torque TOYOTA TERCEL 1996 Service Manual PDF

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)

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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.

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.

EG0023
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- ENGINE MECHANICALCYLINDER HEAD
EM-53
1996 TERCEL (RM440U)
22. INSTALL EGR PIPE
Install a new gasket, sleeve ball and the EGR pipe with the
union nut and 2 nuts.
Torque:
Union nut
40 N´m (400 kgf´cm, 29 in.´lbf)
Nut
30 N´m (300 kgf´cm, 22 in.´lbf)
23. INSTALL THROTTLE BODY (See page MF-32)
24. CONNECT VACUUM HOSES
(a) Connect the vacuum hose from the EGR valve.
(b) Connect the 3 vacuum hoses from the throttle body.
(c) Connect the vacuum hose from TVV (to charcoal canis-
ter).
(d) Connect the vacuum hose from the TVV (to throttle body).
(e) Connect the vacuum hose from the EGR VSV.
25. INSTALL IGNITION COILS AND SPARK PLUGS
26. w/ A/C and w/o PS:
INSTALL IDLER PULLEY BRACKET
(a) Install the idler pulley bracket with the 3 bolts.
Torque:
12 mm head bolt
27 N´m (275 kgf´cm, 20 ft´lbf)
14 mm head bolt
37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Install and adjust the drive belt (See page AC-18).
27. w/ PS:
INSTALL PS PUMP BRACKET AND PS PUMP
(a) Install the PS pump bracket with the 3 bolts.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(b) Temporarily install the PS pump and drive belt with the 2
bolts (See page SR-33).
(c) Adjust the belt tension (See page SR-3).
28. CONNECT FUEL HOSE
Connect the fuel inlet hose with the union bolt and 2 new gas-
kets.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
29. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
30. INSTALL ACCELERATOR CABLE, AND ADJUST IT
31. A/T:
CONNECT THROTTLE CABLE, AND ADJUST IT

P20160
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- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
32. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with
the 2 compression spring and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
33. INSTALL RH ENGINE UNDER COVER
34. FILL WITH ENGINE COOLANT (See page CO-2)
35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT
37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
38. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

Z14321
A242L A/T
P20255
Lift
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P20161
P20245
A/T only
- ENGINE MECHANICALENGINE UNIT
EM-61
1996 TERCEL (RM440U)
(j) A242L A/T:
Remove the bolt and disconnect the ground strap.
(k) Remove the 5 bolts and LH engine mounting bracket.
(l) Lift the engine out of the vehicle slowly and carefully.
HINT:
Clear the battery carrier support while lowering the transaxle.
(m) Place the engine with the transaxle onto the stand.
23. w/PS:
REMOVE PS PUMP ADJUSTING STRUT
Remove the 2 bolts and PS pump adjusting strut.
24. w/A/C:
REMOVE A/C COMPRESSOR MOUNTING BRACKET
Remove the 4 bolts and compressor mounting bracket.
25. A/T only:
REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the engine rear end plate hole cover.
(b) Turn the crankshaft to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench.
(d) Remove the 6 bolts.
26. REMOVE STARTER (See page ST-3 and ST-16)
27. SEPARATE ENGINE AND TRANSAXLE

EM1OI-01
P20245
A/T only
P20161
P20167
P20256
Lower EM-62
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
M/T: (See page MX-4)
A132L A/T: (See page AX-26)
A242L A/T: (See page AX-30)
2. INSTALL STARTER
(See page ST-14 and ST-30)
3. A/T only:
INSTALL TORQUE CONVERTER CLUTCH MOUNTING
BOLTS
(a) First, install the gray bolt and then 5 bolts.
(b) Tighten the bolts evenly.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
(c) Install the engine rear end plate hole cover.
4. w/A/C:
INSTALL A/C COMPRESSOR MOUNTING BRACKET
Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
5. w/PS:
INSTALL PS PUMP ADJUSTING STRUT
Install the PS pump adjusting strut with the 2 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
6. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Lower the engine into the engine compartment.
(c) Tilt the transaxle downward, lower the engine and clear
the LH engine mounting.
NOTICE:
Be careful not to hit the PS gear housing, park/neutral posi-
tion switch and throttle position switch.

P20246
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P20285
M/T
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A132L A/T
A242L A/T
- ENGINE MECHANICALENGINE UNIT
EM-63
1996 TERCEL (RM440U)
(d) Keep the engine level, and align RH and LH engine
mountings with the body bracket.
(e) Attach the RH engine mounting insulator to the mounting
bracket and body, and temporarily install the through bolt,
2 bolts and nut.
(f) Install the LH engine mounting bracket to the transaxle
and mounting insulator with the 5 bolts. Torque the bolts.
Torque:
Bracket to transaxle (bolt head: NT)
65 N´m (650 kgf´cm, 47 ft´lbf)
Bracket to insulator (bolt head: 7T)
49 N´m (490 kgf´cm, 35 ft´lbf)
(g) Connect the ground strap with the bolt.
Torque: 49 N´m (490 kgf´cm, 35 ft´lbf)

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- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
(h) Install and torque the rear engine mounting insulator
through bolt.
Torque: 65 N´m (650 kgf´cm, 47 ft´lbf)
(i) Remove the engine sling device from the engine.
(j) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Bolt and nut
64 N´m (650 kgf´cm, 47 ft´lbf)
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
(k) Connect the ground strap with the bolt.
7. INSTALL DRIVE SHAFTS (See page SA-18)
8. INSTALL FRONT EXHAUST PIPE
(a) Connect the 2 rings to the front exhaust pipe.
(b) Place a new gasket on the exhaust pipe.
(c) Connect the exhaust pipe to the exhaust manifold with 2
compression springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(d) Install the exhaust pipe to the tail pipe with the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(e) Install the heated oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 33 ft´lbf)
HINT:

Before installing the heated oxygen sensor, twist the sen-
sor wire counterclockwise 3 and 1/2 turns.

After installing the heated oxygen sensor, check that the
sensor wire is not twisted. If it is twisted, remove the
heated oxygen sensor and reinstall it.
9. w/ A/C:
INSTALL A/C COMPRESSOR
(a) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Connect A/C compressor connector.

P20577
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M/T
P21044
A132L A/T
P21045
A242L A/T
S06150
M/T only
- ENGINE MECHANICALENGINE UNIT
EM-65
1996 TERCEL (RM440U)
10. w/ PS:
INSTALL PS PUMP
(a) Install the PS pump and drive belt with the 2 bolts.
(b) Adjust the drive belt tension (See page SR-3).
11. M/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the retainer to the cable.
(b) Connect the linkage with the plate washer and clip.
12. A132L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
13. A242L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
14. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder, tube and ground strap with the 3
bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)