1996 TOYOTA TERCEL cooling

SS0MA-05
SS-44
- SERVICE SPECIFICATIONSAIR CONDITIONING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Compressor x Suction hose101007
Compressor x Discharge hose101007
Compressor x Compressor bracket2525018
Receiver x Liquid tube5.45548 in.´lbf
Condenser x Liquid tube5.45548 in.´lbf
Cooling unit x Liquid tube1414010
Cooling unit x Suction tube3233024
Expansion valve x Evaporator5.45548 in.´lbf
Revolution detecting sensor x Compressor1111 08
Pressure plate x Compressor1414010

DI4LF-02
- DIAGNOSTICSENGINE
DI-13
1996 TERCEL (RM440U)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below, for details of each code, turn to the page referred to under the ''See page '' for the respec-
tive ''DTC No.'' in the DTC chart.
SAE Controlled:
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P0105
(DI-20)
Manifold Absolute
Pressure/Barometric
Pressure Circuit
MalfunctionOpen or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM

P0106
(DI-23)
Manifold Absolute
Pressure/Barometric
Pressure Circuit
Range/Performance Problem
Manifold absolute pressure sensor
P0110
(DI-24)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM

P0115
(DI-28)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM

P0116
(DI-32)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI-33)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM

P0121
(DI-37)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
Range/Performance Problem
Throttle position sensor
P0125
(DI-38)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in oxygen sensor circuit
Oxygen sensor
P0130
(DI-41)Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
P0133
(DI-44)Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)
Oxygen sensor
P0136
(DI-45)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI-47) Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
ECM

*: 


MIL lights up

DI-32
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0116 Engine Coolant Temp. Circuit Range/
Performance Problem
CIRCUIT DESCRIPTION
Refer to Engine Coolant Temp. Circuit Malfunction on page DI-28.
DTC No.DTC Detection ConditionTrouble Area
P0116
20 min. or more after the engine starts, engine coolant
temp. sensor value is 40°C (104°F) or less (2 trip detection
logic)
Engine coolant temp. sensor

Cooling system
INSPECTION PROCEDURE
HINT:
If DTC P0115 and P0116 are output Simultaneously, engine coolant temperature sensor circuit may be open.
Perform troubleshooting of DTC P0115 first.
1 Are there any other codes (besides DTC P0116) being output?
YES Go to relevant DTC chart.
NO
2 Check thermostat (See page CO-10).
NG Replace thermostat.
OK
Replace engine coolant temp. sensor.
DI1E7-08

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

EM18V-02
EM-10
- ENGINE MECHANICALIDLE SPEED
431 Author
: Date
:
1996 TERCEL (RM440U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed:
750 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral position)
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

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.

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

CO0HS-03
- COOLINGWATER PUMP
CO-3
583 Author
: Date
:
1996 TERCEL (RM440U)
WATER PUMP
COMPONENTS