1996 TOYOTA TERCEL thermostat

IN-38
- INTRODUCTIONTERMS
1996 TERCEL (RM440U) TCM
Transmission Control ModuleTransmission ECU, ECT ECU
TPThrottle PositionThrottle Position
TRTransmission Range-
TVVThermal Vacuum ValveBimetallic Vacuum Switching Valve (BVSV)
Thermostatic Vacuum Switching Valve (TVSV)
TWCThree-W ay Catalytic Converter
Three-W ay Catalytic (TWC)
Manifold Converter
CC
RO
TWC+OCThree-W ay + Oxidation Catalytic ConverterCCR + CCo
VA FVolume Air FlowAir Flow Meter
VRVoltage RegulatorVoltage Regulator
VSSVehicle Speed SensorVehicle Speed Sensor
WOTWide Open ThrottleFull Throttle
WU-OCWarm Up Oxidation Catalytic Converter-
WU-TWCWarm Up Three-Way Catalytic Converter-
3GRThird Gear-
4GRFourth Gear-

SS0N9-04
- SERVICE SPECIFICATIONSCOOLING
SS-13
143 Author
: Date
:
1996 TERCEL (RM440U)
COOLING
SERVICE DATA
ThermostatValve opening temperature
Valve lift at 95°C (203°F)80 - 84°C (176 - 183°F)
8 mm (0.31 in.) or more
Radiator capRelief valve opening pressure STD
Minimum74 - 103 kPa (0.75 - 1.05 kgf/cm2, 10.7 - 14.9 psi)
59 kPa (0.6 kgf/cm2, 8.5 psi)
No. 1 electric
cooling fanRotating amperage M/T
A/T5.7 - 7.7 A
8.6 - 11.6 A
No. 2 electric
cooling fanRotating amperage6.4 - 7.4 A

DI-32
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0116 Engine Coolant Temp. Circuit Range/
Performance Problem
CIRCUIT DESCRIPTION
Refer to Engine Coolant Temp. Circuit Malfunction on page DI-28.
DTC No.DTC Detection ConditionTrouble Area
P0116
20 min. or more after the engine starts, engine coolant
temp. sensor value is 40°C (104°F) or less (2 trip detection
logic)
Engine coolant temp. sensor

Cooling system
INSPECTION PROCEDURE
HINT:
If DTC P0115 and P0116 are output Simultaneously, engine coolant temperature sensor circuit may be open.
Perform troubleshooting of DTC P0115 first.
1 Are there any other codes (besides DTC P0116) being output?
YES Go to relevant DTC chart.
NO
2 Check thermostat (See page CO-10).
NG Replace thermostat.
OK
Replace engine coolant temp. sensor.
DI1E7-08

CO0HW-04
CO-8
- COOLINGTHERMOSTAT
588 Author
: Date
:
1996 TERCEL (RM440U)
THERMOSTAT
COMPONENTS

CO0HX-01
- COOLINGTHERMOSTAT
CO-9
1996 TERCEL (RM440U)
REMOVAL
NOTICE:
Do not remove the thermostat unless absolutely necessary.
HINT:
Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency.
1. REMOVE AIR CLEANER INLET
2. DRAIN ENGINE COOLANT
3. REMOVE WATER INLET AND THERMOSTAT
(a) Remove the 2 nuts, water inlet and thermostat from the water inlet housing.
(b) Remove the gasket from the thermostat.

CO0HY-03
CO1230
CO1234
CO1233
Valve Lift CO-10
- COOLINGTHERMOSTAT
1996 TERCEL (RM440U)
INSPECTION
INSPECT THERMOSTAT
HINT:
The thermostat is numbered with the valve opening tempera-
ture.
(a) Immerse the thermostat in water, and gradually heat the
water.
(b) Check the valve opening temperature.
Valve opening temperature: 80 - 84°C (176 - 183°F)
If the valve opening temperature is not as specified, replace the
thermostat.
(c) Check the valve lift.
Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F)
If the valve lift is not as specified, replace the thermostat.
(d) Check that the valve is fully closed when the thermostat
is at low temperatures (below 40°C (104°F)).
If not closed, replace the thermostat.

CO0HZ-03
CO1225
Jiggle Valve
Protrusion
- COOLINGTHERMOSTAT
CO-1 1
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE THERMOSTAT IN WATER INLET
(a) Place a new gasket onto the thermostat.
(b) Align the thermostat jiggle valve with the protrusion of the
water inlet, and insert the thermostat in the water inlet.
2. INSTALL WATER INLET
Install the water inlet with the 2 nuts.
Torque: 5.0 N´m (50 kgf´cm, 43 in.´lbf)
3. INSTALL AIR CLEANER INLET
4. REFILL WITH ENGINE COOLANT
5. START ENGINE AND CHECK FOR LEAKS