TOYOTA TERCEL 1996 Service Repair Manual

P21439
2 Revolutions
P20537
Timing Mark
P20552
P20745
P20157
SST
- ENGINE MECHANICALTIMING BELT
EM-19
1996 TERCEL (RM440U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(d) Tighten the No.1 idler pulley bolt.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
(e) Remove the crankshaft pulley bolt.
8. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
9. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 3 bolts.
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-14010, 09330-00021
Torque: 155 N´m (1,550 kgf´cm, 112 ft´lbf)

P20159
P20153
Ground Strap EM-20
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
12. w/ A/C and/or w/ PS:
INSTALL NO.2 CRANKSHAFT PULLEY
Install the No.2 crankshaft pulley with the 4 bolts.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
13. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 4 bolts.
14. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Attach the RH mounting insulator to the mounting bracket
and body, and temporarily install the through bolt, 2 bolts
and nut.
(b) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
Others
64 N´m (650 kgf´cm, 47 ft´lbf)
(c) Connect the ground strap with the bolt.
15. INSTALL GENERATOR DRIVE BELT (See page
CH-2)
16. w/ A/C and/or w/ PS:
INSTALL DRIVE BELT
(See page AC-18 and SR-3)
17. INSTALL RH ENGINE UNDER COVER

EM0JX-05
- ENGINE MECHANICALCYLINDER HEAD
EM-21
442 Author
: Date
:
1996 TERCEL (RM440U)
CYLINDER HEAD
COMPONENTS

EM-22
- ENGINE MECHANICALCYLINDER HEAD
443 Author
: Date
:
1996 TERCEL (RM440U)

P20160
EM1OF-01
P20577
P20290
- ENGINE MECHANICALCYLINDER HEAD
EM-23
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT FRONT EXHAUST PIPE
Remove the 2 bolts and 2 compression springs, and disconnect
the front exhaust pipe.
4. A/T:
DISCONNECT THROTTLE CABLE
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
7. DISCONNECT FUEL HOSE
Remove the union bolt and gaskets, and disconnect the fuel in-
let hose.
NOTICE:
Catch leaking fuel in a container.
8. w/ PS:
REMOVE PS PUMP AND PUMP BRACKET WITHOUT
DISCONNECTING HOSES
(a) Loosen the 2 bolts, and remove the PS drive belt.
(b) Remove the 2 bolts, and disconnect the PS pump from
the engine.
HINT:
Put aside the PS pump, and suspend it.
(c) Remove the 3 bolts and PS pump bracket.

EG0023
EM-24
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. w/ A/C and w/o PS:
REMOVE IDLER PULLEY BRACKET
(a) Loosen the idler pulley mounting nut and adjusting bolt,
and remove the drive belt.
(b) Remove the 3 bolts and idler pulley bracket.
10. REMOVE IGNITION COILS AND SPARK PLUGS
11. DISCONNECT VACUUM HASES
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the 3 vacuum hoses from the throttle body.
(c) Disconnect the vacuum hose from the TVV (to charcoal
canister).
(d) Disconnect the vacuum hose from the TVV (to throttle
body).
(e) Disconnect the vacuum hose from the EGR VSV.
12. REMOVE THROTTLE BODY (See page MF-28)
13. REMOVE EGR PIIPE
Loosen the union nut, and remove the 2 nuts, EGR pipe and
gasket.
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt and disconnect the vacuum modulator.
(b) Remove the 2 nuts, EGR valve, EGR vacuum modulator
with the bracket and gasket.
15. REMOVE EGR VSV AND CAMSHAFT POSITION SEN-
SOR
(a) Disconnect the EGR VSV and camshaft position sensor
connector.
(b) Remove the bbolt and EGR VSV.
(c) Remove the bolt, camshaft position sensor and O-ring.

P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. 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.

P20361
P20532
Shop
Rag
Tape
P20363
P20357
P20364
EM-26
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
22. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, No.2 timing belt cover and gasket.
23. REMOVE GENERATOR DRIVE BELT
Loosen the pivot nut and adjusting bolt, and remove the gener-
ator drive belt.
24. REMOVE NO.3 TIMING BELT COVER FROM NO.1 TIM-
ING BELT COVER
25. SET NO.1 CYLINDER TO TDC/COMPRESSION (See
page EM-12)
26. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
(a) Loosen the mount bolt of the No.1 idler pulley and shift
pulley toward the left as far as it will go and then tempo-
rarily tighten it.
NOTICE:
Be careful not to damage the timing belt.
(b) Remove the timing belt from the camshaft timing pulley.
27. REMOVE NO.2 IDLER PULLEY
Remove the bolt and idler pulley.
NOTICE:

Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift.

Be careful not to drop anything inside the timing belt
cover.

Do not allow the belt to come into contact with oil, wa-
ter or duct.
28. REMOVE CAMSHAFT TIMING PULLEY
Secure the hexagonal portion of the camshaft, and remove the
bolt and pulley.

P20412
Service Bolt Hole
P20409
P20415
Main Gear
Sub-Gear Service
Bolt
- ENGINE MECHANICALCYLINDER HEAD
EM-27
1996 TERCEL (RM440U)
29. REMOVE INTAKE AND EXHAUST CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Set the intake camshaft as shown in the illustration so that
the service bolt holes of the intake camshaft gears are di-
rectly above.
HINT:
This helps to lift the exhaust camshaft levelly and evenly by
pushing No.2 and No.4 cylinder cam lobes of the intake cam-
shaft toward their valve lifters.
(b) Remove the 4 bolts, No.1 and No.2 bearing caps.
(c) Remove the oil seal and housing plug.
(d) Secure the intake camshaft sub-gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm (0.63 - 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub-gear has been eliminated by the above
operation.

Z14275
7
351
48
22
6
P20359
Z14276
P20358
P20417
SST EM-28
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(e) Uniformly loosen and remove the 8 No.3 bearing cap
bolts, in several passes, in the sequence shown.
(f) Remove the 4 bearing caps and intake camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the bearing cap with the 2 bolts.
Then alternately loosen and remove the 2 bearing cap bolts
with the camshaft gear pulled up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(g) Uniformly loosen and remove the 8 No.3 bearing cap
bolts, in several passes, in the sequence shown.
(h) Remove the 4 bearing caps and intake camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the bearing cap with the 2 bolts.
Then alternately loosen and remove the 2 bearing cap bolts
with the camshaft gear pulled up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
30. DISASSEMBLE INTAKE CAMSHAFT
(a) Mount the hexagon head portion of the camshaft in a soft
jaw vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub-gear clockwise, and remove the
service bolt.
SST 09960-10010 (09962-0100, 09963-00500)