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.
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.
EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author: Date:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.
If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.
If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS
P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.
Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.
Immediately remove nozzle from tube and reinstall
cap.
Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.
EM-66
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
15. CONNECT ENGINE WIRE HARNESS
Connect these connectors and wires:
Main heated oxygen sensor connector
Oil pressure switch connector
Engine coolant temperature sender gauge
connector
Engine coolant temperature sensor connector
Camshaft position sensor connector
EGR VSV
Fan engine coolant temperature switch connector
A/T only:
Lock-up solenoid connector
A/T only:
Park/Neutral position switch connector
M/T only:
Backup light switch connector
A/T only:
No.2 vehicle speed sensor connector
Ground strap
Throttle position sensor connector
IAC valve connector
Injector connectors
Crankshaft position sensor connector
Knock sensor connector
Starter connector and wire
Generator connector and wire
16. w/ PS:
CONNECT IDLE-UP AIR HOSES TO AIR CONTROL
VA LV E
17. CONNECT SPEEDOMETER CABLE
18. CONNECT HOSES
(a) Connect the brake booster vacuum hose.
(b) Connect the MAP sensor hose.
(c) Connect the heater hoses.
SF199-02
- MFIIDLE AIR CONTROL (IAC) VALVE
MF-33
557 Author: Date:
1996 TERCEL (RM440U)
IDLE AIR CONTROL (IAC) VALVE
ON-VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:
Engine at normal operating temperature
Idle speed set correctly
Transmission in neutral position
(b) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(c) After engine rpm is kept at 900 - 1,300 rpm for 5 seconds,
check that it returns to idle speed.
If the rpm operation is not as specified, check the IAC valve, wir-
ing and ECM.
(d) Remove the SST from the DLC1.
SST 09843-18020
2. INSPECT IAC VALVE RESISTANCE
NOTICE:
ºColdº and ºHotº in the following sentences express the temper-
ature of the coils themselves. ºColdº is from -10°C (14°F) to 50°C
(122°F) and ºHotº is from 50°C (122°F) to 100°C (212°F).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
minal +B and other terminals (RSC, RSO).
Resistance:
Cold17.0 - 24.5 W
Hot21.5 - 28.5 W
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.
LU08A-06
LU1169
Oil Pressure Gauge
Oil Pressure Switch
LU1107
Adhesive
- LUBRICATIONOIL AND FILTER
LU-1
616 Author: Date:
1996 TERCEL (RM440U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the oil quality is visibly poor, replace it.
Oil grade:
API grade or SH Energy-Conserving II or ILSAC multi-
grade engine oil. Recommended viscosity is as
shown in the illustration, with SAE 5W-30 being the
prefferred engine oil.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ºLº and ºFº marks on the dip-
stick.
If low, check for leakage and add oil up to the ºFº mark.
3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL
PRESSURE GAUGE
(a) Remove the bolt and air intake connector.
(b) M/T only
Remove the 3 bolts, release cylinder and tube from the
transaxle.
(c) Remove the oil pressure switch.
(d) Install the oil pressure gauge.
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle speed
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 - 490 kPa (2.5 - 5.0 kgf/cm
2, 36 - 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or eqivalent
(c) Reinstall the oil pressure switch.