1996 TOYOTA TERCEL engine

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

CO0HT-04
P21028
(b)
(c)
(a)
P21132
(2)(1)(b)
(a)
P21130
P21029
CO-4
- COOLINGWATER PUMP
1996 TERCEL (RM440U)
REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE GENERATOR
3. REMOVE INTAKE MANIFOLD STAY
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
4. REMOVE WATER INLET PIPE
(a) Disconnect the water inlet hose.
(b) Disconnect the heater inlet hose.
(c) Disconnect the water bypass hose.
(d) Remove the bolt, water inlet pipe and O-ring.
5. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
(a) Disconnect the engine wire clamp.
(b) Disconnect the connector clamp for crankshaft position
sensor.
(c) Remove the oil dipstick.
(d) Remove the mounting bolt of the dipstick guide clamp and
generator adjusting bar.
(e) Pull out the dipstick guide. Plug the guide installation hole
of the oil pump.
(f) Remove the O-ring from the dipstick guide.
6. REMOVE WATER PUMP
Remove the bolt, 2 nuts and water pump.

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

CO0HX-01
- COOLINGTHERMOSTAT
CO-9
1996 TERCEL (RM440U)
REMOVAL
NOTICE:
Do not remove the thermostat unless absolutely necessary.
HINT:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. REMOVE AIR CLEANER INLET
2. DRAIN ENGINE COOLANT
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, water inlet and thermostat from the water inlet housing.
(b) Remove the gasket from the thermostat.

CO0HZ-03
CO1225
Jiggle Valve
Protrusion
- COOLINGTHERMOSTAT
CO-1 1
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Place a new gasket onto the thermostat.
(b) Align the thermostat jiggle valve with the protrusion of the
water inlet, and insert the thermostat in the water inlet.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 5.0 N´m (50 kgf´cm, 43 in.´lbf)
3. INSTALL AIR CLEANER INLET
4. REFILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS

CO18A-01
CO1242
Radiator Cap Tester
Radiator Cap
30° or More
- COOLINGRADIATOR
CO-13
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. REMOVE 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.
2. INSPECT RADIATOR CAP
NOTICE:

If the radiator cap has contaminations, always rinse
it with water.

Before using a radiator cap tester, wet the relief valve
and pressure valve with engine coolant or water.

When performing steps (a) and (b) below, keep the
tester at an angle of over 30° above the horizontal.
(a) Using a radiator cap tester, slowly pump the tester and
check that air is coming from the vacuum valve.
Pump speed: 1 push/3 seconds or more
NOTICE:
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radiator
cap.
(b) Pump the tester and measure the relief valve opening
pressure.
Pump speed: 1 push within 1 second
NOTICE:
This pump speed is for the first pump only (in order to close
the vacuum valve). After this, the pump speed can be re-
duced.
Standard opening pressure:
74 - 103 kPa (0.75 - 1.05 kgf/cm
2, 10.7 - 14.9 psi)
HINT:
Use the tester's maximum reading as the opening pressure.
If the opening pressure is less than minimum, replace the radia-
tor cap.
3. INSPECT COOLING SYSTEM FOR LEAKS
(a) Fill the radiator with coolant and attach a radiator cap tes-
ter.
(b) Warm up the engine.
(c) Pump it to 118 kPa (1.2 kgf/cm
2, 17.1 psi), and check that
the pressure does not drop.
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
4. REINSTALL RADIATOR CAP

CO0Y2-02
(b)
(a)
P20609
(c)(d)
P20754
Plug
(e)
P20755
A/T
(A)
P20610
Radiator Lower Hose
Radiator Lower Support CO-16
- COOLINGRADIATOR
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE ENGINE UNDER COVERS
2. DRAIN ENGINE COOLANT
3. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY
4. REMOVE RADIATOR ASSEMBLY
(a) Disconnect the No.1 cooling fan connector.
(b) w/ A/C:
Disconnect the No.2 cooling fan connector.
(c) Disconnect the radiator upper hose from the radiator.
(d) Disconnect the radiator lower hose from the water inlet.
(e) Disconnect the 2 A/T oil cooler hoses from the radiator.
HINT:
Plug the hose to prevent oil from escaping.
(f) Remove the 2 bolts and 2 upper radiator supports.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
HINT:
(A/T only):
After installation, check that the rubber cushion (A) of the sup-
port is not depressed.
(g) Remove the radiator assembly.
(h) Remove the 2 radiator lower supports and the lower ra-
diator hose.

CO0Y5-02
P20875
Above 94°C
P20883
Ammeter
Battery
- COOLINGELECTRIC COOLING FAN
CO-23
603 Author
: Date
:
1996 TERCEL (RM440U)
ELECTRIC COOLING FAN
ON-VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the engine main relay, cooling fan relay, cooling
fan, fuses, and check for short circuit between the cooling fan
relay and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 94°C (201°F))
(a) Start the engine, and raise coolant temperature to above
94°C (201°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
M/T5.7 - 7.7 A
A/T8.6 - 11.6 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 6.4 - 7.4 A
(d) Reconnect the cooling fan connector.