Block TOYOTA TERCEL 1996 Service Service Manual

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.

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.

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.

P20543
P20496
P20747
P20529
Seal PackingCORRECT WRONG
- ENGINE MECHANICALCYLINDER HEAD
EM-51
1996 TERCEL (RM440U)
(b) Install the manifold stay with the bolt and nut.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(c) Connect the engine wire clamps to the intake manifold
stay.
16. CONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
17. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF-22)
18. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 48 N´m (480 kgf´cm, 35 ft´lbf)
(b) Place the exhaust manifold stay snug against the cylinder
block and exhaust manifold.
(c) First, tighten the bolt (A) and then the 2 nuts.
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
(d) Install the heat insulator with the 3 bolts.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
19. INSTALL WATER INLET AND OUTLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contacting surfaces of the water
outlet housing and cylinder head.

Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the gasket sur-
faces.

Thoroughly clean all components to remove all the
loose material.

Clean both sealing surfaces with a non-residue sol-
vent.
(b) Apply seal packing to the water outlet housing as shown
in the illustration.
Seal packing:
Part No. 08826-00100, THREE BOND 1282B
or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

EM0JP-05
EM-68
- ENGINE MECHANICALCYLINDER BLOCK
489 Author
: Date
:
1996 TERCEL (RM440U)
CYLINDER BLOCK
COMPONENTS

- ENGINE MECHANICALCYLINDER BLOCK
EM-69
490 Author
: Date
:
1996 TERCEL (RM440U)

EM0JQ-06
EM9411
EM9412
P20480
SST
P20478
SST
P20477
12 mm
Hexagon
Wrench EM-70
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
DISASSEMBLY
1. M/T:
REMOVE CLUTCH COVER AND DISC
2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
8. REMOVE WATER PUMP WITH WATER INLET PIPE
9. REMOVE GENERATOR BRACKET
10. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816-30010
11. REMOVE RH ENGINE MOUNTING BRACKET
12. REMOVE OIL FILTER
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
14. REMOVE OIL PUMP AND PRESSURE REGULATOR
VA LV E
15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.

EM9988
EM3441
P20487
EM9392
EM3444
- ENGINE MECHANICALCYLINDER BLOCK
EM-71
1996 TERCEL (RM440U)
16. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the rod back and forth.
Standard thrust clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
Maximum thrust clearance:
0.45 mm (0.0177 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using a soft-faced hammer, lightly tap the connecting rod
bolt and lift the cap and lower bearing.
HINT:
Keep the lower bearing inserted with the connecting rod cap.

EM3445
EM9405
EM3447
Plastigage
EM3448
EM3449
EM-72
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin bearing is for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap (See page EM-85).
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
NOTICE:
Do not turn the crankshaft.
(i) Remove the connecting rod cap
(See procedure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.016 - 0.048 mm (0.0006 - 0.0019 in.)
U/S 0.250.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

P20473
Mark
1,2 or 3
Mark
1,2 or 3
P20491
EM3445
- ENGINE MECHANICALCYLINDER BLOCK
EM-73
1996 TERCEL (RM440U)
HINT:
If using a standard bearing, replace with one having the same
number as marked on the bearing cap. There are 3 sizes of
standard bearings, marked
º1º, º2º and º3º accordingly.
Reference:
Connecting rod big end inside diameter
Standard sized
U/S 0.25
Mark 1
Mark 2
Mark 3
-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.)
46.000 - 46.021 mm (1.8110 - 1.8118 in.)
Crankshaft crank pin diameter
Standard sized
U/S 0.25
-
-42.985 - 43.000 mm (1.6923 - 1.6929 in.)
42.745 - 42.755 mm (1.6829 - 1.6833 in.)
Bearing center wall thickness
Standard sized
U/S 0.25
Mark 1
Mark 2
Mark 3
-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.)
(k) Completely remove the Plastigage.
19. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Cover the rod bolts with a short piece of hose to protect
the crankshaft from damage.
(c) Push out the piston and connecting rod assembly and the
upper bearing though the top of the cylinder block.
HINT:

Keep the bearing, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in cor-
rect order.