1996 TOYOTA TERCEL torque

SF0X4-05
FI3271
New
O-Ring
New Grommet
P00159
CORRECT
WRONG
InjectorDelivery Pipe GrommetO-Ring
WRONG
P20295
Spacer
Insulator
Connector MF-22
- MFIINJECTOR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to an O-ring, and install it
to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Place the 2 spacers and 4 insulators in position on the cyl-
inder head.
(e) Place the injectors together with the delivery pipe on the
cylinder head.
(f) Check that the injectors rotate smoothly.
HINT:
If the injectors do not rotate smoothly, the probable cause is in-
correct installation of O-rings. Replace the O-rings.
(g) Position the injector connector upward.
(h) Install the 2 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
2. CONNECT ENGINE WIRE
(a) Connect the 4 injector connectors.
(b) Connect the engine wire to the surge tank stay.
3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Install 2 new gaskets and the inlet hose with the union
bolt.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
(b) Connect the engine wire clamp to the No.2 engine hang-
er.
4. CONNECT FUEL RETURN HOSE TO FUEL RETURN
PIPE
5. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR

SF0X5-04
MF-24
- MFIFUEL TANK AND LINE
548 Author
: Date
:
1996 TERCEL (RM440U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:

Always use new gaskets when replacing the fuel tank or components parts.

Apply the proper torque to all parts tightened.

SF1PX-01
(a)
(b)
(a)
(b)
(c)(d)(e)
MF-28
- MFITHROTTLE BODY
1996 TERCEL (RM440U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE AIR CLEANER CAP
3. DISCONNECT CONTROL CABLES FROM THROTTLE
BODY
(a) Disconnect the accelerator cable
(b) Disconnect the A/T throttle cable.
4. REMOVE THROTTLE BODY
(a) Disconnect the throttle position sensor connector and
wire clamp.
(b) Disconnect the IAC valve connector.
(c) Disconnect the vacuum hose (from upper port of TVV of
EVAP) from port ºPº of throttle body.
(d) Disconnect the vacuum hose (from port ºPº of EGR vacu-
um modulator) from port ºEº of throttle body.
(e) Disconnect the vacuum hose (from port ºRº of EGR vacu-
um modulator) from port ºRº of throttle body.
(f) Remove the 2 nuts and 2 bolts.
Torque: 19.5 N´m (195 kgf´cm, 14 ft´lbf)
(g) Disconnect the throttle body from the intake manifold.
(h) Remove the gasket.
HINT:
At the time of installation, plaese refer to the following items. At-
tach a new gasket to the intake manifold, facing the protrusion
downward.

SF0WN-01
P20327
SST
P01630
Ohmmeter MF-50
- MFIKNOCK SENSOR
1996 TERCEL (RM440U)
INSPECTION
1. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Using SST, remove the knock sensor.
SST 09816-30010
2. INSPECT KNOCK SENSOR
Using an ohmmeter, check that there is no continuity between
the terminal and body.
If there is continuity, replace the sensor.
3. REINSTALL KNOCK SENSOR
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)

SF1PZ-01
P20873
+B
HT Ohmmeter
- MFIHEATED OXYGEN SENSOR
MF-53
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT HEATER RESISTANCE OF MAIN HEATED
OXYGEN SENSOR (BANK 1 SENSOR 1)
(a) Disconnect the oxygen sensor connectors.
(b) Using an ohmmeter, measure the resistance between the
terminals +B and HT.
Resistance: 11 - 16 W at 20°C (68°F)
If the resistance is not as specified, replace the sensor.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(c) Reconnect the oxygen sensor connectors.
2. INSPECT HEATER RESISTANCE OF SUB HEATED
OXYGEN SENSOR (BANK 1 SENSOR 2)
(a) Remove the passenger's seat.
(b) Take out the console box side of the floor carpet.
(c) Disconnect the oxygen sensor connector.
(d) Using an ohmmeter, measure the resistance between the
terminals +B and HT.
Resistance: 11 - 16 W at 20°C (68°F)
If the resistance is not as specified, replace the sensor.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(e) Reconnect the oxygen sensor connectors.
(f) Reinstall the floor carpet.
(g) Reinstall the passenger's seat.

CO0HR-04
P20196
Drain Plug
Drain Plug
CO-2
- COOLINGCOOLANT
1996 TERCEL (RM440U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the 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.
(b) Loosen the radiator drain plug (on the right side of the ra-
diator lower tank) and engine drain plug (on the left front
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use a good brand of ethylene-glycol base coolant
and mix it according to the manufacturer's direc-
tions.

Using coolant which includes more than 50 % ethyl-
ene-glycol (but not more than 70 %) is recom-
mended.
NOTICE:

Do not use an alcohol type coolant.

The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T4.9 liters (5.2 US qts, 4.3 lmp. qts)
A/T5.3 liters (5.6 US qts, 4.7 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
ºFULLº line.
3. CHECK ENGINE COOLANT FOR LEAKS

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.

P21806
New O-Ring
CO1226
Water Inlet Pipe
CORRECT
WRONG O-Ring
Water Pump
- COOLINGWATER PUMP
CO-7
1996 TERCEL (RM440U)
(e) Connect the connector clamp for crankshaft position sen-
sor.
(f) Connect the engine wire clamp.
3. INSTALL WATER INLET PIPE
(a) Install a new O-ring to the water inlet pipe.
(b) Apply a little soap and water to the O-ring.
(c) Insert the water inlet pipe to the water pump.
NOTICE:
Installing the water inlet pipe at an angle or twisting it dur-
ing installation will cause pinching or tearing of the O-ring.
(d) Install the water inlet pipe with the bolt.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
(e) Connect the water inlet hose.
(f) Connect the heater inlet hose.
(g) Connect the water bypass hose
4. INSTALL INTAKE MANIFOLD STAY
(a) Install the intake manifold stay with the bolt and nut.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(b) Connect the engine wire clamps to the intake manifold
stay.
5. INSTALL GENERATOR
6. REFILL WITH ENGINE COOLANT
7. START ENGINE AND CHECK FOR LEAKS