1996 TOYOTA TERCEL ESP

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

SF1PQ-02
- MFIMFI SYSTEM
MF-1
525 Author
: Date
:
1996 TERCEL (RM440U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (-) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative (-) terminal cable is disconnected.
Therefore, if necessary, read the diagnosis before disconnect-
ing the negative (-) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON THE FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, the following precautions
should be taken.
(1) Check proper connection to battery terminals, etc.
(2) Handle higt-tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling the oxygen sensor.
(1) Do not allow the oxygen sensor to drop or hit
against an object.
(2) Do not allow the sensor to come into contact with
water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYS-
TEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
6. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine out of
tune.
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing MFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (-) terminal
cable from the battery.

FI2553
SST
FI4429
Plug MF-2
- MFIMFI SYSTEM
526 Author
: Date
:
1996 TERCEL (RM440U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (-) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all MFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and contact with terminals
can cause further trouble.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent the entry of water. Also, when washing the engine
compartment, prevent water from getting on the MFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) When inspecting a connector with a volt/ohmmeter.
(l) Carefully take off the water-proofing rubber if it is a wa-
ter-proof type connector.
(m) Insert the tester probe into the connector from the wiring
side when checking the continuity, amperage or voltage.
(n) Do not apply unnecessary force to the terminal.
(o) After checking, install the water-proofing rubber securely
on the connector.
(p) Use SST for inspecting or testing the injector or its wiring
connector.
SST 09842-30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(7) Reconnect the fuel pump connector.

ST0J1-01
P13459
Terminal 50
Terminal C
Battery
P13460
Terminal C
Battery
Disconnect
P13461
Battery
Disconnect
P13462
Battery
Ammeter Terminal 50
Terminal 30
- STARTINGSTARTER (Reduction Type)
ST-13
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO HOLD-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter the
current specified in the respective repair manual.

N00173
SST
SST
CM0061
MT0092
SST
- MANUAL TRANSAXLEDIFFERENTIAL CASE
MX-39
1996 TERCEL (RM440U)
3. INSTALL SIDE BEARING
(a) Install the speedometer drive gear to the RH side.
(b) Using SST and a press, install new side bearings to the
both sides of the case.
SST 09350-32014 (09351-32090, 09351-32120)
4. INSPECT DIFFERENTIAL SIDE BEARING PRELOAD
(a) Install the differential case assembly to the transaxle
case.
(b) Install the transmission case.
(c) Install and torque the case bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(d) Using SST and a torque wrench, measure the preload.
SST 09564-3201 1
Preload (at starting):
New bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
Reused bearing
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)
If the preload is not within the specification, remove the trans-
mission case side outer race of the side bearing with SST (See
page MX-36).
(e) Select another shim.
HINT:
The preload will change by approx. 0.3 - 0.4 N´m (3 - 4 kgf´cm,
2.6 - 3.5 in.´lbf) corresponding to a change of 0.05 mm in shim
thickness.
MarkThickness mm (in.)MarkThickness mm (in.)
A2.10 (0.0827)L2.60 (0.1024)
B2.15 (0.0846)M2.65 (0.1043)
C2.20 (0.0866)N2.70 (0.1063)
D2.25 (0.0886)P2.75 (0.1083)
E2.30 (0.0906)Q2.80 (0.1102)
F2.35 (0.0925)R2.85 (0.1122)
G2.40 (0.0945)S2.90 (0.1142)
H2.45 (0.0965)T2.95 (0.1161)
J2.50 (0.0984)U3.00 (0.1181)
K2.55 (0.1004)--

V06938
ED
A
G
BC
F
H Code Shape Size
ù = 8
(0.31)
L = 15
(0.59)Code Shape Size Code Shape Size
ù = 5
(0.20)
L = 16
(0.63)
ù = 8
(0.31)ù = 5
(0.24)
L = 22
(0.87)
ù = 5
(0.20)
L = 14
(0.55)
ù = 6
(0.24)ù = 6
(0.24)
L = 20
(0.55)
ù = 5
(0.20)
L = 12
(0.47)mm (in.)
- BODYINSTRUMENT PANEL
BO-47
1141 Author
: Date
:
1996 TERCEL (RM440U)
HINT:
Screw shapes and sizes are indicated in the table below. The codes (A-H) correspond to those indicated
on the previous pages.