1996 TOYOTA TERCEL Gear oil

P20418
Main Gear
Sub-GearSST
P00400
No.3 Cylinder
No.4 Cylinder
P20378
8
6 13
24
57
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1996 TERCEL (RM440U)
(e) Using snap ring pliers, install the snap ring.
(f) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear clockwise, and
install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
4. INSTALL INTAKE AND EXHAUST CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Apply engine oil to the thrust portion of intake camshaft.
(b) Place the intake camshaft as shown in the illustration so
that the service bolt of the intake camshaft gears are di-
rectly above.
HINT:
This helps to lift the intake camshaft in a level and uniform man-
ner by pushing No.3 and No.4 cylinder cam lobes of the intake
camshaft toward their vale lifters.
(c) Install the 4 bearing caps in their proper locations.
(d) Temporarily tighten the bearing cap bolts uniformly and
alternately, in several passes, in the sequence shown un-
til the bearing caps are snug with the cylinder head.

EG0010
Timing Mark
P20369
Timing Mark
EXIN
Other Timing Mark
P20377
8
6
13 4
2
57
P20248
Seal Packing EM-46
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(e) Apply engine oil to thrust portion of the exhaust camshaft.
(f) Engage the exhaust camshaft gear to the intake cam-
shaft gear by matching the timing marks on each gear.
NOTICE:
There are also assembly reference marks on each gear as
shown in the illustration. Do not use these marks.
(g) Roll down the exhaust camshaft onto the bearing journals
while engaging gears with each other.
HINT:
The above angle allows the No.2 and No.4 cylinder cam lobes
of the exhaust camshaft to push their valve lifters evenly.
(h) Lightly push the exhaust camshaft gear without applying
excessive force.
(i) Install the 4 bearing caps in their proper locations.
(j) Temporarily tighten the bearing cap bolts uniformly and
alternately, in several passes, in the sequence shown un-
til the bearing caps are snug with the cylinder head.
(k) Remove the service bolt.
(l) Clean the installed surfaces of the No.2 bearing cap and
cylinder head with cleaner.
(m) Apply seal packing to the No.2 bearing cap as shown.
Seal packing:
Part No. 08826-00080 or equivalent

P20410
P20366
8
6
13 4
2
57
9 10
P20369
Timing Mark
EXIN
Other Timing Mark
P20557
P20363
EM-48
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(v) Place the No.1 bearing cap in its proper location. When
doing this, check that there is no gap between the cylinder
head and the contact surface of bearing cap.
(w) Temporarily tighten the bearing cap bolts, alternately
tightening the left and right bolts uniformly.
(x) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(y) Turn the camshaft 1 revolution and check that the timing
marks of the camshaft gears are aligned.
5. CHECK AND ADJUST VALVE CLEARANCE (See page
EM-4)
6. 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 the pulley.
(b) Secure the hexagonal portion of the camshaft, and install
and torque the bolt.
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
7. INSTALL NO.2 IDLER PULLEY
Install the idler pulley with the bolt. Torque the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
HINT:
Remove any oil or water on the idler pulley and keep it clean.

P20175
New
Gasket
FI1654
Fulcrum Length
SST
30 cm
FI4295
CORRECT
WRONG
WRONG Delivery Pipe O-Ring
Grommet
Injector
FI4296
Delivery
Pipe
O-Ring
Grommet
InjectorCylinder Head
- MFIMFI SYSTEM
MF-3
527 Author
: Date
:
1996 TERCEL (RM440U)
(b) When connecting the union bolt on the high pressure pipe
union, observe these procedures:
(1) Always use 2 new gaskets.
(2) Tighten the union bolt by hand.
(3) Tighten the union bolt to the specified torque.
Torque: 29.0 N´m (290 kgf´cm, 22 ft´lbf)
(c) When connecting the flare nut on the high pressure pipe
union, observe these procedures:
(1) Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(2) Using SST, tighten the flare nut to specified torque.
SST 09631-22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(d) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O-ring.
(2) When placing a new O-ring on the injector, take
care not to damage it in any way.
(3) Coat a new O-ring with spindle oil or gasoline be-
fore installing-never use engine, gear or brake oil.
(e) Install the injector in the delivery pipe and cylinder head
as shown in the illustration.

ST0N2-01
B11226
End CoverBrush Holder
Rear BearingArmature
Front Bearing
Field Frame (Field Coil)
Startor Housing
Bearing
Idler Gear
Magnetic Switch Assembly
Return Spring
Steel BallClutch Assembly

Terminal C Kit Part
Terminal 30 Kit Part
Terminal Nut
Wave Washer
O-Ring
Terminal Insulater Outer
Contact Plate
Insulation
Paper
Terminal Insulater Inner
Terminal Bolt
Lead Clamp
End Cover
GasketPlungerO-Ring
Wave Washer
Terminal Nut
Terminal Insulater Outer
Terminal Bolt
Lead Terminal
Contact Plate
Terminal Insulater Inner

Non-reusable part ST-2
- STARTINGSTARTER (Reduction Type)
647 Author
: Date
:
1996 TERCEL (RM440U)
STARTER (Reduction Type)
COMPONENTS

ST0199
Continuity
ST0200
No Continuity
N00337
ST0019
ST0203
Continuity
- STARTINGSTARTER (Reduction Type)
ST-7
1996 TERCEL (RM440U)
7. INSPECT FIELD COIL FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
lead wire and field coil brush lead.
If there is no continuity, replace the field frame.
8. INSPECT FIELD COIL FOR GROUND
Using an ohmmeter, check that there is no continuity between
the field coil end and field frame.
If there is continuity, replace the field frame.
9. INSPECT BRUSH LENGTH
Using a vernier caliper, measure the brush length.
Standard length: 13.5 mm (0.531 in.)
Minimum length: 8.5 mm (0.334 in.)
If the length is less than minimum, replace the brush holder and
field frame.
10. INSPECT BRUSH SPRING LOAD
Take the pull scale reading the instant the brush spring sepa-
rates from the brush.
Standard spring installed load:
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
Minimum spring installed load:
11.8 N (1.2 kgf, 2.6 lbf)
If the installed load is not as specified, replace the brush
springs.
11. INSPECT BRUSH HOLDER INSULATION
Using an ohmmeter, check that there is no continuity between
the positive (+) and negative (-) brush holders.
If there is continuity, repair or replace the brush holder.
12. INSPECT GEAR TEETH
Check the gear teeth on the pinion gear, idle gear and the clutch
assembly for wear or damage.
If damaged, replace the gear or clutch assembly.
If damaged, also check the drive plate ring gear for wear or
damage.

P10821
Free
Lock
ST0204
Terminal 50
Continuity
Terminal C
ST0205
Continuity Terminal 50Switch Body ST-8
- STARTINGSTARTER (Reduction Type)
1996 TERCEL (RM440U)
13. INSPECT CLUTCH PINION GEAR
Rotate the pinion gear clockwise, and check that it turns freely.
Try to rotate the pinion gear counterclockwise and check that
it locks.
If necessary, replace the clutch assembly.
14. INSPECT REAR BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
15. INSPECT FRONT BEARING
Turn each bearing by hand while applying inward force.
If resistance is felt or the bearing sticks, replace the bearing.
16. DO PULL-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minals 50 and C.
If there is no continuity, check and replace the magnetic switch.
17. DO HOLD-IN COIL OPEN CIRCUIT TEST
Using an ohmmeter, check that there is continuity between ter-
minal 50 and the switch body.
If there is no continuity, check and replace the magnetic switch.

ST0J1-01
P13459
Terminal 50
Terminal C
Battery
P13460
Terminal C
Battery
Disconnect
P13461
Battery
Disconnect
P13462
Battery
Ammeter Terminal 50
Terminal 30
- STARTINGSTARTER (Reduction Type)
ST-13
1996 TERCEL (RM440U)
TEST
NOTICE:
These tests must be performed within 3 to 5 seconds to
avoid burning out the coil.
1. DO HOLD-IN TEST
(a) Disconnect the field coil lead wire from terminal C.
(b) Connect the battery to the magnetic switch as shown.
Check that the clutch pinion gear moves outward.
2. DO HOLD-IN TEST
With battery connected as above with the clutch pinion gear
out, disconnect the negative (-) lead from terminal C. Check
that the pinion gear remains out.
3. INSPECT CLUTCH PINION GEAR RETURN
Disconnect the negative (-) lead from the switch body.
Check that the clutch pinion gear returns inward.
4. DO NO-LOAD PERFORMANCE TEST
(a) Connect the battery and ammeter to the starter as shown.
(b) Check that the starter rotates smoothly and steadily with
the pinion gear moving out. Check that the ammeter the
current specified in the respective repair manual.