1996 TOYOTA TERCEL grommet

IN00U-36
N17080
Filler Cap
Float
Reservoir
 Grommet
Clip
Slotted Spring Pin
: Specified torque
 Non-reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
- INTRODUCTIONHOW TO USE THIS MANUAL
IN-1
1 Author
: Date
:
1996 TERCEL (RM440U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN-16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

P19770
MA00S-13
MA-6
- MAINTENANCEBRAKE
44 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses.

Check for damage.

Check for wear.

Check for deformation.

Check for cracks.

Check for corrosion.

Check for leaks.

Check for bends.

Check for twists.
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS (See page
BR-26)
HINT:
If a squealing or scraping noise comes from the brake during
driving, check the pad wear indicator to see if it is contacting the
disc. If so, the disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS (See
page BR-32)

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

P20175
New
Gasket
FI1654
Fulcrum Length
SST
30 cm
FI4295
CORRECT
WRONG
WRONG Delivery Pipe O-Ring
Grommet
Injector
FI4296
Delivery
Pipe
O-Ring
Grommet
InjectorCylinder Head
- MFIMFI SYSTEM
MF-3
527 Author
: Date
:
1996 TERCEL (RM440U)
(b) When connecting the union bolt on the high pressure pipe
union, observe these procedures:
(1) Always use 2 new gaskets.
(2) Tighten the union bolt by hand.
(3) Tighten the union bolt to the specified torque.
Torque: 29.0 N´m (290 kgf´cm, 22 ft´lbf)
(c) When connecting the flare nut on the high pressure pipe
union, observe these procedures:
(1) Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(2) Using SST, tighten the flare nut to specified torque.
SST 09631-22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(d) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O-ring.
(2) When placing a new O-ring on the injector, take
care not to damage it in any way.
(3) Coat a new O-ring with spindle oil or gasoline be-
fore installing-never use engine, gear or brake oil.
(e) Install the injector in the delivery pipe and cylinder head
as shown in the illustration.

SF0X2-03
MF-18
- MFIINJECTOR
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT VACUUM SEMSING HOSE FROM FUEL
PRESSURE REGULATOR
2. DISCONNECT FUEL RETURN HOSE FROM FUEL RE-
TURN PIPE
NOTICE:
Catch leaking in a container.
3. DISCONNECT FUEL INLET HOSE FROM DELIVERY
PIPE
(a) Disconnect the engine wire clamp from the No. 2 engine
hanger.
(b) Remove the union bolt, 2 gaskets and inlet hose.
4. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the surge tank stay.
(b) Disconnect the 4 injector connectors.
5. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the 2 bolts and delivery pipe together with the 4
injectors.
NOTICE:
Be careful not to drop the injectors when removing the de-
livery pipe.
(b) Pull out the 4 injectors from the delivery pipe.
(c) Remove the 2 spacers and 4 insulators from the cylinder
head.
(d) Remove the O-ring and grommet from each injector.

Z14695
SST (Hose)
SST (Union)
O-Ring
SST
(Clamp)
Vinyl Tube
P19552
TOYOTA Hand-Held Tester
DLC3
FI3211
SST
(Wire)
Connect
FI1676
MF-20
- MFIINJECTOR
1996 TERCEL (RM440U)
(h) Install the grommet and a O-ring to the injector.
(i) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09368-41046
(j) Put the injector into the graduated cylinder.
CAUTION:
Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(k) Remove the fuse cover on the instrument panel.
(l) Connect the TOYOTA hand-held tester to the DLC3.
(m) Turn the ignition switch ON and TOYOTA hand-held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(n) Select the active test mode on the TOYOTA hand-held
tester.
(o) Please refer to the TOYOTA hand-held tester operator's
manual for further details.
(p) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page MF-5).
(q) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842-30070
Volume:
39 - 49 cm
3 (2.4 - 3.0 cu in.) per 15 sec.
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the tester probes of
SST (wire) from the battery and check the fuel leakage
from the injector.
SST 09842-30070
Fuel drop:
1 drop or less per 3 minutes
(b) Disconnect the negative (-) terminal cable from the bat-
tery.
(c) Remove the SST.

SF0X4-05
FI3271
New
O-Ring
New Grommet
P00159
CORRECT
WRONG
InjectorDelivery Pipe GrommetO-Ring
WRONG
P20295
Spacer
Insulator
Connector MF-22
- MFIINJECTOR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to an O-ring, and install it
to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Place the 2 spacers and 4 insulators in position on the cyl-
inder head.
(e) Place the injectors together with the delivery pipe on the
cylinder head.
(f) Check that the injectors rotate smoothly.
HINT:
If the injectors do not rotate smoothly, the probable cause is in-
correct installation of O-rings. Replace the O-rings.
(g) Position the injector connector upward.
(h) Install the 2 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
2. CONNECT ENGINE WIRE
(a) Connect the 4 injector connectors.
(b) Connect the engine wire to the surge tank stay.
3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Install 2 new gaskets and the inlet hose with the union
bolt.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
(b) Connect the engine wire clamp to the No.2 engine hang-
er.
4. CONNECT FUEL RETURN HOSE TO FUEL RETURN
PIPE
5. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR

P20908
CORRECT
WRONG
S06255
P21178
Ohmmeter
S06256
Push
P04690
CORRECT
WRONG IG-2
- IGNITIONIGNITION SYSTEM
633 Author
: Date
:
1996 TERCEL (RM440U)
2. INSPECT HIGH-TENSION CORDS
(a) Disconnect the high-tension cords from the spark plugs.
(1) Disconnect the high-tension cords at the rubber
boot. Do not pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(2) Disconnect the high-tension cords from the clamp.
(b) Disconnect the high-tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high-tension cord at the grommet.
(3) Do not pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside. Do not wipe any of the oil from the grommet after the
high-tension cord is disconnected.
(c) Reconnect the high-tension cords to the ignition coils.
Maximum resistance: 25 kW per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high-tension cord.
(d) Reinstall the high-tension cords.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and distributor cap as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(4) Connect the high-tension cords to the clamp.
(e) Reconnect high-tension cords to spark plugs.