1996 TOYOTA TERCEL lock

BE4061I00298I09784
1
2 Disconnect
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-247
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check engine hood courtesy switch.
PREPARATION:
(a) Remove engine hood lock assembly.
(b) Disconnect engine hood courtesy switch connector.
CHECK:
Check continuity between terminals 1 and 2 when engine hood
lock is locked and unlocked.
OK:
Engine hood lockTester connectionSpecified condition
LOCK-No continuity
UNLOCK1 - 2Continuity
NG Replace engine hood courtesy switch.
OK
2 Check harness and connector between theft deterrent ECU and switch, switch
and body ground (See page IN-26).
NG Repair or replace harness or connector.
OK
Check and replace theft deterrent ECU
(See
page
IN-26).

EM1OD-01
P20154
Oil Pan
P20153
Ground Strap
P20536
Timing Mark
P20159
EM-12
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. w/ A/C and/or w/ PS:
REMOVE DRIVE BELT
3. REMOVE GENERATOR DRIVE BELT
4. SLIGHTY JACK UP ENGINE
5. SLIGHTLY JACK UP ENGINE
Raise the engine enough to remove the weight from the engine
mounting on the right side.
6. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Remove the bolt and disconnect the ground strap.
(b) Remove the through bolt, 2 bolts, nut and mounting insu-
lator.
7. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, timing belt cover and gasket.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the hole of the camshaft timing pulley on the
side with the 5E mark is aligned with the timing mark of the
No.1 bearing cap.
If not, turn the crankshaft pulley 1 complete revolution (360°).
9. w/ A/C and/or w/ PS:
REMOVE NO.2 CRANKSHAFT PULLEY
Remove the 4 bolts and No.2 crankshaft pulley.

EM0K6-01
EM0126
No!
P20576
EM3385
- ENGINE MECHANICALTIMING BELT
EM-15
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT TIMING BELT
NOTICE:

Do not bend, twist or turn the timing belt inside out.

Do not allow the timing belt to come into contact with
oil, water or steam.

Do not utilize timing belt tension when installing or re-
moving the mounting bolt of the camshaft timing
pulley.
If there are any defects as shown in the illustration, check these
points:
(a) Premature parting

Check for proper installation.

Check the timing cover gasket for damage and
proper installation.
(b) If the belt teeth are cracked or damaged, check to see if
either camshaft or oil pump is locked.
(c) If there is noticeable wear or cracks on the belt face,
check to see if there are nicks on the side of the idler
pulley lock.
(d) If there is wear or damage on only one side of the belt,
check the belt guide and the alignment of each pulley.
(e) If there is noticeable wear on the belt teeth, check the tim-
ing belt cover for damage and check gasket has been
installed correctly and for foreign material on the pulley
teeth.
If necessary, replace the timing belt.
2. INSPECT IDLER PULLEYS
(a) Visually check the seal portion of the idler pulley for oil
leakage.
If leakage is found, replace the idler pulley.
(b) Check that the idler pulley turns smoothly.
If necessary, replace the idler pulley.

P21439
2 Revolutions
P20537
Timing Mark
P20552
P20745
P20157
SST
- ENGINE MECHANICALTIMING BELT
EM-19
1996 TERCEL (RM440U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) 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.
(d) Tighten the No.1 idler pulley bolt.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
(e) Remove the crankshaft pulley bolt.
8. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
9. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 3 bolts.
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-14010, 09330-00021
Torque: 155 N´m (1,550 kgf´cm, 112 ft´lbf)

Z14275
7
351
48
22
6
P20359
Z14276
P20358
P20417
SST EM-28
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(e) Uniformly loosen and remove the 8 No.3 bearing cap
bolts, in several passes, in the sequence shown.
(f) Remove the 4 bearing caps and intake camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the bearing cap with the 2 bolts.
Then alternately loosen and remove the 2 bearing cap bolts
with the camshaft gear pulled up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
(g) Uniformly loosen and remove the 8 No.3 bearing cap
bolts, in several passes, in the sequence shown.
(h) Remove the 4 bearing caps and intake camshaft.
HINT:
If the camshaft is not being lifted out straight and level, reinstall
the bearing cap with the 2 bolts.
Then alternately loosen and remove the 2 bearing cap bolts
with the camshaft gear pulled up.
NOTICE:
Do not pry on or attempt to force the camshaft with a tool
or other object.
30. DISASSEMBLE INTAKE CAMSHAFT
(a) Mount the hexagon head portion of the camshaft in a soft
jaw vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Using SST, turn the sub-gear clockwise, and remove the
service bolt.
SST 09960-10010 (09962-0100, 09963-00500)

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.

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.