TOYOTA TERCEL 1996 Service Repair Manual

Z14274
(g)(c)
(e)(d)
P20420
Bi-Hexagon Wrench
12
3
4 56 7
8 9
10
P20405
- ENGINE MECHANICALCYLINDER HEAD
EM-29
1996 TERCEL (RM440U)
(c) Using snap ring pliers, remove the snap ring.
(d) Remove the wave washer.
(e) Remove the camshaft sub-gear.
(f) Remove the camshaft gear spring.
31. REMOVE CYLINDER HEAD
(a) Using a bi-hexagon wrench 8 mm, uniformly loosen and
remove the 10 cylinder head bolts, in several passes, in
the sequence shown.
NOTICE:
Cylinder head warpage or cracking could result from re-
moving bolts in incorrect order.
(b) Lift the cylinder head from the dowels on the cylinder
block and place the head on wooden blocks on a bench.
HINT:
If the cylinder head is difficult to lift off, pry with a screwdriver be-
tween the cylinder head and block saliences.
NOTICE:
Be careful not to damage the contact surfaces of the cylin-
der head and cylinder block.

EM9937
EM0JZ-03
P20416
SST
EM9939
EM-30
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE NO.2 ENGINE HANGER
2. REMOVE STUD BOLT FOR CYLINDER HEAD COVER
3. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
4. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202-70010
(b) Remove the spring retainer, valve spring, valve and
spring seat.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in correct order.
(c) Using needle-nose pliers, remove the oil seal.

EM0K0-05
P20381
P20380
P20350
P20353
EG0031
- ENGINE MECHANICALCYLINDER HEAD
EM-31
1996 TERCEL (RM440U)
INSPECTION
1. CLEAN TOP SURFACES OF PISTONS AND CYL-
INDER BLOCK
(a) Turn the crankshaft, and bring each piston to top dead
center (TDC). Using a gasket scraper, remove all the car-
bon from the piston top surface.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
(c) Using compressed air, blow carbon and oil from the bolt
holes.
CAUTION:
Protect your eyes when using high-pressure compressed
air.
2. CLEAN CYLINDER HEAD
(a) Remove the gasket material.
(b) Using a gasket scraper, remove all the gasket material
from the cylinder block contact surface.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(c) Clean the combustion chambers.
(d) Using a wire brush, remove all the carbon from the com-
bustion chambers.
NOTICE:
Be careful not to scratch the cylinder block contact sur-
face.
(e) Clean the valve guide bushings.
(f) Using a valve guide bushing brush and solvent, clean all
the guide bushings.

P20354
P20421
Cylinder Block Side
Intake Manifold Side
Exhaust Manifold Side
P20351
EM0580
EM-32
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(g) Clean the cylinder head.
(h) Using a soft brush and solvent, thoroughly clean the cylin-
der head.
3. INSPECT CYLINDER HEAD
(a) Inspect the for flatness.
(b) Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder block and the
manifolds for warpage.
Maximum warpage:
Cylinder block side0.05 mm (0.0020 in.)
Manifold side0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder head.
(c) Inspect the for cracks.
(d) Using a dye penetrant, check the combustion chambers,
intake ports, exhaust ports and cylinder block surface for
cracks.
If cracked, replace the cylinder head.
4. CLEAN VALVES
(a) Using a gasket scraper, chip off any carbon from the valve
head.
(b) Using a wire brush, thoroughly clean the valve.

P20382
Z00052
Z00054
44.5°
EM0181
Margin Thickness
- ENGINE MECHANICALCYLINDER HEAD
EM-33
1996 TERCEL (RM440U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 - 6.030 mm (0.2366 - 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 - 5.985 mm (0.2350 - 0.2356 in.)
Exhaust5.965 - 5.980 mm (0.2348 - 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM-40).
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
0.8 - 1.2 mm (0.031 - 0.047 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

P03849
Overall Length
EM0255
P20367
45° Carbide Cutter
Z07819
Width
Z08336
45°
1.0 - 1.4 mm30° EM-34
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(d) Check the valve overall length.
Standard overall length:
Intake93.45 mm (3.6791 in.)
Exhaust93.89 mm (3.6768 in.)
Minimum overall length:
Intake92.95 mm (3.6594 in.)
Exhaust93.39 mm (3.6768 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
(c) Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(d) Check the valve face and seat for the following:
(1) If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

Z07818
75
60° (IN only)
45°
1.0 - 1.4 mm
P20352
EM0988
Deviation
EM0801
EM0281
- ENGINE MECHANICALCYLINDER HEAD
EM-35
1996 TERCEL (RM440U)
(2) If the seating is too low on the valve face, use 75°,
60° (IN only) and 45° cutters to correct the seat.
(e) Hand-lap the valve and valve seat with an abrasive com-
pound.
(f) After hand-lapping, clean the valve and valve seat.
8. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 53.58 mm (2.1094 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
at 31.8 mm (1.252 in.)
If the installed tension is not as specified, replace the valve
spring.

P20379
P20385
P20386
EG0008
EM-36
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. INSPECT CAMSHAFTS AND BEARINGS
Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
10. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake41.514 - 41.614 mm (1.6344 - 1.6383 in.)
Exhaust41.011 - 41.111 mm (1.6146 - 1.6185 in.)
Minimum cam lobe height:
Intake41.35 mm (1.6279 in.)
Exhaust40.85 mm (1.6083 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
11. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
Exhaust No.124.949 - 24.965 mm (0.9822 - 0.9829 in.)
Others22.949 - 22.965 mm (0.9035 - 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
12. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.

EM3322
Free Distance
EM9949
Plastigage
P20360
EG0117
P20404
- ENGINE MECHANICALCYLINDER HEAD
EM-37
1996 TERCEL (RM440U)
13. INSPECT CAMSHAFT GEAR SPRING
Using a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 - 22.9 mm (0.886 - 0.902 in.)
If the free distance is not as specified, replace the gear spring.
14. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM-44).
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.
15. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshaft (See page EM-44).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.045 - 0.100 mm (0.0018 - 0.0039 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)

P20403
EM9940
EM2196
EM-38
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
16. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam
sub-gear (See page EM-44).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum backlash:
0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
17. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
27.975 - 27.985 mm (1.1014 - 1.1018 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.015 - 0.046 mm (0.0005 - 0.0018 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.