrench 8 mm .Cylinder head bolt
09090-04020Engine Sling DeviceFor suspending engine
09200-00010Engine Adjust Kit .
09258-00030Hose Plug Set .Plug for vacuum hose, fuel hose, etc.
09904-00010Expander Set .Intake camshaft snap ring

PP18S-01
PP-6
- PREPARATIONENGINE MECHANICAL
1996 TERCEL (RM440U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune-up tester
Heater
Magnetic finger
Micromerer
OBD II scan toolIdle speed
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Torque wrench
Valve seat cutter
Vernier calipers

PP18T-03
- PREPARATIONENGINE MECHANICAL
PP-7
1996 TERCEL (RM440U)
SSM (Special Service Materials)
08826-00080Seal Packing Black or equivalent
(FIPG)Camshaft bearing cap (No. 1 and
No. 2)
Cylinder head cover
Rear oil seal retainer
08826-00100Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)Water outlet housing
08833-00070Adhesive 1324,
THREE BOND 1324 or equivalentSpark plug tube
Flywheel or drive plate bolt
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentOil pressure switch

- PREPARATIONSTEERING
PP-63
11 0 Author
: Date
:
1996 TERCEL (RM440U)
09631-20081Seal Ring ToolPS gear
09631-20090Cylinder End Stopper Nut WrenchPS gear
09631-22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS gear
09633-00020Power Steering Hose Nut WrenchPS gear
09640-10010Power Steering Pressure Gauge
Set
(09641-01010)Gauge AssyPower steering fluid
(09641-01030)Attachment BPower steering fluid
(09641-01060)Attachment EPower steering fluid
09922-10010Variable Open WrenchManual steering gear
PS gear
09950-4001 1Puller B Set
(09951-04010)Hanger 150Manual steering gear
PS gear
(09952-04010)Slide ArmManual steering gear
PS gear
(09953-04020)Center Bolt 150Manual steering gear
PS gear

SS0N5-03
- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-5
135 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,275 kPa (13.0 kgf/cm2, 185 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) No. 02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
340.15 - 0.25 mm (0.006 - 0.010 in.)
0.31 - 0.41 mm (0.012 - 0.016 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC110° BTDC @ idle
Idle speed-750 ± 50 rpm
Idler pulley tension
springFree length
Installed load at 47.4 mm (1.866 in.)38.4 mm (1.512 in.)
32 N (3.3 kgf, 7.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve guide bore diameter STD
O/S 0.05
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
11.000 - 11.027 mm (0.4331 - 0.4342 in.)
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
30°, 45°, 60°, 75°
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 - 6.030 mm (0.2366 - 0.2374 in.)
11.048 - 11.059 mm (0.4350 - 0.4354 in.)
11.098 - 11.109 mm (0.4369 - 0.4374 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum93.45 mm (3.6791 in.)
93.89 mm (3.6965 in.)
92.95 mm (3.6594 in.)
93.39 mm (3.6768 in.)
44.5°
5.970 - 5.985 mm (0.2350 - 0.2356 in.)
5.965 - 5.980 mm (0.2348 - 0.2354 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 - 1.2 mm (0.031 - 0.047 in.)
0.5 mm (0.020 in.)

SS-6
- SERVICE SPECIFICATIONSENGINE MECHANICAL
136 Author
: Date
:
1996 TERCEL (RM440U) Valve spring
Deviation Maximum
Free length
Installed tension at 31.8 mm (1.252 in.)2.0 mm (0.079 in.)
53.58 mm (2.1094 in.)
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
CamshaftThrust clearance STD
Maximum
Cam lobe height STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter Exhaust No. 1
Others
Journal oil clearance STD
Maximum
Circle runout
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.045 - 0.100 mm (0.0018 - 0.0039 in.)
0.12 mm (0.0047 in.)
41.514 - 41.614 mm (1.6344 - 1.6383 in.)
41.011 - 41.111 mm (1.6146 - 1.6185 in.)
41.35 mm (1.6279 in.)
40.85 mm (1.6083 in.)
24.949 - 24.965 mm (0.9822 - 0.9829 in.)
22.949 - 22.965 mm (0.9035 - 0.9041 in.)
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
0.10 mm (0.0039 in.)
0.04 mm (0.0016 in.)
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0118 in.)
22.5 - 22.9 mm (0.886 - 0.902 in.)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum27.975 - 27.985 mm (1.1014 - 1.1018 in.)
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
0.015 - 0.046 mm (0.0006 - 0.0018 in.)
0.10 mm (0.0039 in.)
ManifoldWarpageMaximum Intake
Exhaust0.1 mm (0.004 in.)
0.5 mm (0.020 in.)
Spark tubeProtrusion47.5 - 48.5 mm (1.870 - 1.909 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter Mark 1
2
3
Maximum
Main journal bore diameter (Reference) Mark 1
2
30.05 mm (0.0020 in.)
74.000 - 74.010 mm (2.9134 - 2.9138 in.)
74.011 - 74.020 mm (2.9138 - 2.9142 in.)
74.021 - 74.030 mm (2.9142 - 2.9146 in.)
74.23 mm (2.9244 in.)
54.018 - 54.024 mm (2.1267 - 2.1269 in.)
54.025 - 54.030 mm (2.1270 - 2.1272 in.)
54.031 - 54.036 mm (2.1272 - 2.1274 in.)
Piston and piston
ringPiston diameter Mark 1
2
3
Piston oil clearance STD
Maximum
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil73.900 - 73.910 mm (2.9094 - 2.9098 in.)
73.910 - 73.920 mm (2.9098 - 2.9102 in.)
73.920 - 73.930 mm (2.9102 - 2.9106 in.)
0.09 - 0.11 mm (0.0035 - 0.0043 in.)
0.13 mm (0.0051 in.)
0.04 - 0.08 mm (0.0016 - 0.0031 in.)
0.03 - 0.07 mm (0.0012 - 0.0028 in.)
0.26 - 0.48 mm (0.0102 - 0.0189 in.)
0.30 - 0.57 mm (0.0118 - 0.0224 in.)
0.13 - 0.50 mm (0.0059 - 0.0197 in.)
1.07 mm (0.0421 in.)
1.02 mm (0.0354 in.)
1.10 mm (0.0433 in.)

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

- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-9
1996 TERCEL (RM440U) LH engine mounting bracket x Transaxle case
6565047
LH engine mounting bracket x Insulator4949035
LH engine mounting bracket x Ground strap4949035
Rear engine mounting bracket x Insulator6565047
A/C compressor x Bracket2525018
Clutch release cylinder x Transaxle case131309
Front exhaust pipe x Tailpipe (clamp bolt)1919014
Sub heated oxygen sensor x Front exhaust pipe4445033