1996 TOYOTA TERCEL engine assembly

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513

SS0N2-05
- SERVICE SPECIFICATIONSSTEERING
SS-37
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
STEERING COLUMN
Steering support x Column tube5.45548 in.´lbf
Control valve shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Steering column assembly set nut2526019
Steering wheel set nut3435025
Steering wheel pad set screw8.89078 in.´lbf
PS VANE PUMP
Pressure port union x Front housing6970051
Suction port union x Front housing131309
Pressure feed tube x Pressure port union5455040
PS vane pump pulley set nut4344032
PS vane pump assembly set nut Bolt A4344032 PS vane um assembly set nut Bolt A
Bolt B
43
39
440
400
32
30
MANUAL STEERING GEAR
Pinion bearing adjusting screw lock nut for use with SST
for use without SST85
11 3871
1,15063
83
Rack guide spring cap lock nut for use with SST
for use without SST41
56419
57530
42
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Manual steering gear bracket x Body5859043
Pinion shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Column hole cover x Body4.95043 in.´lbf
PS GEAR
Cylinder end stopper5960043
Self-locking nut5960043
Rack housing cap5960043
Rack guide spring cap lock nut for use with SST
for use without SST31
44316
45023
33
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Turn pressure tube union nut for use with SST
for use without SST20
25203
25015
18
Air control valve2930022
PS gear bracket x Body5859043
Engine rear mount insulator Bolt A6465047 Engine rear mount insulator Bolt A
Bolt B
64
78
650
800
47
58
Engine rear mount bracket x Transaxle4849035
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe clamp1919014
Front exhaust pipe x Oxygen sensor4445032

H09396
MAIN
FL
B
ALT
B-RB-R
2 2
Engine
Room
R/B
AM1
W-GDriver Side J/B
1
1J
1BW-G 2ACC
AM13
B-Y4
1B
1H
CIG/RADIO Driver Side J/B
G-R*1
10
ACCAirbag
Sensor
Assembly
8
*2
B-OIG2 *1
9
7
*2 2
1H 1B5
IGN B-W 6
AM2
Ignition
Switch 7 B-R 12
IC1 B-R
2
AM2
EA2 1
B*1: USA
*2: CANADA EA214
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI-177
1996 TERCEL (RM440U)
DTC Normal Source Voltage Drop
CIRCUIT DESCRIPTION
The SRS is equipped with a voltage-increase circuit (DC-DC converter) in the airbag sensor assembly in
case the source voltage drops.
When the battery voltage drops, the voltage-increase circuit (DC-DC converter) functions to increase the
voltage of the SRS to normal voltage.
The diagnosis system malfunction display for this circuit is different to other circuits-when the SRS warning
light remains lit up and the DTC is a normal code, source voltage drop is indicated.
Malfunction in this circuit is not recorded in the airbag sensor assembly and the source voltage returns to
normal, the SRS warning light automatically goes off.
DTC No.DTC Detection ConditionTrouble Area
(Normal)Source voltage drop.
Battery

Airbag sensor assembly
WIRING DIAGRAM
DI4MI-02

DI4MO-01
I05900
Door Lock Control Relay or
Theft Deterrent ECUIgnition Switch

Key Unlock Warning Switch
J/B No.7

POWER Fuse
Door Lock Control Switch
Door Key Lock and Unlock Switches
Engine Room R/B

DOME Fuse
Door Lock Assembly

Door Lock Motor

Door Unlock Detection SwitchDoor Courtesy Switches
Door Lock Assembly

Door Lock Motor

Door Unlock Detection Switch
Door Lock Assembly

Door Lock Motor

Door Unlock
Detection Switch
Door Courtesy Switches DI-192
- DIAGNOSTICSPOWER DOOR LOCK CONTROL SYSTEM
1996 TERCEL (RM440U)
PARTS LOCATION

N12897
EB W-BEngine Room
Relay Block
(JUNCTION CONNECTOR)A
A
2 2Engine Hood
Courtesy Switch
12
LG-B12
IC2
LG-B14
T4 Theft Deterrent ECU
DSWH
E5
W-B DI-246
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
Engine Hood Courtesy Switch Circuit
CIRCUIT DESCRIPTION
The engine hood courtesy switch is built into the engine hood lock assembly and goes on when the engine
hood is opened and goes off when the engine hood is closed.
WIRING DIAGRAM
DI4NE-02

BE4061I00298I09784
1
2 Disconnect
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-247
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check engine hood courtesy switch.
PREPARATION:
(a) Remove engine hood lock assembly.
(b) Disconnect engine hood courtesy switch connector.
CHECK:
Check continuity between terminals 1 and 2 when engine hood
lock is locked and unlocked.
OK:
Engine hood lockTester connectionSpecified condition
LOCK-No continuity
UNLOCK1 - 2Continuity
NG Replace engine hood courtesy switch.
OK
2 Check harness and connector between theft deterrent ECU and switch, switch
and body ground (See page IN-26).
NG Repair or replace harness or connector.
OK
Check and replace theft deterrent ECU
(See
page
IN-26).

P20160
EM1OF-01
P20577
P20290
- ENGINE MECHANICALCYLINDER HEAD
EM-23
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT FRONT EXHAUST PIPE
Remove the 2 bolts and 2 compression springs, and disconnect
the front exhaust pipe.
4. A/T:
DISCONNECT THROTTLE CABLE
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
7. DISCONNECT FUEL HOSE
Remove the union bolt and gaskets, and disconnect the fuel in-
let hose.
NOTICE:
Catch leaking fuel in a container.
8. w/ PS:
REMOVE PS PUMP AND PUMP BRACKET 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.
(c) Remove the 3 bolts and PS pump bracket.

EM9937
EM0JZ-03
P20416
SST
EM9939
EM-30
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE NO.2 ENGINE HANGER
2. REMOVE STUD BOLT FOR CYLINDER HEAD COVER
3. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
4. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202-70010
(b) Remove the spring retainer, valve spring, valve and
spring seat.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in correct order.
(c) Using needle-nose pliers, remove the oil seal.