engine mount TOYOTA TERCEL 1996 Service Owner's Manual

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

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.

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.

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)

EM0K2-04
Z14084
Protrusion
47.5 - 48.5 mm
Mark
EM9934
Adhesive
P20370
Protrusion
EM9938
EM-42
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
REASSEMBLY
HINT:

Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil to all slid-
ing and rotating surfaces.

Replace all gaskets and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the
spark plug tube.
Standard protrusion:
47.5 - 48.5 mm (1.870 - 1.909 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Adhesive:
Part No. 08833-00070, Adhesive 1324,
THREE BOND 1324 or equivalent
(c) Using a press, press in a new spark plug tube until there
is standard protrusion protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using a 10 mm socket-driver, push in a new oil seal.

P20389
Gasket
EM1OG-01
P20419
EX
(A)
Bi-Hexagon Wrench
(B)IN
(B)
(A)(B)
(B)(B)
(B)
8
61 3
9
10 4 257
(A) (A) (A)(A) IN
EX
P20413
Painted Mark
90°
P20174
(b)(c)
(d)(e)
EM-44
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any cylinder head bolt is broken or deformed, replace
it.

There are 2 lengths of cylinder head bolts, long (A) and
short (B).
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) First, using a bi-hexagon wrench 8 mm, install and uni-
formly tighten the 10 cylinder head bolts, in several
passes, in the sequence shown.
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts 90° in the numerical or-
der shown.
(e) Check that the painted mark is now at a 90° angle to front.
3. ASSEMBLE INTAKE CAMSHAFT
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring.
(c) Install the camshaft sub-gear.
(d) Install the wave washer.
HINT:
Align the pins on the gears with the gear spring ends.

P20948
P20953
Timing Mark
Installation
Mark
P20746
P20748
P20749
- ENGINE MECHANICALCYLINDER HEAD
EM-49
1996 TERCEL (RM440U)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
(b) Turn the camshaft, and align the hole of the camshaft tim-
ing pulley on the side with the 5E mark with the timing
mark of the bearing cap.
9. INSTALL TIMING BELT
(a) Starting from the right hand side of the pulley and instal-
ling the belt counterclockwise.
(b) Loosen the No.1 idler pulley mounting bolt until the pulley
is moved slightly by the spring tension.
(c) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.

P20538
Timing Mark
Installation Mark
P20361
P20286
Seal Packing
P20406
EM-50
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(d) 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.
(e) Tighten the mounting bolt of the No.1 idler pulley.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL GENERATOR DRIVE BELT (See page
CH-2)
12. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 4 bolts.
13. INSTALL CHARCOAL CANISTER (See page EM-17)
14. INSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing:
Part No. 08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 5 seal washers and
nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install the oil filler cap.
15. INSTALL INTAKE MANIFOLD
(a) Install air pipe a new gasket and the intake manifold with
the 2 bolts and 3 nuts.
Torque: 19.5 N´m (195 kgf´cm, 14 ft´lbf)

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

P20572
A132 LA/T
A242 LA/T
P20577
P20292
P20164
- ENGINE MECHANICALENGINE UNIT
EM-59
1996 TERCEL (RM440U)
17. A/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the 2 bolts from the LH engine mounting bracket.
18. w/ PS:
REMOVE PS PUMP 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.
19. w/ A/C:
REMOVE A/C COMPRESSOR
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put aside the compressor, and suspend it.
20. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the heated oxygen sensor.
(b) Remove the 2 bolts, compression springs and disconnect
the exhaust pipe.
(c) Remove the bolts and rear clamp.
(d) Disconnect the 2 rings and remove the front exhaust pipe.
21. REMOVE DRIVE SHAFTS (See page SA-18)