1996 TOYOTA TERCEL compression ratio

PP18S-01
PP-6
- PREPARATIONENGINE MECHANICAL
1996 TERCEL (RM440U)
EQUIPMENT
Caliper gauge
CO/HC meter
Compression gauge
Connecting rod aligner
Cylinder gauge
Dial indicator
Dye penetrant
Engine tune-up tester
Heater
Magnetic finger
Micromerer
OBD II scan toolIdle speed
Piston ring compressor
Piston ring expander
Plastigage
Precision straight edge
Soft brush
Spring testerValve spring
Steel squareValve spring
Torque wrench
Valve seat cutter
Vernier calipers

DI4LI-02
- DIAGNOSTICSENGINE
DI-19
1996 TERCEL (RM440U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSee page
Does not start (Engine does not crank)1. Starter and starter relayST-13
ST-31
Does not start (No combustion)1. ECM power source circuit
2. Fuel pump control circuitDI-97
DI-100
Does not start (No complete combustion)1. Fuel pump control circuitDI-100
Difficult to start (Engine cranks normally)
1. Starter signal circuit
2. Fuel pump control circuit
3. CompressionDI-90
DI-100
EM-3
Difficult to start (Cold engine)1. Starter signal circuit
2. Fuel pump control circuitDI-90
DI-100
Difficult to start (Hot engine)1. Starter signal circuit
2. Fuel pump control circuitDI-90
DI-100
Poor idling (High engine idle speed)1. A/C signal circuit
2. ECM power source circuitAC-66
DI-97
Poor idling (Low engine idle speed)1. A/C signal circuit
2. Fuel pump control circuitAC-66
DI-100
Poor idling (Rough idling)1. Compression
2. Fuel pump control circuitEM-3
DI-100
Poor idling (Hunting)1. ECM power source circuit
2. Fuel pump control circuitDI-97
DI-100
Poor driveability (Hesitation/Poor acceleration)
1. Fuel pump control circuit
2. A/T faulty (A132L)
A/T faulty (A242L)
3. A/C cut control circuitDI-100
AX-10
AX-13
DI-106
Poor driveability (Surging)1. Fuel pump control circuitDI-100
Engine stall (Soon after starting)1. Fuel pump control circuitDI-100
Engine stall (During A/C operation)1. A/C signal circuit
2. Engine control module (ECM)AC-66
IN-26

DI-52
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the
MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detection ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any particular
200 or 1,000 revolutions
Ignition system


Injector
P0301
P0302
For any particular 200 revolutions of the engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)

Injector

Fuel line pressure

Compression pressure

Valve clearance not to specification
P0302
P0303
P0304For any particular 1,000 revolutions of the engine, misfiring is
detected which causes a deterioration in emissions
(2 trip detection logic)
Valve clearance not to s ecification

Valve timing

Manifold absolute pressure sensor

Engine coolant temp. sensor
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI39Y-04

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

EM0JT-05
P20471
Front Mark
(Cavity)
Front Mark
(Protrusion)
Z08055
SST
Piston Pin
SSTSST
SST
SST
SST SST
P20549
P20560
1R
2R
- ENGINE MECHANICALCYLINDER BLOCK
EM-85
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.
Replace all gaskets, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Coat the piston pin and pin holes of the piston with engine
oil.
(b) Align the cavity on the piston with the protrusion on the
connecting rod.
(c) Using SST, press in the piston pin.
SST 09221-25025 (09221-00020, 09221-00030,
09221-00130, 09221-00140, 09221-00150)
(d) After installing the piston pin, check that when the con-
necting rod is aligned with the center of the piston the
space between the piston and each end of the piston pin
are equal on the left and right sides.
HINT:
If the piston pin is off-center due to insufficient insertion pres-
sure on the piston pin, place a washer at the position indicated
by
in the illustration for (c). Then, while checking that the
space is equal at the ends of the piston pin on the left and right
sides, press in the washer.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code Mark:
No.11R
No.22R

P20867
Front
ExpanderNo.2
Compression
Ring
Upper Side
Rail
Front Mark (Cavity) No.1
Compression
RingLower Side Rail
EM3477
EM9416
P20550
EM9417
EM-86
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the end gaps.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
illustration position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position with
the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK

I01450
Condition: Insufficient cooling
I01393
Condition : Does not cool AC-8
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
(8) Expansion valve improperly
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 Frost or large amount of dew on
piping on low pressure side
Trouble in expansion valve or heat
sensing tube not installed correctly
 Excessive refrigerant in low
pressure piping
 Expansion valve opened too
wide
Check expansion valve
Replace if defective
(9) Defective compression compressor
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on low and
high pressure sides
 Pressure too low on high pres-
sure side
Internal leak in compressor
 Compression defective
 Valve leaking or broken sliding
parts
Repair or replace compressor