TOYOTA TERCEL 1996 Service Repair Manual

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

EM18V-02
EM-10
- ENGINE MECHANICALIDLE SPEED
431 Author
: Date
:
1996 TERCEL (RM440U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed:
750 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral position)
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

EM0K4-05
- ENGINE MECHANICALTIMING BELT
EM-1 1
432 Author
: Date
:
1996 TERCEL (RM440U)
TIMING BELT
COMPONENTS

EM1OD-01
P20154
Oil Pan
P20153
Ground Strap
P20536
Timing Mark
P20159
EM-12
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. w/ A/C and/or w/ PS:
REMOVE DRIVE BELT
3. REMOVE GENERATOR DRIVE BELT
4. SLIGHTY JACK UP ENGINE
5. SLIGHTLY JACK UP ENGINE
Raise the engine enough to remove the weight from the engine
mounting on the right side.
6. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Remove the bolt and disconnect the ground strap.
(b) Remove the through bolt, 2 bolts, nut and mounting insu-
lator.
7. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, timing belt cover and gasket.
8. 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.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the hole of the camshaft timing pulley on the
side with the 5E mark is aligned with the timing mark of the
No.1 bearing cap.
If not, turn the crankshaft pulley 1 complete revolution (360°).
9. w/ A/C and/or w/ PS:
REMOVE NO.2 CRANKSHAFT PULLEY
Remove the 4 bolts and No.2 crankshaft pulley.

P20158
SST
P20155
SST
P20745
P20559
P20554
- ENGINE MECHANICALTIMING BELT
EM-13
1996 TERCEL (RM440U)
10. REMOVE CRANKSHAFT PULLEY
(a) Using SST, remove the pulley bolt.
SST 09213-14010, 09330-00021
(b) Using SST, remove the pulley.
SST 09950-50010 (09951-05010, 09952-05010,
09953-05020, 09954-05020)
11. REMOVE NO.3 TIMING BELT COVER
12. REMOVE NO.1 TIMING BELT COVER
Remove the 3 bolts, timing belt cover and gasket.
13. REMOVE TIMING BELT GUIDE
14. REMOVE TIMING BELT
HINT:
When re-using timing belt:
Draw a direction arrow on the timing belt (in direction of engine
revolution), and place matchmarks on the timing belt and pul-
leys as shown in the illustration.
(a) Remove the tension spring.

P20553
P20368
SST
P20741
EM-14
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
(b) Loosen the No.1 idler pulley bolt and push it left as far as
it will go and then temporarily tighten it.
(c) Remove the timing belt.
15. REMOVE CAMSHAFT TIMING PULLEY
Using SST, remove the bolt and timing pulley.
SST 09960-10010 (09962-01000, 09963-01000)
16. REMOVE NO.1 IDLER PULLEY
17. REMOVE NO.2 IDLER PULLEY
18. REMOVE CRANKSHAFT TIMING PULLEY
If the timing pulley cannot be removed by hand, use a plastic-
faced hammer.
NOTICE:
Do not pry the rotor part of the pulley with the screwdriver.

EM0K6-01
EM0126
No!
P20576
EM3385
- ENGINE MECHANICALTIMING BELT
EM-15
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:

Do not bend, twist or turn the timing belt inside out.

Do not allow the timing belt to come into contact with
oil, water or steam.

Do not utilize timing belt tension when installing or re-
moving the mounting bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustration, check these
points:
(a) Premature parting

Check for proper installation.

Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft or oil pump is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check the tim-
ing belt cover for damage and check gasket has been
installed correctly and for foreign material on the pulley
teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.

P20528
38.4 mm EM-16
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
3. INSPECT TENSION SPRING
(a) Measure the free length of tension spring.
Free length:
38.4 mm (1.512 in.)
If the free length is not as specified, replace the tension spring.
(b) Measure the tension of the tension spring at the specified
installed length.
Installed tension (at 47.4 mm (1.866 in.)):
32 N (3.3 kgf, 7.3 lbf)
If the installed tension is not as specified, replace the tension
spring.

EM1OE-01
P20743
P20742
P20744
P20390SST
P20915
Timing Mark
SST
Installation
Mark
- ENGINE MECHANICALTIMING BELT
EM-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the rotor side of the
crankshaft position sensor inward.
2. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING
(a) Install the tension spring to the idler pulley.
(b) Align the bracket pin hole with the pivot pin.
(c) Install the idler pulley with the bolt. Do not tighten the bolt
yet.
(d) Pry the idler pulley toward the left as far as it will go and
temporarily tighten the bolt.
(e) Check that the idler pulley moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
(b) Check that the idler pulley moves smoothly.
4. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove on
the pulley side with the 5E mark, and slide on the timing
pulley.
(b) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, align the hole of the camshaft timing pulley on
the side with the 5E mark with the timing mark of the bear-
ing cap.
SST 09960-10010 (09962-01000, 09963-01000)

P20556
P20558
P20535
Tension
P20555
EM-18
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
(b) Using the crankshaft pulley bolt, turn the crankshaft and
align the timing marks of the crankshaft timing pulley and
oil pump body.
6. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
HINT:
When re-using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
(a) Remove any oil or water on the pulleys, and keep them
clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
7. CHECK VALVE TIMING
(a) Loosen the No.1 idler pulley mount bolt, until the pulley is
moved slightly by the spring tension.