1996 TOYOTA TERCEL engine

EG0023
P20290
- ENGINE MECHANICALCYLINDER HEAD
EM-53
1996 TERCEL (RM440U)
22. INSTALL EGR PIPE
Install a new gasket, sleeve ball and the EGR pipe with the
union nut and 2 nuts.
Torque:
Union nut
40 N´m (400 kgf´cm, 29 in.´lbf)
Nut
30 N´m (300 kgf´cm, 22 in.´lbf)
23. INSTALL THROTTLE BODY (See page MF-32)
24. CONNECT VACUUM HOSES
(a) Connect the vacuum hose from the EGR valve.
(b) Connect the 3 vacuum hoses from the throttle body.
(c) Connect the vacuum hose from TVV (to charcoal canis-
ter).
(d) Connect the vacuum hose from the TVV (to throttle body).
(e) Connect the vacuum hose from the EGR VSV.
25. INSTALL IGNITION COILS AND SPARK PLUGS
26. w/ A/C and w/o PS:
INSTALL IDLER PULLEY BRACKET
(a) Install the idler pulley bracket with the 3 bolts.
Torque:
12 mm head bolt
27 N´m (275 kgf´cm, 20 ft´lbf)
14 mm head bolt
37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Install and adjust the drive belt (See page AC-18).
27. w/ PS:
INSTALL PS PUMP BRACKET AND PS PUMP
(a) Install the PS pump bracket with the 3 bolts.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(b) Temporarily install the PS pump and drive belt with the 2
bolts (See page SR-33).
(c) Adjust the belt tension (See page SR-3).
28. CONNECT FUEL HOSE
Connect the fuel inlet hose with the union bolt and 2 new gas-
kets.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
29. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
30. INSTALL ACCELERATOR CABLE, AND ADJUST IT
31. A/T:
CONNECT THROTTLE CABLE, AND ADJUST IT

P20160
EM-54
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
32. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with
the 2 compression spring and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
33. INSTALL RH ENGINE UNDER COVER
34. FILL WITH ENGINE COOLANT (See page CO-2)
35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT
37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
38. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

EM0JU-06
- ENGINE MECHANICALENGINE UNIT
EM-55
476 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE UNIT
COMPONENTS

EM-56
- ENGINE MECHANICALENGINE UNIT
477 Author
: Date
:
1996 TERCEL (RM440U)

EM1OH-01
- ENGINE MECHANICALENGINE UNIT
EM-57
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN TRANSAXLE OIL (FLUID)
6. REMOVE AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
7. REMOVE RADIATOR (See page CO-16)
8. DISCONNECT ACCELERATOR CABLE
9. DISCONNECT FUEL HOSE
Remove the union bolt and gaskets, and disconnect the fuel in-
let hose.
NOTICE:
Catch leaking fuel in a container.
10. REMOVE CHARCOAL CANISTER
(a) Disconnect the canister hoses.
(b) Remove the charcoal canister.
11. DISCONNECT HOSES
(a) Disconnect the brake booster vacuum hose.
(b) Disconnect the MAP sensor hose.
(c) Disconnect the heater hoses.
12. DISCONNECT SPEEDOMETER CABLE FROM
TRANSAXLE
13. w/ PS:
DISCONNECT IDLE-UP AIR HOSES FROM AIR CON-
TROL VALVE
14. DISCONNECT ENGINE WIRE HARNESS
Disconnect these connectors and wires:

Main heated oxygen sensor connector

Oil pressure switch connector

P20565
M/T EM-58
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)

Engine coolant temperature sender gauge connec-
tor

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
15. M/T only:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
(a) Remove the 3 bolts, release cylinder and tube from the
transaxle.
(b) Disconnect the ground strap.
16. M/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.

P20572
A132 LA/T
A242 LA/T
P20577
P20292
P20164
- ENGINE MECHANICALENGINE UNIT
EM-59
1996 TERCEL (RM440U)
17. A/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the 2 bolts from the LH engine mounting bracket.
18. w/ PS:
REMOVE PS PUMP WITHOUT DISCONNECTING
HOSES
(a) Loosen the 2 bolts, and remove the PS drive belt.
(b) Remove the 2 bolts, and disconnect the PS pump from
the engine.
HINT:
Put aside the PS pump, and suspend it.
19. w/ A/C:
REMOVE A/C COMPRESSOR
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put aside the compressor, and suspend it.
20. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor.
(b) Remove the 2 bolts, compression springs and disconnect
the exhaust pipe.
(c) Remove the bolts and rear clamp.
(d) Disconnect the 2 rings and remove the front exhaust pipe.
21. REMOVE DRIVE SHAFTS (See page SA-18)

P20246
P20336
P20153
Ground Strap
P20285
M/T
P20002
A132L A/T EM-60
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
22. REMOVE ENGINE WITH TRANSAXLE FROM VE-
HICLE
(a) Install the No.1 engine hanger in the correct direction.
Part No.:
No.1 engine hanger 12281-11031
Bolt 91642-80825
(b) Attach the engine sling device to the engine hangers.
(c) Remove the rear engine mounting insulator through bolt.
(d) Remove the bolt and disconnect the ground strap.
(e) Remove the through bolt, 2 bolts, nut and RH engine
mounting insulator.
(f) M/T:
Remove the bolt and disconnect the ground strap.
(g) Remove the 5 bolts and LH engine mounting bracket.
(h) A132L A/T:
Remove the bolt and disconnect the ground strap.
(i) Remove the 5 bolts and LH engine mounting bracket.