TOYOTA TERCEL 1996 Service Repair Manual

P20484
FrontThrust
Direction
Axial
Direction
10 mm
(0.39 in.)
10 mm
(0.39 in.) A
B
C
P20491
P20541
P20542
- ENGINE MECHANICALCYLINDER BLOCK
EM-79
1996 TERCEL (RM440U)
Using a cylinder gauge, measure the cylinder bore diameter at
positions A, B and C in the thrust and axial directions.
Standard diameter:
Mark º1º74.000 - 74.010 mm (2.9134 - 2.9138 in.)
Mark º2º74.011 - 74.020 mm (2.9138 - 2.9142 in.)
Mark º3º74.021 - 74.030 mm (2.9142 - 2.9146 in.)
Maximum diameter:
74.23 mm (2.9224 in.)
If the diameter is greater than maximum, replace the cylinder
block.
5. REMOVE CYLINDER RIDGE
If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer,
grind the top of the cylinder.
6. CLEAN PISTON
(a) Using a gasket scraper, remove the carbon from the pis-
ton top.
(b) Using a groove cleaning tool or broken ring, clean the ring
grooves.

P20539
P20561
Mark 1, 2 or 3
Front mark (Cavity)
P20474
23 mm
(0.91 in.)
P20571
Mark 1, 2 or 3
Front
Front mark (Cavity)Mark 1, 2 or 3 EM-80
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(c) Using a soft brush and solvent, thoroughly clean the pis-
ton.
NOTICE:
Do not damage the piston.
7. INSPECT PISTON OIL CLEARANCE
HINT:
There are 3 sizes of the standard piston diameter, marked º1º,
º2º and º3º accordingly. The mark is stamped on the piston top.
(a) Using a micrometer, measure the piston diameter at right
angles to the piston pin center line, 23 mm (0.91 in.) from
the piston head.
Piston diameter:
Mark º1º73.900 - 73.910 mm (2.9094 - 2.9098 in.)
Mark º2º73.910 - 73.920 mm (2.9098 - 2.9120 in.)
Mark º3º73.920 - 73.930 mm (2.9120 - 2.9106 in)
(b) Measure the cylinder bore diameter in the thrust direc-
tions (See step 4).
(c) Subtract the piston diameter measurement from the cylin-
der bore diameter measurement.
Standard oil clearance:
0.09 - 0.11 mm (0.0035 - 0.0043 in.)
Maximum oil clearance:
0.13 mm (0.0051 in.)
If the oil clearance is greater than maximum, replace all 4 pis-
tons. If necessary, replace the cylinder block.
HINT:
Use new cylinder block:
Use a piston with the same number mark as the cylinder bore
diameter marked on the cylinder block.

P20540
P20527
Top of Cylinder Block
110 mm
(4.33 in.,)
EM7639
N00301
- ENGINE MECHANICALCYLINDER BLOCK
EM-81
1996 TERCEL (RM440U)
8. INSPECT PISTON RING GROOVE CLEARANCE
Using a feeler gauge, measure the clearance between new pis-
ton ring and the wall of the ring groove.
Ring groove clearance:
No.10.04 - 0.08 mm (0.0016 - 0.0031 in.)
No.20.03 - 0.07 mm (0.0012 - 0.0028 in.)
If the oil clearance is greater than maximum, replace the piston.
9. INSPECT PISTON RING END GAP
(a) Insert the piston ring into the cylinder bore.
(b) Using a piston, push the piston ring a little beyond the bot-
tom of the ring travel, 110 mm (4.33 in.) from the top of the
cylinder block.
(c) Using a feeler gauge, measure the end gap.
Standard end gap:
No.10.26 - 0.48 mm (0.0102 - 0.0189 in.)
No.20.36 - 0.57 mm (0.0142 - 0.0224 in.)
Oil (Side rail)0.13 - 0.50 mm (0.0051 - 0.0197 in.)
Maximum end gap:
No.11.07 mm (0.0421 in.)
No.21.02 mm (0.0402 in.)
Oil (Side rail)1.10 mm (0.0433 in.)
If the end gap is greater than maximum, replace the piston ring.
If necessary, replace the cylinder block.
10. INSPECT CONNECTING RODS
Using a rod aligner, check the connecting rod alignment.

Check for out-of-alignment.
Maximum out-of-alignment:
0.03 mm (0.0012 in.) per 100 mm (3.94 in.)
If out-of-alignment is greater than maximum, replace the con-
necting rod assembly.

N00302
EM3208
N00295
EM-82
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)

Check for twist
Maximum twist:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
HINT:
If replacing the connection rods, replace the same number of
connecting rod bearings as that of new connecting rod caps.
11. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(b) Using a dial indicator, measure the circle runout at the
center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
12. INSPECT MAIN JOURNALS AND CRANK PINS
(a) Using a micrometer, measure the diameter of each main
journal and crank pin.
Main journal diameter:
STD49.985 - 50.000 mm (1.9679 - 1.9685 in.)
U/S 0.2549.745 - 49.755 mm (1.9585 - 1.9589 in.)
Crank pin diameter:
STD42.985 - 43.000 mm (1.6923 - 1.6929 in.)
U/S 0.2542.745 - 42.755 mm (1.6829 - 1.6833 in.)
If the diameter is not as specified, check the oil clearance (See
page EM-70).
If necessary, grind or replace the crankshaft.
(b) Check each main journal and crank pin for taper and out-
of-round as shown.
Maximum taper:
0.08 mm (0.0031 in.)
Maximum out-of-round:
0.07 mm (0.0028 in.)
If the taper and out-of-round is greater than maximum, replace
the crankshaft.
13. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
(a) Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure in step 2).
(b) Install new main journal and/or crank pin undersized
bearings.

EM0JS-04
P20490
P20482
SST
P20564
Cut PositionTape
P20563
SST
P20492
- ENGINE MECHANICALCYLINDER BLOCK
EM-83
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE CRANKSHAFT FRONT OIL SEAL
HINT:
There are 2 methods to replace the oil seal which are as follows:
If oil pump is removed from cylinder block
(a) Using a screwdriver, pry out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the oil pump case edge.
SST 09309-37010
(c) Apply MP grease to the oil seal lip.
If oil pump is installed to the cylinder block
(d) Using a knife, cut off the oil seal lip.
(e) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(f) Apply MP grease to a new oil seal lip.
(g) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the oil pump case edge.
SST 09309-37010
2. REPLACE CRANKSHAFT REAR OIL SEAL
HINT:
There are 2 methods to replace the oil seal which are as follows:
If rear oil retainer is removed from cylinder block
(a) Using a screwdriver and hammer, tap out the oil seal.

N00264
Tape
Cut Position
EM-84
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(b) Using SST and a hammer, tap in a new oil seal until its sur-
face is flush with the rear oil seal edge.
SST 09223-15030, 09550-10012 (09552-10010)
(c) Apply MP grease to the oil seal lip.
If rear oil seal retainer is installed to cylinder block
(d) Using a knife, cut off the oil seal lip.
(e) Using a screwdriver, pry out the oil seal.
NOTICE:
Be careful not to damage the crankshaft.
Tape the screwdriver tip.
(f) Apply MP grease to a new oil seal lip.
(g) Using SST and a hammer, tap in the oil seal until its sur-
face is flush with the rear oil seal retainer edge.
SST 09223-15030, 09550-10012 (09552-10010)

EM0JT-05
P20471
Front Mark
(Cavity)
Front Mark
(Protrusion)
Z08055
SST
Piston Pin
SSTSST
SST
SST
SST SST
P20549
P20560
1R
2R
- ENGINE MECHANICALCYLINDER BLOCK
EM-85
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, O-rings and oil seals with new parts.
1. ASSEMBLE PISTON AND CONNECTING ROD
(a) Coat the piston pin and pin holes of the piston with engine
oil.
(b) Align the cavity on the piston with the protrusion on the
connecting rod.
(c) Using SST, press in the piston pin.
SST 09221-25025 (09221-00020, 09221-00030,
09221-00130, 09221-00140, 09221-00150)
(d) After installing the piston pin, check that when the con-
necting rod is aligned with the center of the piston the
space between the piston and each end of the piston pin
are equal on the left and right sides.
HINT:
If the piston pin is off-center due to insufficient insertion pres-
sure on the piston pin, place a washer at the position indicated
by
in the illustration for (c). Then, while checking that the
space is equal at the ends of the piston pin on the left and right
sides, press in the washer.
2. INSTALL PISTON RINGS
(a) Install the oil ring expander and 2 side rails by hand.
(b) Using a piston ring expander, install the 2 compression
rings with the code mark facing upward.
Code Mark:
No.11R
No.22R

P20867
Front
ExpanderNo.2
Compression
Ring
Upper Side
Rail
Front Mark (Cavity) No.1
Compression
RingLower Side Rail
EM3477
EM9416
P20550
EM9417
EM-86
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(c) Position the piston rings so that the ring ends are as
shown.
NOTICE:
Do not align the end gaps.
3. INSTALL BEARINGS
(a) Align the bearing claw with the groove of the connecting
rod or connecting cap.
(b) Install the bearings in the connecting rod and connecting
rod cap.
4. INSTALL MAIN BEARINGS
(a) Align the bearing claw with the claw groove of the cylinder
block, and push in the 5 upper bearings.
NOTICE:
Install the bearing with the oil hole in the cylinder block.
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
illustration position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position with
the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK

P20551
P20530
Front
Z14291
1
2 3
45
6
7
89
10
EM3480
P20569
Front Mark
(Cavity)
FrontPush
- ENGINE MECHANICALCYLINDER BLOCK
EM-87
1996 TERCEL (RM440U)
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the oil grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing caps.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing caps, in several passes, in the sequence shown.
Torque: 58 N´m (580 kgf´cm, 42 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the crankshaft thrust clearance (See page
EM-70).
8. INSTALL PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(b) Using a piston ring compressor, push the correctly num-
bered piston and connecting rod assemblies into each
cylinder with the front mark of the piston facing forward.

EM3481
Front Mark
(Protrusion)
Front
EM3448
P20475
Seal Packing
A'B'
A
B
A - A' B - B' EM-88
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
9. INSTALL CONNECTING ROD CAPS
(a) Match the numbered connecting rod cap with the num-
bered connecting rod.
(b) Install the connecting rod cap with the front mark facing
forward.
(c) Apply a light coat of engine oil on the threads and under
the nuts of the connecting rod cap.
(d) Install and alternately tighten the nuts of the connecting
rod cap in several passes.
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
(e) Check that the crankshaft turns smoothly.
(f) Check the connecting rod thrust clearance (See page
EM-70).
10. INSTALL REAR OIL SEAL RETAINER
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the rear oil
seal retainer and cylinder block.
Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the gasket sur-
faces and sealing groove.
Thoroughly clean all components to remove all the
loose material.
Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the rear oil seal retainer as shown
in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.