1996 TOYOTA TERCEL engine

EM3322
Free Distance
EM9949
Plastigage
P20360
EG0117
P20404
- ENGINE MECHANICALCYLINDER HEAD
EM-37
1996 TERCEL (RM440U)
13. INSPECT CAMSHAFT GEAR SPRING
Using a vernier caliper, measure the free distance between the
spring ends.
Free distance:
22.5 - 22.9 mm (0.886 - 0.902 in.)
If the free distance is not as specified, replace the gear spring.
14. INSPECT CAMSHAFT JOURNAL OIL CLEARANCE
(a) Clean the bearing caps and camshaft journals.
(b) Place the camshafts on the cylinder head.
(c) Lay a strip of Plastigage across each of the camshaft jour-
nals.
(d) Install the bearing caps (See page EM-44).
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
NOTICE:
Do not turn the camshaft.
(e) Remove the bearing caps.
(f) Measure the Plastigage at its widest point.
Standard oil clearance:
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the cam-
shaft. If necessary, replace the bearing caps and cylinder head
as a set.
(g) Completely remove the Plastigage.
15. INSPECT CAMSHAFT THRUST CLEARANCE
(a) Install the camshaft (See page EM-44).
(b) Using a dial indicator, measure the thrust clearance while
moving the camshaft back and forth.
Standard thrust clearance:
0.045 - 0.100 mm (0.0018 - 0.0039 in.)
Maximum thrust clearance:
0.12 mm (0.0047 in.)

P20403
EM9940
EM2196
EM-38
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
If the thrust clearance is greater than maximum, replace the
camshaft. If necessary, replace the bearing caps and cylinder
head as a set.
16. INSPECT CAMSHAFT GEAR BACKLASH
(a) Install the camshafts without installing the exhaust cam
sub-gear (See page EM-44).
(b) Using a dial indicator, measure the backlash.
Standard backlash:
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
Maximum backlash:
0.30 mm (0.0188 in.)
If the backlash is greater than maximum, replace the cam-
shafts.
17. INSPECT VALVE LIFTERS AND LIFTER BORES
(a) Using a caliper gauge, measure the lifter bore diameter
of the cylinder head.
Lifter bore diameter:
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
(b) Using a micrometer, measure the lifter diameter.
Lifter diameter:
27.975 - 27.985 mm (1.1014 - 1.1018 in.)
(c) Subtract the lifter diameter measurement from the lifter
bore diameter measurement.
Standard oil clearance:
0.015 - 0.046 mm (0.0005 - 0.0018 in.)
Maximum oil clearance:
0.10 mm (0.0039 in.)
If the oil clearance is greater than maximum, replace the lifter.
If necessary, replace the cylinder head.

P20414
Intake
Exhaust
P20497
P20472
SST
SST
- ENGINE MECHANICALCYLINDER HEAD
EM-39
1996 TERCEL (RM440U)
18. INSPECT INTAKE AND EXHAUST MANIFOLDS
Using a precision straight edge and feeler gauge, measure the
surface contacting the cylinder head for warpage.
Maximum warpage:
Intake
0.1 mm (0.004 in.)
Exhaust
0.5 mm (0.020 in.)
If warpage is greater than maximum, replace the manifold.
19. IF NECESSARY, REPLACE SPARK PLUG TUBE GAS-
KETS
(a) Using a screwdriver, pry off the tube gasket.
(b) Using SST and a hammer, tap in a new tube gasket until
the upper edge of the cylinder head cover.
SST 09550-10012 (09252-10010, 09556-10010)
(c) Apply MP grease to the gasket lip.

EM0K1-03
P20388
SST
P20383
Both intake and exhaust
Bushing bore diameter
mm (in.)Bushing size
11.000 - 11.027
(0.4331 - 0.4342)
11.050 - 11.077
(0.4350 - 0.4361)Use STD
Use O/S 0.05
P20387
SST
12.7 -
13.1 mm
EM5935
IntakeExhaust
38.5 mm
(1.516 in.)40.5 mm
(1.594 in.) EM-40
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
REPLACEMENT
REPLACE VALVE GUIDE BUSHINGS
(a) Using SST and a hammer, tap out the guide bushing.
SST 09201-10000 (09201-01060),
09550-10012 (09252-10010)
(b) Using a caliper gauge, measure the bushing bore diame-
ter of the cylinder head.
(c) Select a new guide bushing (STD size or O/S 0.05).
If the bushing bore diameter of the cylinder head is greater than
11.027 mm (0.4341 in.), machine the bushing bore to the follow-
ing dimension:
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
If the bushing bore diameter of the cylinder head is greater than
11.077 mm (0.4361 in.), replace the cylinder head.
(d) Using SST and a hammer, tap in a new guide bushing to
where there is 12.7 - 13.1 mm (0.500 - 0.510 in.) left pro-
truding from the cylinder head.
SST 09201-70010
HINT:
Different bushings are used for the intake and exhaust.

P20384
Sharp 6 mm
Reamer
- ENGINE MECHANICALCYLINDER HEAD
EM-41
1996 TERCEL (RM440U)
(e) Using a sharp 6 mm reamer, ream the guide bushing to
obtain the standard specified clearance (See page
EM-31) between the guide bushing and valve stem.

EM0K2-04
Z14084
Protrusion
47.5 - 48.5 mm
Mark
EM9934
Adhesive
P20370
Protrusion
EM9938
EM-42
- ENGINE MECHANICALCYLINDER HEAD
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 and oil seals with new ones.
1. INSTALL SPARK PLUG TUBES
HINT:
When using a new cylinder head, spark plug tubes must be
installed.
(a) Mark the standard position away from the edge, onto the
spark plug tube.
Standard protrusion:
47.5 - 48.5 mm (1.870 - 1.909 in.)
(b) Apply adhesive to the spark plug tube hole of the cylinder
head.
Adhesive:
Part No. 08833-00070, Adhesive 1324,
THREE BOND 1324 or equivalent
(c) Using a press, press in a new spark plug tube until there
is standard protrusion protruding from the camshaft bear-
ing cap installation surface of the cylinder head.
NOTICE:
Avoid pressing a new spark plug tube in too far by measur-
ing the amount of protrusion while pressing.
2. INSTALL VALVES
(a) Using a 10 mm socket-driver, push in a new oil seal.

Z14254
Painted
Black Painted Silver Intake Exhaust
P20416
SST
EM9933
- ENGINE MECHANICALCYLINDER HEAD
EM-43
1996 TERCEL (RM440U)
HINT:
The intake valve oil seal is silver and the exhaust valve oil seal
is black.
(b) Install the valve.
(c) Install the spring seat.
(d) Install the valve spring.
(e) Install the spring retainer.
(f) Using SST, compress the valve spring and place the 2
keepers around the valve stem.
SST 09202-70010
(g) Using a plastic-faced hammer, lightly tap the valve stem
tip to assure proper fit.
3. INSTALL VALVE LIFTERS AND SHIMS
(a) Install the valve lifter and shim.
(b) Check that the valve lifter rotates smoothly by hand.
4. INSTALL STUD BOLT FOR CYLINDER HEAD COVER
5. INSTALL NO.2 ENGINE HANGER
Torque:
No. 1
21 N´m (210 kgf´cm, 15 ft´lbf)
No. 2
53 N´m (530 kgf´cm, 38 ft´lbf)

P20389
Gasket
EM1OG-01
P20419
EX
(A)
Bi-Hexagon Wrench
(B)IN
(B)
(A)(B)
(B)(B)
(B)
8
61 3
9
10 4 257
(A) (A) (A)(A) IN
EX
P20413
Painted Mark
90°
P20174
(b)(c)
(d)(e)
EM-44
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
INSTALLATION
1. PLACE CYLINDER HEAD ON CYLINDER BLOCK
(a) Place a new cylinder head gasket in position on the cylin-
der block.
NOTICE:
Be careful of the installation direction.
(b) Place the cylinder head in position on the cylinder head
gasket.
2. INSTALL CYLINDER HEAD BOLTS
HINT:

The cylinder head bolts are tightened in 2 progressive
steps (steps (b) and (d)).

If any cylinder head bolt is broken or deformed, replace
it.

There are 2 lengths of cylinder head bolts, long (A) and
short (B).
(a) Apply a light coat of engine oil on the threads and under
the heads of the cylinder head bolts.
(b) First, using a bi-hexagon wrench 8 mm, install and uni-
formly tighten the 10 cylinder head bolts, in several
passes, in the sequence shown.
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
If any one of the cylinder head bolts does not meet the torque
specification, replace the cylinder head bolt.
(c) Mark the front of the cylinder head bolt head with paint.
(d) Retighten the cylinder head bolts 90° in the numerical or-
der shown.
(e) Check that the painted mark is now at a 90° angle to front.
3. ASSEMBLE INTAKE CAMSHAFT
(a) Mount the hexagonal wrench head portion of the cam-
shaft in a vise.
NOTICE:
Be careful not to damage the camshaft.
(b) Install the camshaft gear spring.
(c) Install the camshaft sub-gear.
(d) Install the wave washer.
HINT:
Align the pins on the gears with the gear spring ends.