1996 TOYOTA TERCEL check oil

EM0494
P20156
SST(A)
SST(B)
EM-6
- ENGINE MECHANICALVALVE CLEARANCE
427 Author
: Date
:
1996 TERCEL (RM440U)
(b) Determine the replacement adjusting shim size by the fol-
lowing Formula or Charts on the next 2 pages:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N = T + (A - 0.20 mm (0.008 in.))
Exhaust:
N = T + (A - 0.36 mm (0.014 in.))
Select a new shim with a thickness as close as possible
to the calculated value.
HINT:
Shims are available in 17 increments of 0.05 mm (0.0020 in.),
from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
(1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248-55040 (09248-05410, 09248-05020)
(d) Recheck the valve clearance.
7. REINSTALL 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
cap nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install oil filler cap.
8. REINSTALL IGNITION COILS AND HIGH-TENSION
CORDS
9. RECONNECT EGR VACUUM MODULATOR
10. RECONNECT PCV HOSES TO CYLINDER HEAD COV-
ER

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.

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.

P20382
Z00052
Z00054
44.5°
EM0181
Margin Thickness
- ENGINE MECHANICALCYLINDER HEAD
EM-33
1996 TERCEL (RM440U)
5. INSPECT VALVE STEMS AND GUIDE BUSHINGS
(a) Using a caliper gauge, measure the inside diameter of the
guide bushing.
Bushing inside diameter:
6.010 - 6.030 mm (0.2366 - 0.2374 in.)
(b) Using a micrometer, measure the diameter of the valve
stem.
Valve stem diameter:
Intake5.970 - 5.985 mm (0.2350 - 0.2356 in.)
Exhaust5.965 - 5.980 mm (0.2348 - 0.2354 in.)
(c) Subtract the valve stem diameter measurement from the
guide bushing inside diameter measurement.
Standard oil clearance:
Intake0.025 - 0.060 mm (0.0010 - 0.0024 in.)
Exhaust0.030 - 0.065 mm (0.0012 - 0.0026 in.)
Maximum oil clearance:
Intake0.08 mm (0.0031 in.)
Exhaust0.10 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve and
guide bushing (See page EM-40).
6. INSPECT AND GRIND VALVES
(a) Grind the valve enough to remove pits and carbon.
(b) Check that the valve is ground to the correct valve face
angle.
Valve face angle: 44.5°
(c) Check the valve head margin thickness.
Standard margin thickness:
0.8 - 1.2 mm (0.031 - 0.047 in.)
Minimum margin thickness:
0.5 mm (0.020 in.)
If the margin thickness is less than minimum, replace the valve.

P20379
P20385
P20386
EG0008
EM-36
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. INSPECT CAMSHAFTS AND BEARINGS
Inspect the camshaft for runout.
(1) Place the camshaft on V-blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than maximum, replace the cam-
shaft.
10. INSPECT CAM LOBES
Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake41.514 - 41.614 mm (1.6344 - 1.6383 in.)
Exhaust41.011 - 41.111 mm (1.6146 - 1.6185 in.)
Minimum cam lobe height:
Intake41.35 mm (1.6279 in.)
Exhaust40.85 mm (1.6083 in.)
If the cam lobe height is less than minimum, replace the cam-
shaft.
11. INSPECT CAMSHAFT JOURNALS
Using a micrometer, measure the journal diameter.
Journal diameter:
Exhaust No.124.949 - 24.965 mm (0.9822 - 0.9829 in.)
Others22.949 - 22.965 mm (0.9035 - 0.9041 in.)
If the journal diameter is not as specified, check the oil clear-
ance.
12. INSPECT CAMSHAFT BEARINGS
Check that bearings for flaking and scoring.
If the bearings are damaged, replace the bearing caps and cyl-
inder head as a set.

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.