1996 TOYOTA TERCEL timing belt

P20528
38.4 mm EM-16
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
3. INSPECT TENSION SPRING
(a) Measure the free length of tension spring.
Free length:
38.4 mm (1.512 in.)
If the free length is not as specified, replace the tension spring.
(b) Measure the tension of the tension spring at the specified
installed length.
Installed tension (at 47.4 mm (1.866 in.)):
32 N (3.3 kgf, 7.3 lbf)
If the installed tension is not as specified, replace the tension
spring.

EM1OE-01
P20743
P20742
P20744
P20390SST
P20915
Timing Mark
SST
Installation
Mark
- ENGINE MECHANICALTIMING BELT
EM-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the rotor side of the
crankshaft position sensor inward.
2. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING
(a) Install the tension spring to the idler pulley.
(b) Align the bracket pin hole with the pivot pin.
(c) Install the idler pulley with the bolt. Do not tighten the bolt
yet.
(d) Pry the idler pulley toward the left as far as it will go and
temporarily tighten the bolt.
(e) Check that the idler pulley moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
(b) Check that the idler pulley moves smoothly.
4. INSTALL CAMSHAFT TIMING PULLEY
(a) Align the camshaft knock pin with the knock pin groove on
the pulley side with the 5E mark, and slide on the timing
pulley.
(b) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, align the hole of the camshaft timing pulley on
the side with the 5E mark with the timing mark of the bear-
ing cap.
SST 09960-10010 (09962-01000, 09963-01000)

P20556
P20558
P20535
Tension
P20555
EM-18
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
(b) Using the crankshaft pulley bolt, turn the crankshaft and
align the timing marks of the crankshaft timing pulley and
oil pump body.
6. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
HINT:
When re-using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
(a) Remove any oil or water on the pulleys, and keep them
clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
7. CHECK VALVE TIMING
(a) Loosen the No.1 idler pulley mount bolt, until the pulley is
moved slightly by the spring tension.

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)

P20159
P20153
Ground Strap EM-20
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
12. w/ A/C and/or w/ PS:
INSTALL NO.2 CRANKSHAFT PULLEY
Install the No.2 crankshaft pulley with the 4 bolts.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
13. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 4 bolts.
14. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Attach the RH mounting insulator to the mounting bracket
and body, and temporarily install the through bolt, 2 bolts
and nut.
(b) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
Others
64 N´m (650 kgf´cm, 47 ft´lbf)
(c) Connect the ground strap with the bolt.
15. INSTALL GENERATOR DRIVE BELT (See page
CH-2)
16. w/ A/C and/or w/ PS:
INSTALL DRIVE BELT
(See page AC-18 and SR-3)
17. INSTALL RH ENGINE UNDER COVER

P20361
P20532
Shop
Rag
Tape
P20363
P20357
P20364
EM-26
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
22. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, No.2 timing belt cover and gasket.
23. REMOVE GENERATOR DRIVE BELT
Loosen the pivot nut and adjusting bolt, and remove the gener-
ator drive belt.
24. REMOVE NO.3 TIMING BELT COVER FROM NO.1 TIM-
ING BELT COVER
25. SET NO.1 CYLINDER TO TDC/COMPRESSION (See
page EM-12)
26. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
(a) Loosen the mount bolt of the No.1 idler pulley and shift
pulley toward the left as far as it will go and then tempo-
rarily tighten it.
NOTICE:
Be careful not to damage the timing belt.
(b) Remove the timing belt from the camshaft timing pulley.
27. REMOVE NO.2 IDLER PULLEY
Remove the bolt and idler pulley.
NOTICE:

Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift.

Be careful not to drop anything inside the timing belt
cover.

Do not allow the belt to come into contact with oil, wa-
ter or duct.
28. REMOVE CAMSHAFT TIMING PULLEY
Secure the hexagonal portion of the camshaft, and remove the
bolt and pulley.

P20948
P20953
Timing Mark
Installation
Mark
P20746
P20748
P20749
- ENGINE MECHANICALCYLINDER HEAD
EM-49
1996 TERCEL (RM440U)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
(b) Turn the camshaft, and align the hole of the camshaft tim-
ing pulley on the side with the 5E mark with the timing
mark of the bearing cap.
9. INSTALL TIMING BELT
(a) Starting from the right hand side of the pulley and instal-
ling the belt counterclockwise.
(b) Loosen the No.1 idler pulley mounting bolt until the pulley
is moved slightly by the spring tension.
(c) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.

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)