1996 TOYOTA TERCEL check engine

P20547
P20190
481062
1
5
9
7
3
P20486
EM9403
EM-74
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
20. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.02 - 0.20 mm (0.0008 - 0.0079 in.)
Maximum thrust clearance:
0.3 mm (0.012 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
STD2.430 - 2.480 mm (0.0957 - 0.0976 in.)
O/S 0.1252.493 - 2.543 mm (0.0981 - 0.1001 in.)
21. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts, in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the 5 main bear-
ing caps, 5 lower bearings and 2 lower thrust washers
(No.3 main bearing cap only).
HINT:

Keep the lower bearing inserted together with cap.

Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.

P20488
EM9443
Plastigage
Z14291
4
810
6
2 159
73
EM9442
- ENGINE MECHANICALCYLINDER BLOCK
EM-75
1996 TERCEL (RM440U)
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearing.
If necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps (See page EM-85).
Torque: 58 N´m (580 kgf´cm, 42 ft´lbf)
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See procedure (a) and (b) above)
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.016 - 0.035 mm (0.0006 - 0.0014 in.)
U/S 0.250.015 - 0.055 mm (0.0006 - 0.0022 in.)
Maximum oil clearance: 0.08 mm (0.0031 in.)
HINT:

If replacing the cylinder block subassembly, the bearing
standard clearance will be: 0.018- 0.045 mm
(0.0007-0.0018 in.).
If the oil clearance is greater than maximum replace the bear-
ings. If necessary, grind or replace the crankshaft.

P20489
P20548
Z07984
SST SST
SST
SSTSSTPiston
Pin
SST
- ENGINE MECHANICALCYLINDER BLOCK
EM-77
1996 TERCEL (RM440U)
23. CHECK FIT BETWEEN PISTON AND PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
24. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the compression
rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the rings in the correct order only.
25. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using SST, press out the piston pin from the piston.
(b) Remove the connecting rod.
SST 09221-25024 (09221-00020, 09221-00030,
09221-00130, 09221-00140, 09221-00150)
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in correct order.

P00393
EM0JR-04
Z07983
P00390
EM9429
Front
Cylinder Bore Size Mark (1,2 or 3) EM-78
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
(b) Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(c) Clean the cylinder block.
(d) Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR
FLATNESS
Using a precision straight edge and feeler gauge, measure the
surfaces contacting the cylinder head gasket for warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
3. INSPECT CYLINDER FOR VERTICAL SCRATCHES
Visually check the cylinder for vertical scratches.
If deep scratches are present, replace the cylinder block.
4. INSPECT CYLINDER BORE DIAMETER
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of 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.

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

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.