MA003-28
MA-4
- MAINTENANCEUNDER HOOD
42 Author: Date:
1996 TERCEL (RM440U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE AND CLUTCH FLUID LEVELS
(a) Check that the brake fluid level is near the upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within ±5 mm (0.20 in.). of the reservoir hem.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick and check
that the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F).
If the If the level is at the low side, add fluid.
NOTICE:
Do not overfill.
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.
P21589
SA3501
Grease
RA0489
MA-8
- MAINTENANCECHASSIS
46 Author: Date:
1996 TERCEL (RM440U)
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
(a) M/T:
Replace the transaxle oil (See page MX-6).
(b) A/T:
Replace the transaxle fluid.
(A132L: See page AX-2)
(A242L: See page AX-2)
8. REPACK REAR WHEEL BEARINGS
(a) Change rear wheel bearing grease.
(1) Remove the hub and inner and outer bearings.
Clean in solvent and inspect the bearings for dam-
age.
(2) Pack the bearings and axle hubs with multipurpose
grease.
Wheel bearing grease grade:
Lithium base multipurpose grease (NLGI No.2)
(b) Install inner bearing and new oil seal.
(c) Install the hub and adjust the wheel bearing preload (See
page SA-42).
Preload (while turning):
Add frictional force plus
0 - 11.8 N (0 - 1.2 kgf, 0 - 2.6 lbf)
PP196-04
PP-22
- PREPARATIONLUBRICATION
1996 TERCEL (RM440U)
LUBRICANT
ItemCapacityClassification
Engine oil
Drain and refill w/o Oil filter change
w/ Oil filter change
Dry fill
2.6 liters (2.7 US qts, 2.3 lmp. qts)
2.8 liters (3.0 US qts, 2.5 lmp. qts)
3.7 liters (3.9 US qts, 3.3 lmp. qts)
API grade SH, Energy-Conserving II multigrade
engine oil or ILSAC multigrade engine oil and
recommended viscosity oil
- DIAGNOSTICSENGINE
DI-63
1996 TERCEL (RM440U)
DTC P0340 Camshaft Position Sensor Circuit
Malfunction
CIRCUIT DESCRIPTION
Camshaft position sensor (G signal) consist of signal plate and pickup coil.
The G signal plate has one tooth on its outer circumference and is mounted on the exhaust camshaft.
When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change,
causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil.
The NE signal plate has 34 teeth and is mounted on the crankshaft. The NE signal sensor generates 34
signals for every engine revolution. The ECM detects the standard crankshaft angle based on the G signals
and the actual crankshaft angle and the engine speed by the NE signals.
DTC No.DTC Detection ConditionTrouble Area
P0340
No camshaft position sensor signal to ECM during cranking
(2 trip detection logic)Open or short in camshaft position sensor circuit
Camshaft position sensor
P0340No camshaft position sensor signal to ECM with engine speed
600 rpm or more
Camshaft osition sensor
Starter
ECM
WIRING DIAGRAM
Refer to DI-60.
INSPECTION PROCEDURE
1 Check resistance of camshaft position sensor (See page IG-1).
Reference: INSPECTION USING OSCILLOSCOPE
Refer to page DI-60.
NG Replace camshaft position sensor.
OK
2 Check for open and short in harness and connector between ECM and camshaft
position sensor (See page IN-26).
NG Repair or replace harness or connector.
OK
DI014-23
BR3583
BR3582F00010
RotorSpeed Sensor
Magnet
To ECU
+V
-VHigh Speed
Low Speed
CoilNS
0 DI-128
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
1996 TERCEL (RM440U)
DTC 31, 32, 33, 34 Speed Sensor Circuit
CIRCUIT DESCRIPTION
The speed sensor detects wheel speed and sends the ap-
propriate signals to the ECU. These signals are used to control
the ABS system. The front and rear rotors each have 48 serra-
tions.
When the rotors rotate, the magnetic field emitted by the perma-
nent magnet in the speed sensor generates an AC voltage.
Since the frequency of this AC voltage changes in direct propor-
tion to the speed of the rotors, the frequency is used by the ECU
to detect the speed of each wheel.
DTC No.DTC Detecting ConditionTrouble Area
31, 32, 33, 34
Detection of any of conditions 1 through 3:
1. At vehicle speed of 10 km/h (6 mph) or more, pulses are
not input for 5 sec.
2. Momentary interruption of the speed sensor signal oc-
curs at least 7 times in the time between switching the
ignition switch ON and switching it OFF
3. Abnormal fluctuation of speed sensor signals with the
vehicle speed 20 km/h (12 mph) or more
Right front, left front, right rear or left rear speed sensor
Open or short in each speed sensor circuit
ECU
HINT:
DTC 31 is for the right front speed sensor.
DTC 32 is for the left front speed sensor.
DTC 33 is for the right rear speed sensor.
DTC 34 is for the left rear speed sensor.
Fail safe function:
If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS control (solenoid) relay and
prohibits ABS control.
DI983-01
LU08B-04
P20919
SST
LU0490
SST
- LUBRICATIONOIL AND FILTER
LU-3
1996 TERCEL (RM440U)
REPLACEMENT
CAUTION:
Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Ade-
quate means of skin protection and washing facilities
should be provided.
Care should be taken, therefore, when changing en-
gine oil, to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves, that cannot be penetrated by oil,
should be worn. Wash your skin throughly with soap
and water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline, thinners, or
solvents.
In order to preserve the environment, used oil must
be disposed of only at designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-06501
(b) Clean the filter contact surface on the filter mounting.
(c) Lubricate the filter rubber gasket with engine oil.
(d) Tighten filter until the gasket contacts seat of the filter
mounting. Then using SST, give it an additional 3/4 turn
to seat the filter.
SST 09228-06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Fill the engine with new oil.
Oil grade: See step 1 in oil oressure check
Oil capacity:
Drain and refill w/ Oil filter change
w/o Oil filter change2.8 liters (3.0 US qts, 2.5 lmp. qts)
2.6 liters (2.7 US qts, 2.3 lmp. qts)
Dry fill3.7 liters (3.9 US qts, 3.3 lmp. qts)
ST084-06
Z07247
York Side
Terminal
Served PartCut
York Side
Terminal
Served Part
Z07248
Width Thickness
Z07249
Weld Side
Z07250
3.3 mm
7 mm
Z03208
SST
- STARTINGSTARTER (Planetary Type)
ST-23
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE BRUSHES
HINT:
Only the 2 brushes of the positive (+) side (york side) are ex-
changeable, negative (-) side brush must be changed in the
body with the brush holder.
(a) Cut the brush lead wire at the terminal side.
(b) Shave welded mark of the brush lead wire with sandpaper
etc., and correct the terminal to the specified.
NOTICE:
Part to be shaved is so narrow that you should take care not
to harm the field coil.
Specified width: 5.0 mm (0.197 in.)
Specified thickness: 1.5 - 1.7 mm (0.059 - 0.067 in.)
(c) Press the plate of the supply brush on the welded side of
the terminal lead wire.
(d) Solder the pressed part, and shave to the specified mea-
sures with the sandpaper etc.
Specified width: 7.0 mm (0.276 in.)
Specified thickness: 3.3 mm (0.130 in.)
Heat the soldered part well, and fiow the solder in-
side the plate, take care not to flow it into flow it into
the inside lead wire.
Take care not to flow the solder into field.
2. REPLACE CENTER BEARING
(a) Using SST and press, press out the center bearing.
SST 09221-25026 (09221-00090)
SR4254
N00345
R14426
SST
Oil Seal
W04041
SST
5 mm
Oil Seal SR-40
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
4. IF NECESSARY, REPLACE BUSHING
(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the rack housing.
(b) Ensure that the hole of the rack housing is not clogged
with grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(c) Coat inside a new bushing with molybdenum disulfide lith-
ium base grease.
(d) Install the bushing into the rack housing, making sure to
align into the 3 holes.
5. IF NECESSARY, REPLACE OIL SEAL
(a) Using SST, press out the oil seal from the pinion bearing
adjusting screw.
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
(b) Coat a new oil seal lip with molybdenum disulfide lithium
base grease.
(c) Using SST, press in the oil seal with it is protruding 5 mm
(0.21 in.).
SST 09950-60010 (09951-00240),
09950-70010 (09951-07100)
NOTICE:
Make sure to install the oil seal facing the correct direction.