1996 TOYOTA TERCEL coolant

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.

CO0HU-01
P21030
- COOLINGWATER PUMP
CO-5
1996 TERCEL (RM440U)
INSPECTION
INSPECT WATER PUMP
(a) Visually check the water hole for coolant leakage.
If leakage is found, replace the water pump.
(b) Turn the pulley, and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.

CO0Y1-02
P21031
CO1231 CORRECT WRONG
Seal Diameter
2 - 3 mm
(0.08 - 0.12 in.)
Seal Packing
P21131
New
O-Ring CO-6
- COOLINGWATER PUMP
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the contact
surfaces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water pump groove.
Seal packing:
Part No. 08826-00100, THREE BOND 1282B or
equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water pump with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 14 ft´lbf)
2. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide, and install it with the mounting
bolt of the generator adjusting bar and dipstick guide
clamp.
Torque: 18.5 N´m (185 kgf´cm, 14 ft´lbf)
(d) Install the oil dipstick.

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