Toyota Tercel Manual – How to Replace a Catalytic Converter

This Toyota Manual  Will Guide You of How to Replace a Catalytic Converter on a Toyota Tercel

The first thing you can do to replace the catalytic converter in your Toyota Tercel is forget about the cheaper universal fit catalytic converter at the auto parts stores. Although this may seemingly save you money for the part, you’re going to have to buy adapters or figure out how to make that universal fit converter fit like a direct fit converter. A direct fit converter for a Tercel will have a two-point flange on either side and will do just as its label describes: fit directly. In the long run it will save you time, money, and will work better for your Tercel since it was specifically designed for it.

Lift the Toyota Tercel on a car lift all the way up.

Put on the cutting glasses, and light the acetylene torch using a striker. Cut the bolts and nuts from the catalytic converter from the flange(s) on the converter side. This way you will not incur damage to the flanges bolted to the converter flanges. Cut the bolt heads (with the torch) or the nuts flush to the converter flange.

Turn the torch off, switch over to safety glasses, and knock out the bolts from the converter side of the flanges using the hammer and a long stemmed punch. If they do not punch through, you may need to relight the torch and cut into the bolt hole a little deeper.

Remove the old converter.

Pick the old gaskets off of the pipe flanges on both side using a pick or awl.

Clean the surface of the flat part of the pipe flanges on both sides using an angled die grinder with a sanding disk.

Place the new gaskets onto the small pipe outlet protruding from the pipe flanges.

Check the exhaust flow of the new catalytic converter. It will be stamped on the shell or shields of the converter and be easy to see. There will be an arrow pointing in the direction of the exhaust flow or an A and B marking. A would indicate towards the front of the motor, and B would indicate towards the back of the Tercel.

Attach the converter flanges to the pipe flanges and place the bolts into the flanges (in any direction) in this fashion: bolt head with a flat washer through the flanges, then a lock washer and nut.

Tighten the bolts and nuts holding one end with a wrench and tightening with an air ratchet. Tighten each bolt a little bit, switch to the next one, and continue this pattern until all four nuts and bolts have seated the flanges tight together.

Remove tools and lower the Tercel on the lift. Start it up, raise it up again, and check for any possible leaks coming from the flange connections. If so, tighten the bolts some more.

things you’ll need:

Car lift
Acetylene torch
Striker
Safety glasses and cutting glasses
Hammer
Long step punch
Angled die grinder with sanding disk
Pick or awl
Replacement gaskets
Direct fit converter
4 8mm Bolts, 1-1/2? long
4 8mm Flat washers
4 8mm Lock washers
4 8mm Nuts
Air ratchet
Metric hand wrench set

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Toyota Tercel Manual – How to Remove Door Panel

This Toyota Manual  Will Guide You of How to Remove a Toyota Tercel Door Panel

The door panels inside of a fifth generation Toyota Tercel are covering the window regulator, door lock mechanisms, crank handle and wiring for lights inside the door. The only way to add a keyless entry or security system to the Tercel is to remove the door panels. All vehicle door panels are removed in a similar way, but each make/model requires certain steps that, if not done correctly, can break parts of the panel.

Flathead screwdriver (medium to large size)
Phillips head screwdriver (small size)

Open the door and locate the window crank. Pull the end of the handle away from the door and wedge the flathead screwdriver between the crank handle and the door panel. There is a small, C-shaped wire around the base of the crank handle against the door panel. Use the screwdriver to pop the C-shaped wire off of the base.

Use the flat head screwdriver to pry the arm rest of the door up and off. Look under that space and and locate two Phillips screws. Remove them with the Phillips head screwdriver.

Pull the door handle lever out and away from the door. Remove the one Phillips screw. Use the handle end of the screwdriver to hit the door handle lever forward, toward the front of the car. This releases the inside of the door handle from the door.

Pry the bottom edge of the door panel away from the door. There are plastic clips holding the edge of the panel to the door. Pull the door panel until you can hear the clips pop. There are three clips along the bottom edge of the door, three clips along the back edge, and two clips along the front edge.

Lift the door panel up and away from the door. There is one wire connection to unsnap and free the panel from the door. Press down on the connection and slide it away from the door panel. The door panel is now free.

Tips & Warnings

Use a small container to keep all hardware and small parts in while working on the door panel. This makes it easy to find them when replacing the door panel.

Never jerk or pull on the door panel until after double checking that all rods, clips and wires are disconnected.

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