Toyota Tercel 1984-1994 Repair Guide

Engine

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REMOVAL & INSTALLATION



See Figures 1 through 23

All wires, hoses and necessary components should be marked before removal for correct installation. Review the complete service procedure before continuing.

1984-1986 Sedans and All Wagons
  1. Disconnect the negative battery cable.
  2.  
  3. With the help of an assistant, remove the hood (mark hood hinges for correct installation) from the car. Be careful not to damage the paint finish.
  4.  
  5. Drain the engine coolant.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Drain the engine oil and transmission fluids.
  2.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. Remove the battery and the battery carrier.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the radiator.
  6.  
  7. On air conditioned vehicles, remove the A/C condenser fan.
  8.  
  9. If so equipped, remove the power steering pump from its mounts and lay it aside. Leave the hoses attached. The pump may be hung on a piece of stiff wire to be kept out of the way.
  10.  
  11. Remove the air conditioning compressor, if applicable, from its mounts and position out of the way. DO NOT loosen any hoses or fittings-simply move the compressor out of the way. It may be hung from a piece of stiff wire.
  12.  
  13. Label and remove all wiring running to the motor. Be careful when unhooking wiring connectors; many have locking devices which must be released.
  14.  
  15. Disconnect the accelerator cable.
  16.  
  17. Disconnect the throttle linkage on Automatic Transaxle (A/T) cars.
  18.  
  19. Label and disconnect vacuum hoses. Make sure your labels contain accurate information for reconnecting both ends of the hose. Make sure the labels will stay on the hoses.
  20.  
  21. Disconnect the fuel lines.
  22.  

Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Remove the the Air Suction (AS) filter from the engine block.
  2.  
  3. Remove the transaxle upper mount bolts.
  4.  



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Fig. Fig. 1: Transaxle upper mounting bolt locations; 3A and 3A-C engines



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Fig. Fig. 2: Removing the engine stiffener plate; 3A and 3A-C engines



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Fig. Fig. 3: Disconnecting the engine mounting absorber from the crossmember; 3A and 3A-C engines



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Fig. Fig. 4: Its a good idea to wrap both drive shaft boots with shop towels before removing the engine; 3A and 3A-C engines

  1. Raise the vehicle. Be sure that the vehicle is supported securely.
  2.  
  3. Remove the exhaust front pipe.
  4.  
  5. On A/T equipped cars, remove the cooler lines.
  6.  
  7. On Manual Transaxle (M/T) cars, disconnect the clutch release cable.
  8.  
  9. Remove the stiffener plates.
  10.  
  11. Remove the engine mounting absorber.
  12.  
  13. Remove the two bolts holding the engine mounting insulator to the crossmember.
  14.  
  15. On A/T cars, remove the torque converter cover and the converter mounting bolts.
  16.  
  17. Wrap both driveshaft boots with a shop towel.
  18.  
  19. Place a jack under the transaxle.
  20.  
  21. Remove the transaxle lower mounting bolts. Hold the starter during this procedure.
  22.  
  23. Attach a engine hoist chain to the lift brackets of the engine.
  24.  
  25. Remove the engine from the vehicle slowly and carefully. Make sure the engine is clear of all wiring and hoses.
  26.  

To install:
  1. Apply multi-purpose grease to the input shaft and the front of the release bearing on M/T cars. On A/T cars, apply multi-purpose grease to the center hub of the torque converter.
  2.  
  3. Install a guide pin on A/T cars.
  4.  
  5. Lower the engine into the engine compartment. On A/T models, align the guide pin with one of the drive plate holes. Connect the engine to the transaxle.
  6.  
  7. Install the starter and the transaxle lower mounting bolts. Remove the chain hoist.
  8.  
  9. Remove the guide pin and install the torque converter mounting bolts on A/T models.
  10.  
  11. Take the jack out from under the transaxle.
  12.  
  13. Install the engine mounting bolts.
  14.  
  15. Install the mounting absorber.
  16.  
  17. Install the stiffener plates.
  18.  
  19. On M/T models, connect the clutch release cable. On A/T models, install the cooler pipes.
  20.  
  21. Install the exhaust front pipe.
  22.  
  23. Lower the vehicle.
  24.  
  25. Install the transaxle upper mounting bolts.
  26.  
  27. Install the AS filter to the engine block.
  28.  
  29. Paying close attention to proper routing and labeling, connect the wiring and vacuum hoses to the engine.
  30.  
  31. Connect the throttle and accelerator cables to the engine.
  32.  
  33. Depending on equipment, reinstall the power steering pump and/or the air conditioning compressor. Tighten the mounting bolts enough to hold the unit in place but no more; the belts will be installed later.
  34.  
  35. Connect the heater hoses.
  36.  
  37. Install the drive belts (alternator, power steering and air conditioning) and make sure the belts are properly seated on the pulleys. Adjust the belts to the correct tension and tighten the bolts.
  38.  
  39. Connect the fuel hoses. Use new clamps if necessary.
  40.  
  41. Install the radiator and fan.
  42.  
  43. Remove the shop towels on the driveshaft boots.
  44.  
  45. Install the air cleaner assembly onto the carburetor.
  46.  
  47. Install the washer and radiator reserve tanks.
  48.  
  49. Have an assistant help install the hood. Make sure its is properly adjusted and secure.
  50.  
  51. Refill the transmission with the proper fluid.
  52.  
  53. Refill the engine oil to the proper level.
  54.  
  55. Refill the engine coolant with the proper amount of fluid.
  56.  
  57. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  58.  
  59. Check all fluid levels. Bleed systems as necessary. Make all necessary adjustments. Start the engine. Check for any fluid leaks, road test the vehicle for proper operation.
  60.  



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Fig. Fig. 5: Support the transaxle with a floor jack; 3A and 3A-C engines



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Fig. Fig. 6: Transaxle lower mounting bolt locations; 3A and 3A-C engines



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Fig. Fig. 7: Lift the engine out of the vehicle slowly and carefully. Protect the fenders from damage by placing fender covers over them; 3A and 3A-C engines

1987-1994 Sedans

CAUTION
On models equipped with a Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

  1. Remove the battery.
  2.  
  3. Drain the cooling system and save the coolant for reuse.
  4.  
  5. Remove the washer and radiator reserve tanks.
  6.  
  7. Drain the engine oil and the transmission fluids.
  8.  
  9. With the help of an assistant, remove the hood (mark hood hinges for correct installation) from the car. Be careful not to damage the paint finish.
  10.  
  11. Remove the air cleaner assembly from the engine.
  12.  
  13. Remove the engine under covers.
  14.  
  15. Remove the radiator.
  16.  
  17. Disconnect the upper radiator hose from the engine and remove the overflow hose.
  18.  
  19. Remove the coolant hose at the cylinder head rear coolant pipe and remove the coolant hose at the thermostat housing.
  20.  
  21. Remove all heater hoses.
  22.  
  23. Remove the cruise control actuator, if equipped.
  24.  
  25. Disconnect the accelerator and throttle cables.
  26.  
  27. Remove the fuel hoses.
  28.  

On 3E-E engines, the fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Remove the charcoal canister.
  2.  
  3. Loosen the adjustor(s) and remove the alternator belt, the power steering and/or air conditioning drive belts depending on equipment.
  4.  
  5. Label and remove all wiring running to the motor. Be careful when unhooking wiring connectors; many have locking devices which must be released.
  6.  
  7. Label and disconnect vacuum hoses. Make sure your labels contain accurate information for reconnecting both ends of the hose. Make sure the labels will stay on the hoses.
  8.  



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Fig. Fig. 8: Removing the cruise control actuator on 3E and 3E-E engines



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Fig. Fig. 9: When disconnecting fuel lines on 3E-E engines, keep in mind that a small amount of fuel pressure may be left even after following the pressure relief procedure. Loosen the fuel lines slowly



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Fig. Fig. 10: Disconnect the heater hoses at these points; 3E and 3E-E engines

  1. Disconnect the wiring at the transaxle.
  2.  
  3. Disconnect the speedometer cable at the transaxle.
  4.  
  5. Disconnect the transaxle control cables.
  6.  
  7. Remove the clutch release cylinder and selecting bell crank on manual transaxle cars.
  8.  
  9. Remove the intake manifold stay, if equipped.
  10.  
  11. Remove the Vacuum Switching Valve (VSV).
  12.  
  13. If so equipped, remove the power steering pump from its mounts and lay it aside. Leave the hoses attached. The pump may be hung on a piece of stiff wire to be kept out of the way.
  14.  
  15. Remove the air conditioning compressor, if applicable, from its mounts and position out of the way. DO NOT loosen any hoses or fittings-simply move the compressor out of the way. It may be hung from a piece of stiff wire.
  16.  
  17. Disconnect the exhaust pipe from the manifold. Be ready to deal with rusty hardware.
  18.  
  19. Disconnect the air hose at the converter pipe, if so equipped.
  20.  
  21. Disconnect the steering knuckles at the lower control arms.
  22.  
  23. Have an assistant step on the brake pedal while you loosen the nuts and bolts holding the driveshafts to the transaxle.
  24.  
  25. Remove the driveshafts.
  26.  
  27. Install the engine hoist to the lifting brackets on the engine. Keep the wiring harness in front of the chain. Draw tension on the hoist enough to support the engine but no more. Double check the hoist attachments before proceeding.
  28.  
  29. Disconnect the front and rear mounts at the crossmember by first removing the two bolt covers and removing the two bolts at each mount. Remove the center crossmember under the engine.
  30.  
  31. Remove the through-bolt to the right side engine mount.
  32.  
  33. Remove the left side transaxle mount bolt and remove the mount.
  34.  
  35. Lift the engine and transaxle assembly out of the engine compartment, proceeding slowly and watching for any interference. Clear the battery carrier support while lowering the transaxle. Pay particular attention to not damaging the right side engine mount, the power steering housing and the neutral safety switch. Make sure wiring, hoses and cables are clear of the engine.
  36.  
  37. Support the engine assembly on a suitable stand; do not allow it to remain on the hoist for any length of time.
  38.  
  39. Remove the transaxle from the engine.
  40.  

To install:
  1. Install the transaxle to the engine.
  2.  
  3. Lower the engine and transaxle into the car, paying attention to clearance and proper position. Raise and lower the vehicle as necessary to perform each service operation.
  4.  
  5. Install the left side transaxle mount and its bolt(s).
  6.  
  7. Install and tighten the right side through-bolt for the motor mount.
  8.  
  9. Connect the front and rear mountings for the crossmember and reinstall the bolt covers.
  10.  
  11. When the engine is securely mounted within the car, the lifting devices may be removed.
  12.  
  13. Connect the driveshafts to the transaxle. Install the driveshaft assembly to the rear differential on four wheel drive vehicles.
  14.  
  15. Reconnect the steering knuckles to the lower control arms.
  16.  
  17. Connect the exhaust pipe.
  18.  
  19. Depending on equipment, reinstall the power steering pump and/or the air conditioning compressor. Tighten the mounting bolts enough to hold the unit in place but no more; the belts will be installed later.
  20.  
  21. Install the Vacuum Switching Valve (VSV).
  22.  
  23. Install the intake manifold stay.
  24.  
  25. Install the selecting bell crank and clutch release cylinder on manual transaxle cars.
  26.  
  27. Connect the transaxle control cables.
  28.  
  29. Reconnect the speedometer cable at the transaxle.
  30.  
  31. Paying close attention to proper routing and labeling, connect the wiring and vacuum hoses to the engine.
  32.  
  33. Connect the heater hoses.
  34.  
  35. Install the drive belts (alternator, power steering and air conditioning) and make sure the belts are properly seated on the pulleys. Adjust the belts to the correct tension and tighten the bolts.
  36.  
  37. Install the charcoal canister.
  38.  
  39. Connect the fuel hoses. Use new clamps if necessary.
  40.  
  41. Connect the accelerator and throttle cables.
  42.  
  43. Install the cruise control actuator.
  44.  
  45. Install the radiator.
  46.  
  47. Attach the coolant hoses: at the thermostat housing, at the cylinder head rear pipe, at the overflow, and at the outlet for the upper hose. Insure that the hoses are firmly over the ports; use new clamps wherever needed.
  48.  
  49. Install the air cleaner assembly.
  50.  
  51. Install the washer and radiator reserve tanks.
  52.  
  53. Have an assistant help install the hood. Make sure its is properly adjusted and secure.
  54.  
  55. Refill the transmission with the proper fluid.
  56.  
  57. Refill the engine oil to the proper level.
  58.  
  59. Refill the engine coolant with the proper amount of fluid.
  60.  
  61. Install the engine under covers.
  62.  
  63. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  64.  
  65. Check all fluid levels. Bleed systems as necessary. Make all necessary adjustments. Start the engine. Check for any fluid leaks, road test the vehicle for proper operation.
  66.  



Click image to see an enlarged view

Fig. Fig. 11: The transmission control cables are retained with clips; 3E and 3E-E engines



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Fig. Fig. 12: The speedometer cable can be loosened from the transaxle with a pair of slip-joint pliers; 3E and 3E-E engines



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Fig. Fig. 13: It is not necessary to remove the air conditioning compressor when removing the engine. Simply hang it aside with a piece of stiff wire



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Fig. Fig. 14: On 3E and 3E-E engines, the exhaust pipe stay must be disconnected from the engine block



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Fig. Fig. 15: The hoist should be securely attached to the engine hangers



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Fig. Fig. 16: Removing the two bolts from the rear mounting insulator; 3E and 3E-E engines



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Fig. Fig. 17: The rear mounting insulator can be removed after these four bolts have been removed; 3E and 3E-E engines



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Fig. Fig. 18: Removing the front mounting insulator through-bolt; 3E and 3E-E engines



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Fig. Fig. 19: Removing the right hand mounting insulator through-bolt; 3E and 3E-E engines



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Fig. Fig. 20: Remove the remaining right hand insulator attaching bolts and insulator; 3E and 3E-E engines



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Fig. Fig. 21: Be sure remove the ground strap from the left hand mounting bracket; 3E and 3E-E engines



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Fig. Fig. 22: Remove the remaining bolts from the left hand mounting bracket, then remove it from the engine; 3E and 3E-E engines



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Fig. Fig. 23: Lift the engine out of the vehicle slowly and carefully. Protect the fenders by placing fender covers over them

 
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