1996 TOYOTA TERCEL Service Repair Manual

- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-7
137 Author
: Date
:
1996 TERCEL (RM440U) Connecting rod
Thrust clearance STD
Maximum
Connecting rod oil clearance STD STD
U/S 0.25
Maximum
Connecting rod big end inside diameter (Reference)
Mark 1
2
3
Connecting rod bearing center wall thickness (Reference)
STD Mark 1
2
3
U/S 0.25
Rod out-of-alignment per 100 mm (3.94 in.) Maximum
Rod twist per 100 mm (3.94 in.)Maximum0.15 - 0.35 mm (0.0059 - 0.0138 in.)
0.45 mm (0.0177 in.)
0.016 - 0.048 mm (0.0006 - 0.0019 in.)
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.08 mm (0.0031 in.)
46.000 - 46.007 mm (1.8110 - 1.8113 in.)
46.007 - 46.014 mm (1.8113 - 1.8116 in.)
46.014 - 46.021 mm (1.8116 - 1.8118 in.)
1.487 - 1.491 mm (0.0585 - 0.0587 in.)
1.491 - 1.495 mm (0.0587 - 0.0589 in.)
1.495 - 1.499 mm (0.0589 - 0.0590 in.)
1.609 - 1.615 mm (0.0633 - 0.0636 in.)
0.03 mm (0.0012 in.)
0.05 mm (0.0020 in.)
CrankshaftThrust clearance STD
Maximum
Thrust washer thickness STD
O/S 0.125
Main journal oil clearance STD STD
U/S 0.25
Maximum
Main journal diameter STD
U/S 0.25
Main journal bore diameter (Reference) Mark 1
2
3
Main journal diameter (Reference) STD Mark 0
1
2
Main bearing center wall thickness (Reference)
STD Mark 1
2
3
4
5
U/S 0.25
Crank pin diameter STD
U/S 0.25
Circle runout Maximum
Main journal taper and out-of-round Maximum
Crank pin taper and out-of-round Maximum0.020 - 0.200 mm (0.0008 - 0.0078 in.)
0.30 mm (0.0118 in.)
2.430 - 2.480 mm (0.0957 - 0.0976 in.)
2.493 - 2.543 mm (0.0981 - 0.1001 in.)
0.016 - 0.035 mm (0.0006 - 0.0014 in.)
0.015 - 0.055 mm (0.0006 - 0.0022 in.)
0.08 mm (0.0031 in.)
49.985 - 50.000 mm (1.9679 - 1.9685 in.)
49.745 - 49.755 mm (1.9585 - 1.9589 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.)
49.996 - 50.000 mm (1.9683 - 1.9685 in.)
49.991 - 49.995 mm (1.9081 - 1.9683 in.)
49.985 - 49.990 mm (1.9679 - 1.9681 in.)
1.997 - 2.000 mm (0.0786 - 0.0787 in.)
2.001 - 2.003 mm (0.0788 - 0.0789 in.)
2.004 - 2.006 mm (0.0789 - 0.0790 in.)
2.007 - 2.009 mm (0.0790 - 0.0791 in.)
2.010 - 2.012 mm (0.0791 - 0.0792 in.)
2.118 - 2.124 mm (0.0834 - 0.0836 in.)
42.985 - 43.000 mm (1.6923 - 1.6929 in.)
42.745 - 42.755 mm (1.6829 - 1.6833 in.)
0.06 mm (0.0024 in.)
0.08 mm (0.0031 in.)
0.07 mm (0.0028 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

SS1IT-01
SS-10
- SERVICE SPECIFICATIONSEMISSION CONTROL
140 Author
: Date
:
1996 TERCEL (RM440U)
EMISSION CONTROL
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TVV x Water outlet housing3535026
EGR valve x Cylinder head3030022
EGR pipe x Intake manifold Nut3030022
EGR valve x EGR pipe Union nut4040030

SS0N7-04
- SERVICE SPECIFICATIONSMFI
SS-1 1
141 Author
: Date
:
1996 TERCEL (RM440U)
MFI
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum281 - 287 kPa (2.87 - 2.93 kgf/cm2, 40.8 - 41.7 psi)
Fuel pumpResistance at 20°C (68°F)0.2 - 3.0 W
InjectorResistance at 20°C (68°F)
Injection volume
Difference between each cylinder
Fuel leakage13.4 - 14.2 W
39 - 49 cm3 (2.4 - 3.0 cu in.) per 15 sec.
5 cm3 (0.31 cu in.) or less
1 drop or less per 3 min.
Throttle bodyThrottle body fully closed angle6°
Throttle position
sensorResistance
0 mm (0 in.) VTA - E2
0.50 mm (0.020 in.)IDL - E2
0.70 mm (0.028 in.)IDL - E2
Throttle valve fully open VTA - E2
- VC - E2
0.2 - 5.7 kW
2.3 kW or less
Infinity
2.0 - 10.2 kW
2.5 - 5.9 kW
IAC valveResistance +B - RSO (or RSC)
Cold (-10°C (14°F) to 50°C (122°F))
Hot (50°C (122°F) to 100°C (212°F))
17.0 - 24.5 W
21.5 - 28.5 W
VSV for EGRResistance at 20°C (68°F)33 - 39 W
ECT sensor and
IAT sensorResistance at -20°C (-4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 - 20 kW
4 - 7 kW
2 - 3 kW
0.9 - 1.3 kW
0.4 - 0.7 kW
0.2 - 0.4 kW
MAP sensorPower source voltage4.5 - 5.5 V
Main heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Sub heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Fuel cut rpmFuel return rpm900 rpm

SS0N8-03
SS-12
- SERVICE SPECIFICATIONSMFI
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Fuel line Union bolt type
Flare nut type29
30290
30022
23
Fuel inlet hose x Fuel filter2929022
Fuel outlet pipe x Fuel pump bracket2929022
Fuel tank x Fuel pump set bolt3.43530 in.´lbf
Fuel pressure regulator x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Fuel pressure regulator2020014
Delivery pipe x Cylinder head1919014
Fuel inlet hose x Delivery pipe3030023
Fuel pump bracket x Fuel cut-off valve1.51513 in.´lbf
Fuel tank x Fuel tank filler pipe3.43530 in.´lbf
Fuel tank x Body3334025
Throttle body x Intake manifold19.519514
Main heated oxygen sensor x Exhaust manifold4444032
Sub heated oxygen sensor x Exhaust pipe4444032
Knock sensor x Cylinder block4545033

SS0N9-04
- SERVICE SPECIFICATIONSCOOLING
SS-13
143 Author
: Date
:
1996 TERCEL (RM440U)
COOLING
SERVICE DATA
ThermostatValve opening temperature
Valve lift at 95°C (203°F)80 - 84°C (176 - 183°F)
8 mm (0.31 in.) or more
Radiator capRelief valve opening pressure STD
Minimum74 - 103 kPa (0.75 - 1.05 kgf/cm2, 10.7 - 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)
No. 1 electric
cooling fanRotating amperage M/T
A/T5.7 - 7.7 A
8.6 - 11.6 A
No. 2 electric
cooling fanRotating amperage6.4 - 7.4 A

SS0NA-03
SS-14
- SERVICE SPECIFICATIONSCOOLING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug x Cylinder block2525018
Water pump x Cylinder block17.517513
Oil dipstick guide x RH engine mounting bracket18.518514
Water inlet pipe x Cylinder block7.57565 in.´lbf
Intake manifold stay x Cylinder block2020015
Water inlet x Water outlet housing5.05043 in.´lbf
Radiator upper support x Body121209
Oil cooler x Radiator lower tank Nut A
Nut B, C15.0
8.5150
8511
75 in.´lbf
No. 1 cooling fan x Radiator7.07061 in.´lbf
No. 2 cooling fan x Radiator7.07061 in.´lbf