Page 43 of 1202
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)
Page 426 of 1202
EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author: Date:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. 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.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)
Page 633 of 1202
IG08E-06
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
SPARK TEST
Replace the camshaft position sensor.
CHECK RESISTANCE OF HIGH-TENSION
CORD (See step 2)
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL
(See step 4) 1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL IGNITER
Resistance: Cold Hot
Secondary
9.3 - 16.0 kW
11.7 - 18.8 kW
CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
(See step 5)
Resistance:Cold Hot
985 - 1,600 W1,265 - 1,890 W
CHECK IGT SIGNAL FROM ECM
(See page
DI-84)
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
(See step 6)
Resistance:Cold
Hot
TRY ANOTHER IGNITERReplace the crankshaft position sensor. Replace the ignition coil. Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
NO
OK OK
OK
OK
OK
OKBAD
BAD
BAD
BAD
BAD
BAD
BAD
Primary
0.67 - 1.05 kW0.85 - 1.23 kW
985 - 1,600 W1,265 - 1,890 W
- IGNITIONIGNITION SYSTEM
IG-1
632 Author: Date:
1996 TERCEL (RM440U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in following sentences express the tem-
perature 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).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high-tension cord from the spark
plug.
(2) Remove the spark plugs.
(3) Install the spark plugs to the high-tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time. If the spark done not occur, do the test as fol-
lows:
Page 634 of 1202
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.
Page 635 of 1202
S06257
16 mm Plug Wrench
IG0152
P20433
P20584
- IGNITIONIGNITION SYSTEM
IG-3
634 Author: Date:
1996 TERCEL (RM440U)
3. INSPECT SPARK PLUGS
(a) Disconnect high-tension cords from spark plugs.
(b) Using a 16 mm plug wrench, remove the spark plug.
(c) Using a spark plug cleaner or wire brush, clean the spark
plug.
If the electrode has traces of wet carbon, allow it to dry and then
clean with a spark plug cleaner.
Air pressure:
Below 588 kPa (6 kgf/cm
2, 85 psi)
Duration: 20 seconds or less
HINT:
If there are traces of oil, remove it with gasoline before using the
spark plug cleaner.
(d) Visually checkthe spark plug for thread damage and insu-
lator damage.
If abnormal, replace the spark plug.
Recommended spark plug:
DENSOK16TR11
NGKBKR5EKB11
(e) Inspect the electrode gap.
Correct electrode gap: 1.1 mm (0.043 in.)
(f) Using a 16 mm plug wrench, remove the spark plug.
Torque: 18 N´m (180 kgf´cm, 13 ft´lbf)
(g) Reconnect the high-tension cords from the ignition coils.
