low oil pressure TOYOTA TERCEL 1996 Service Repair Manual

MA001-24
- MAINTENANCEOUTSIDE VEHICLE
MA-1
39 Author
: Date
:
1996 TERCEL (RM440U)
OUTSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. TIRES
(a) Check the pressure with a gauge.
If necessary, adjust.
(b) Check for cuts, damage or excessive wear.
3. WHEEL NUTS
When checking the tires, check the nuts for looseness or for missing nuts.
If necessary, tighten them.
4. TIRE ROTATION
Check the owner's manual supplement in which the maintenance schedule is shown.
5. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they do not wipe clean.
If necessary, replace.
6. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.
7. DOORS AND ENGINE HOOD
(a) Check that all doors and includiing the trunk lid operate smoothly, and that all latches lock securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the primary latch
is released.

P25916
S00553
DI-10
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Remove the fuse cover on the instrument panel.
(d) Connect the TOYOTA hand-held tester to DLC3 on the
vehicle.
(e) Use ACTIVE TEST mode to operate the fuel pump.
(f) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page MF-1).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page MF-1 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high-tension cord from spark plug or re-
move the ignition coil.
(b) Remove spark plug.
(c) Install the spark plug to high-tension cord or ignition coil.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
NG Proceed to page IG-1 and continue to trouble-
shoot.
OK

EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.

If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.

If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS

EM0K0-05
P20381
P20380
P20350
P20353
EG0031
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1996 TERCEL (RM440U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high-pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Remove the gasket material.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Clean the combustion chambers.
(d) Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(e) Clean the valve guide bushings.
(f) Using a valve guide bushing brush and solvent, clean all
the guide bushings.

CO0HQ-03
- COOLINGCOOLANT
CO-1
581 Author
: Date
:
1996 TERCEL (RM440U)
COOLANT
INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ºLOWº and ºFULLº lines.
If low, check for leaks and add engine coolant up to the ºFULLº line, ºwhen the engine is cold.º
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

LU08A-06
LU1169
Oil Pressure Gauge
Oil Pressure Switch
LU1107
Adhesive
- LUBRICATIONOIL AND FILTER
LU-1
616 Author
: Date
:
1996 TERCEL (RM440U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the oil quality is visibly poor, replace it.
Oil grade:
API grade or SH Energy-Conserving II or ILSAC multi-
grade engine oil. Recommended viscosity is as
shown in the illustration, with SAE 5W-30 being the
prefferred engine oil.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ºLº and ºFº marks on the dip-
stick.
If low, check for leakage and add oil up to the ºFº mark.
3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL
PRESSURE GAUGE
(a) Remove the bolt and air intake connector.
(b) M/T only
Remove the 3 bolts, release cylinder and tube from the
transaxle.
(c) Remove the oil pressure switch.
(d) Install the oil pressure gauge.
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle speed
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 - 490 kPa (2.5 - 5.0 kgf/cm
2, 36 - 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or eqivalent
(c) Reinstall the oil pressure switch.

S06257
16 mm Plug Wrench
IG0152
P20433
P20584
- IGNITIONIGNITION SYSTEM
IG-3
634 Author
: Date
:
1996 TERCEL (RM440U)
3. INSPECT SPARK PLUGS
(a) Disconnect high-tension cords from spark plugs.
(b) Using a 16 mm plug wrench, remove the spark plug.
(c) Using a spark plug cleaner or wire brush, clean the spark
plug.
If the electrode has traces of wet carbon, allow it to dry and then
clean with a spark plug cleaner.
Air pressure:
Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(d) Visually checkthe spark plug for thread damage and insu-
lator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSOK16TR11
NGKBKR5EKB11
(e) Inspect the electrode gap.
Correct electrode gap: 1.1 mm (0.043 in.)
(f) Using a 16 mm plug wrench, remove the spark plug.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
(g) Reconnect the high-tension cords from the ignition coils.

CL05O-03
- CLUTCHTROUBLESHOOTING
CL-1
696 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Engine mounting (Loosen)-1.Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
CL-14
2.Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
CL-14
CL-14
Clutch grabs/chatters
3.Clutch disc (Oily)
4. Clutch disc (Worn out)
CL-14
CL-14Clutch grabs/chatters4.Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged)
CL-14
CL-145.Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed)
CL 14
CL-146.Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)
CL 14
CL-14
1. Clutch line (Air in line)-
Clutch pedal spongy
1.Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
CL-4
Clutch edal s ongy2.Master cylinder cu (Damaged)
3. Release cylinder cup (Damaged)
CL 4
CL-9
1. Release bearing (Worn, dirty, or damaged)CL-14
Clutch noisy
1.Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or damaged)
CL-14
-Clutch noisy2.In ut shaft bearing (Worn or damaged)
3. Clutch disc torsion rubber (Damaged)CL-14
1. Clutch pedal (Free play out of adjustment)CL-21.Clutch edal (Free lay out of adjustment)
2. Clutch disc (Oily)
CL-2
CL-14
Cl t h li
2.Clutch disc (Oily)
3. Clutch disc (Worn out)
CL-14
CL-14Clutch slips3.Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
CL 14
CL-144.Dia hragm s ring (Damaged)
5. Pressure plate (Distortion)
CL 14
CL-145. Pressure late (Distortion)
6. Flywheel (Distortion)
CL 14
-
1 Clutchpedal (Freeplay out of adjustment)CL-21.Clutch pedal (Free play out of adjustment)
2 Clutch line (Air in line)CL-2
-2.Clutch line (Air in line)
3 Master cylinder cu
p(Damaged)
-
CL-43.Master cylinder cup (Damaged)
4. Release cylinder cu
p(Damaged)
CL-4
CL
-94.Release cylinder cup (Damaged)
5
. Input shaft bearing (Worn or damaged)
CL-9
-5.In ut shaft bearing (Worn or damaged)
6. Clutch disc (Out of true)
-
CL-14
Cl t h d t di
6.Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
CL-14
CL-14Clutch does not disengage7.Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
CL-14
CL-148.Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned)
CL-14
CL-149.Clutch disc (Dirty or burned)
10.Clutch disc (Oily)
CL 14
CL-1410.Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
CL 14
CL-1711. Clutch disc (Lack of s line grease)
12.Diaphragm spring (Damaged)
CL 17
CL-14gg(g)
13.Diaphragm spring (Out of tip alignment)CL-17gg( g)
14.Pressure plate (Distortion)CL-14

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-7
1996 TERCEL (RM440U)
5. HYDRAULIC TEST
(a) Measure the line pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00150, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80°C (122 - 176 °F).
(3) Fully apply the parking brake and check the 4 wheels.
(4) Start the engine and check the idle speed.
(5) Shift into the D position,step down strongly on the brake pedal with your left foot and while manip-
ulating the accelerator pedal with the right foot, measure the line pressure at the engine speeds
specified in the toble.
(6) In the same manner, do the test in the R position.
Specified line pressure:
D positionIdling
Stall363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
R position Idling
Stall530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
(7) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
and retest it (see step 2).
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
If the measured values at all positions are lower.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
 Oil pump defective
If pressure is low in the D position only. D position circuit fluid leakage
 Forward clutch defective
If pressure is low in the R position only.
 R position circuit fluid leakage
 Direct clutch defective
 1st and reverse brake defective
(b) Measure the governor pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00230, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.

- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-7
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective
If the measured values at all positions are lower.

Throttle cable out of adjustment

Throttle valve defective

Regulator valve defective

Oil pump defective

U/D one-way clutch not operating properly
If pressure is low in the D position only.

D position circuit fluid leakage

Forward clutch defective

U/D one-way clutch not operating properly
If pressure is low in the R position only.

R position circuit fluid leakage

Direct clutch defective

1st and reverse brake defective

U/D one-way clutch not operating properly
(b) Measure the governor pressure.
(1) Warm up the ATF.
(2) Remove the transaxle case test plug and mount SST (See page AX-29).
SST 09992-00094 (09992-00111, 09992-00270)
NOTICE:

Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).

Check that the throttle cable is adjusted within the specifications.

Check that the tire pressures are adjusted according to the specifications.
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.
EVALUATION
ProblemPossible cause
If governor pressure is defective.

Line pressure defective

Fluid leakage in governor pressure circuit

Governor valve operation defective
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
90 km/h (56 mph)363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
6. ROAD TEST
NOTICE:
Do this test at normal operating ATF temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constantly at the throttle valve
fully open, check on the following points:
(1) 1 " 2, 2 " 3 and 3 "O/D up-shifts should take place, and shift points should conform to those
shown in the automatic shift schedule (See page SS-30).