TOYOTA TERCEL 1996 Service Repair Manual

SS00F-01
V06821
Mark
Mark Class
Class
Hexagon head
bolt
Bolt
head No.4-
5-
6-
7-
8-
9-
10-
11 -4T
5T
6T
7T
8T
9T
10T
11 T
No mark
No mark Hexagon
flange bolt
w/ washer
hexagon bolt4T
4T
5T
6T
7T
8T Hexagon head
bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon head
bolt
Hexagon head
bolt2
Protruding
lines
2
Protruding
lines
3
Protruding
lines
4
Protruding
linesHexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Hexagon
flange bolt
w/ washer
hexagon bolt
Stud bolt
Welded bolt4
Protruding
lines
5
Protruding
lines
6
Protruding
lines
No mark
Grooved9T
10T
11 T
4T
6T
4T
- SERVICE SPECIFICATIONSSTANDARD BOLT
SS-1
131 Author
: Date
:
1996 TERCEL (RM440U)
STANDARD BOLT
HOW TO DETERMINE BOLT STRENGTH

SS00G-01
V00079
ClassDiameter
mmPitch
mmSpecified torque
Hexagon head bolt
Hexagon flange bolt
N´m kgf´cm
ft´lbf N´mkgf´cm
ft´lbf
in.´lbf
in.´lbf
in.´lbfin.´lbf
in.´lbf
in.´lbf SS-2
- SERVICE SPECIFICATIONSSTANDARD BOLT
1996 TERCEL (RM440U)
SPECIFIED TORQUE FOR STANDARD BOLTS

SS0N3-01
- SERVICE SPECIFICATIONSMAINTENANCE
SS-3
133 Author
: Date
:
1996 TERCEL (RM440U)
MAINTENANCE
SERVICE DATA
ChassisBall joint
Vertical play Maximum
0 mm (0 in.)

SS0N4-01
SS-4
- SERVICE SPECIFICATIONSMAINTENANCE
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Front seat x Body3737527

SS0N5-03
- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-5
135 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,275 kPa (13.0 kgf/cm2, 185 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) No. 02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
340.15 - 0.25 mm (0.006 - 0.010 in.)
0.31 - 0.41 mm (0.012 - 0.016 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC110° BTDC @ idle
Idle speed-750 ± 50 rpm
Idler pulley tension
springFree length
Installed load at 47.4 mm (1.866 in.)38.4 mm (1.512 in.)
32 N (3.3 kgf, 7.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve guide bore diameter STD
O/S 0.05
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
11.000 - 11.027 mm (0.4331 - 0.4342 in.)
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
30°, 45°, 60°, 75°
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 - 6.030 mm (0.2366 - 0.2374 in.)
11.048 - 11.059 mm (0.4350 - 0.4354 in.)
11.098 - 11.109 mm (0.4369 - 0.4374 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum93.45 mm (3.6791 in.)
93.89 mm (3.6965 in.)
92.95 mm (3.6594 in.)
93.39 mm (3.6768 in.)
44.5°
5.970 - 5.985 mm (0.2350 - 0.2356 in.)
5.965 - 5.980 mm (0.2348 - 0.2354 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 - 1.2 mm (0.031 - 0.047 in.)
0.5 mm (0.020 in.)

SS-6
- SERVICE SPECIFICATIONSENGINE MECHANICAL
136 Author
: Date
:
1996 TERCEL (RM440U) Valve spring
Deviation Maximum
Free length
Installed tension at 31.8 mm (1.252 in.)2.0 mm (0.079 in.)
53.58 mm (2.1094 in.)
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
CamshaftThrust clearance STD
Maximum
Cam lobe height STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter Exhaust No. 1
Others
Journal oil clearance STD
Maximum
Circle runout
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.045 - 0.100 mm (0.0018 - 0.0039 in.)
0.12 mm (0.0047 in.)
41.514 - 41.614 mm (1.6344 - 1.6383 in.)
41.011 - 41.111 mm (1.6146 - 1.6185 in.)
41.35 mm (1.6279 in.)
40.85 mm (1.6083 in.)
24.949 - 24.965 mm (0.9822 - 0.9829 in.)
22.949 - 22.965 mm (0.9035 - 0.9041 in.)
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
0.10 mm (0.0039 in.)
0.04 mm (0.0016 in.)
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0118 in.)
22.5 - 22.9 mm (0.886 - 0.902 in.)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum27.975 - 27.985 mm (1.1014 - 1.1018 in.)
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
0.015 - 0.046 mm (0.0006 - 0.0018 in.)
0.10 mm (0.0039 in.)
ManifoldWarpageMaximum Intake
Exhaust0.1 mm (0.004 in.)
0.5 mm (0.020 in.)
Spark tubeProtrusion47.5 - 48.5 mm (1.870 - 1.909 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter Mark 1
2
3
Maximum
Main journal bore diameter (Reference) Mark 1
2
30.05 mm (0.0020 in.)
74.000 - 74.010 mm (2.9134 - 2.9138 in.)
74.011 - 74.020 mm (2.9138 - 2.9142 in.)
74.021 - 74.030 mm (2.9142 - 2.9146 in.)
74.23 mm (2.9244 in.)
54.018 - 54.024 mm (2.1267 - 2.1269 in.)
54.025 - 54.030 mm (2.1270 - 2.1272 in.)
54.031 - 54.036 mm (2.1272 - 2.1274 in.)
Piston and piston
ringPiston diameter Mark 1
2
3
Piston oil clearance STD
Maximum
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil73.900 - 73.910 mm (2.9094 - 2.9098 in.)
73.910 - 73.920 mm (2.9098 - 2.9102 in.)
73.920 - 73.930 mm (2.9102 - 2.9106 in.)
0.09 - 0.11 mm (0.0035 - 0.0043 in.)
0.13 mm (0.0051 in.)
0.04 - 0.08 mm (0.0016 - 0.0031 in.)
0.03 - 0.07 mm (0.0012 - 0.0028 in.)
0.26 - 0.48 mm (0.0102 - 0.0189 in.)
0.30 - 0.57 mm (0.0118 - 0.0224 in.)
0.13 - 0.50 mm (0.0059 - 0.0197 in.)
1.07 mm (0.0421 in.)
1.02 mm (0.0354 in.)
1.10 mm (0.0433 in.)

- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-7
137 Author
: Date
:
1996 TERCEL (RM440U) Connecting rod
Thrust clearance STD
Maximum
Connecting rod oil clearance STD STD
U/S 0.25
Maximum
Connecting rod big end inside diameter (Reference)
Mark 1
2
3
Connecting rod bearing center wall thickness (Reference)
STD Mark 1
2
3
U/S 0.25
Rod out-of-alignment per 100 mm (3.94 in.) Maximum
Rod twist per 100 mm (3.94 in.)Maximum0.15 - 0.35 mm (0.0059 - 0.0138 in.)
0.45 mm (0.0177 in.)
0.016 - 0.048 mm (0.0006 - 0.0019 in.)
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.08 mm (0.0031 in.)
46.000 - 46.007 mm (1.8110 - 1.8113 in.)
46.007 - 46.014 mm (1.8113 - 1.8116 in.)
46.014 - 46.021 mm (1.8116 - 1.8118 in.)
1.487 - 1.491 mm (0.0585 - 0.0587 in.)
1.491 - 1.495 mm (0.0587 - 0.0589 in.)
1.495 - 1.499 mm (0.0589 - 0.0590 in.)
1.609 - 1.615 mm (0.0633 - 0.0636 in.)
0.03 mm (0.0012 in.)
0.05 mm (0.0020 in.)
CrankshaftThrust clearance STD
Maximum
Thrust washer thickness STD
O/S 0.125
Main journal oil clearance STD STD
U/S 0.25
Maximum
Main journal diameter STD
U/S 0.25
Main journal bore diameter (Reference) Mark 1
2
3
Main journal diameter (Reference) STD Mark 0
1
2
Main bearing center wall thickness (Reference)
STD Mark 1
2
3
4
5
U/S 0.25
Crank pin diameter STD
U/S 0.25
Circle runout Maximum
Main journal taper and out-of-round Maximum
Crank pin taper and out-of-round Maximum0.020 - 0.200 mm (0.0008 - 0.0078 in.)
0.30 mm (0.0118 in.)
2.430 - 2.480 mm (0.0957 - 0.0976 in.)
2.493 - 2.543 mm (0.0981 - 0.1001 in.)
0.016 - 0.035 mm (0.0006 - 0.0014 in.)
0.015 - 0.055 mm (0.0006 - 0.0022 in.)
0.08 mm (0.0031 in.)
49.985 - 50.000 mm (1.9679 - 1.9685 in.)
49.745 - 49.755 mm (1.9585 - 1.9589 in.)
54.018 - 54.024 mm (2.1267 - 2.1269 in.)
54.025 - 54.030 mm (2.1270 - 2.1272 in.)
54.031 - 54.036 mm (2.1272 - 2.1274 in.)
49.996 - 50.000 mm (1.9683 - 1.9685 in.)
49.991 - 49.995 mm (1.9081 - 1.9683 in.)
49.985 - 49.990 mm (1.9679 - 1.9681 in.)
1.997 - 2.000 mm (0.0786 - 0.0787 in.)
2.001 - 2.003 mm (0.0788 - 0.0789 in.)
2.004 - 2.006 mm (0.0789 - 0.0790 in.)
2.007 - 2.009 mm (0.0790 - 0.0791 in.)
2.010 - 2.012 mm (0.0791 - 0.0792 in.)
2.118 - 2.124 mm (0.0834 - 0.0836 in.)
42.985 - 43.000 mm (1.6923 - 1.6929 in.)
42.745 - 42.755 mm (1.6829 - 1.6833 in.)
0.06 mm (0.0024 in.)
0.08 mm (0.0031 in.)
0.07 mm (0.0028 in.)

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015

- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-9
1996 TERCEL (RM440U) LH engine mounting bracket x Transaxle case
6565047
LH engine mounting bracket x Insulator4949035
LH engine mounting bracket x Ground strap4949035
Rear engine mounting bracket x Insulator6565047
A/C compressor x Bracket2525018
Clutch release cylinder x Transaxle case131309
Front exhaust pipe x Tailpipe (clamp bolt)1919014
Sub heated oxygen sensor x Front exhaust pipe4445033

SS1IT-01
SS-10
- SERVICE SPECIFICATIONSEMISSION CONTROL
140 Author
: Date
:
1996 TERCEL (RM440U)
EMISSION CONTROL
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
TVV x Water outlet housing3535026
EGR valve x Cylinder head3030022
EGR pipe x Intake manifold Nut3030022
EGR valve x EGR pipe Union nut4040030