1996 TOYOTA TERCEL oil filter

MA00R-19
MA0659
Upper Lower
- MAINTENANCEENGINE
MA-5
43 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. REPLACE TIMING BELT (See pages EM-12 and
EM-17)
2. INSPECT DRIVE BELTS (See pages CH-2, SR-3 and
AC-18)
3. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty,
damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
First blow from the upper side thoroughly, then blow off
the lower side of the air filter.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE SPARK PLUGS (See page IG-1)
6. REPLACE ENGINE OIL AND OIL FILTER (See page
LU-3)
7. REPLACE ENGINE COOLANT (See page CO-2)
8. INSPECT CHARCOAL CANISTER (See page EC-5)
9. REPLACE GASKET IN FUEL TANK CAP (See page
EC-5)
10. INSPECT FUEL LINES AND CONNECTIONS (See
page EC-5)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for severe
corrosion, leaks or damage.
12. ADJUST VALVE CLEARANCE (See page EM-4)

PP3IP-01
- PREPARATIONENGINE MECHANICAL
PP-5
1996 TERCEL (RM440U)
RECOMMENDED TOOLS
09040-0001 1Hexagon Wrench Set .Oil filter union
09043-50080Bi-hexagon Wrench 8 mm .Cylinder head bolt
09090-04020Engine Sling DeviceFor suspending engine
09200-00010Engine Adjust Kit .
09258-00030Hose Plug Set .Plug for vacuum hose, fuel hose, etc.
09904-00010Expander Set .Intake camshaft snap ring

PP193-01
- PREPARATIONLUBRICATION
PP-19
66 Author
: Date
:
1996 TERCEL (RM440U)
LUBRICATION
SST (Special Service Tools)
09032-00100Oil Pan Seal Cutter
09228-06501Oil Filter Wrench

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

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015

MA0659
Outside
Inside
DI-8
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
YES
2 Is engine cranked ?
NO Proceed to ST-13, ST-28, ST-31 and continue
to troubleshoot.
YES
3 Does engine start ?
NO Go to step 7.
YES
4 Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visual check that the air cleaner element is not excessively dirty
or oily.
HINT:
If necessary, clean the filter with compressed air. First blow from
inside thoroughly, then blow from outside of filter.
NG Repair or replace.
OK
5 Check engine idle speed.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all accessories.
(c) Switch off air conditioning.
(d) Shift transmission into ºNº position.

EM0JQ-06
EM9411
EM9412
P20480
SST
P20478
SST
P20477
12 mm
Hexagon
Wrench EM-70
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
DISASSEMBLY
1. M/T:
REMOVE CLUTCH COVER AND DISC
2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
8. REMOVE WATER PUMP WITH WATER INLET PIPE
9. REMOVE GENERATOR BRACKET
10. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816-30010
11. REMOVE RH ENGINE MOUNTING BRACKET
12. REMOVE OIL FILTER
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
14. REMOVE OIL PUMP AND PRESSURE REGULATOR
VA LV E
15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.

EM9966
P20476
12 mm
Hexagon
Wrench
P00496
Adhesive
P20479
SST
- ENGINE MECHANICALCYLINDER BLOCK
EM-89
1996 TERCEL (RM440U)
Immediately remove nozzle from the tube and rein-
stall cap.
(c) Install the oil seal retainer with the 4 bolts.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
11. INSTALL OIL FILTER UNION
Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
12. INSTALL OIL PUMP AND PRESSURE REGULATOR
VA LV E
13. INSTALL OIL PRESSURE SWITCH
(a) Clean the switch threads and cylinder block switch holes
of any sealer, oil or foreign materials. Remove any oil with
kerosene or gasoline.
(b) Apply adhesive to 2 or 3 threads of the switch end.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(c) Using SST, install the oil pressure switch.
SST 09816-30010
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
14. INSTALL OIL FILTER (See page LU-1)