1996 TOYOTA TERCEL belt

P20750
P20480
SST
P20545
EM9412
EM7333
EM-90
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
15. INSTALL RH ENGINE MOUNTING BRACKET
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
16. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816-30010
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
17. INSTALL GENERATOR BRACKET
Torque: 24 N´m (240 kgf´cm, 18 ft´lbf)
18. INSTALL WATER PUMP WITH WATER INLET PIPE
19. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
20. INSTALL CYLINDER HEAD
21. INSTALL TIMING BELT AND PULLEYS
22. REMOVE ENGINE STAND
23. INSTALL REAR END PLATE
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
24. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of new mounting bolt
end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent

LU08D-05
P20907
EM9278
EM9755
P20160
- LUBRICATIONOIL PUMP
LU-7
1996 TERCEL (RM440U)
REMOVAL
HINT:
When repairing the oil pump, the oil pan and strainer should be
removed and cleaned.
1. REMOVE HOOD
2. REMOVE OIL DIPSTICK
3. DRAIN ENGINE OIL
4. REMOVE TIMING BELT (See page EM-12)
5. SUSPEND ENGINE WITH ENGINE SLING DEVICE
6. REMOVE CRANKSHAFT TIMING PULLEY(See page
EM-12)
7. w/ A/C:
REMOVE A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Disconnect the compressor connector.
(b) Remove the 4 compressor mounting bolts.
HINT:
Put a side compressor, and suspend it.
(c) Remove the 4 bolts and compressor mounting
bracket.
8. DISCONNECT FRONT EXHAUST PIPE
(a) Remove the 2 bolts and the 2 compresson springs.
(b) Disconnect the exhaust pipe.

LU-16
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with 2
compresson springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
6. w/ A/C:
INSTALL A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (270 kgf´cm, 20 ft´lbf)
(b) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Connect the A/C compressor connector.
7. INSTALL CRANKSHAFT TIMING PULLEY (See page
EM-17)
8. INSTALL TIMING BELT (See page EM-17)
9. INSTALL OIL DIPSTICK
10. FILL WITH ENGINE OIL
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK ENGINE OIL LEVEL
13. INSTALL HOOD

IG08M-04
P21254
Connector Clamp
P21034
- IGNITIONCRANKSHAFT POSITION SENSOR
IG-13
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CRANKSHAFT POSITION SENSOR
CONNECTOR AND CLAMP
2. REMOVE RH ENGINE UNDER COVER
3. REMOVE NO.2 TIMING BELT COVER (See page
EM-12)
4. REMOVE CRANKSHAFT POSITION SENSOR
Remove the bolt and disconnect the crankshaft position sensor.
Torque: 8 N´m (80 kgf´cm, 69 in.´lbf)

CH0H6-01
Z11580
Blue White Red
OK Charging
NecessaryInsufficient
Water
N00313
CH-2
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. CHECK BATTERY SPECIFIC GRAVITY AND ELEC-
TROLYTE LEVEL
(a) Check the electrolyte quantity of each cell.
If insufficient, refill with distilled (or purified) water.
(b) Check the specific gravity of each cell.
Standard specific gravity:
1.27 - 1.29 at 20°C (68°F)
If the specific gravity is less than specification, charge the bat-
tery.
HINT:
Check the indicator as shown in illustration.
2. CHECK BATTERY TERMINALS, FUSIBLE LINK AND
FUSES
(a) Check that the battery terminals are not loose or cor-
roded.
If the terminals are corroded, clean the terminals.
(b) Check the fusible link and fuses for continuity.
Fusible linkMAIN 2.0A
HfALT 100AH-fuseAM1 50A
AM2 15A
FGAUGE 15AFuseIGN 7.5A
ALT-S 7.5A
3. INSPECT DRIVE BELT
(a) Visually check the drive belt for excessive wear, frayed
cords etc.
If any defect is found, replace the drive belt.
HINT:
Cracks on the rib side of a drive belt are considered acceptable.
If the drive belt has chunks missing from the ribs, it should be
replaced.

N00280
DENSO
Borroughs
CH0087
CORRECTWRONG WRONG
P13685
CH0732
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter
B
- CHARGINGCHARGING SYSTEM
CH-3
1996 TERCEL (RM440U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooved.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
4. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
5. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the charge warn-
ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the generator
and connect it to the negative (-) tester probe of the
ammeter.

CH0H9-01
P13685
P21508
Adjusting Bolt
Pivot Bolt
CH-6
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT CONNECTOR AND WIRE FROM
GENERATOR
(a) Disconnect the connector from the generator.
(b) Remove the connector cover and nut, and disconnect the
wire from the generator.
2. REMOVE DRIVE BELT
Loosen the pivot bolt and adjusting bolt, and remove the drive
belt.
Torque:
Pivot bolt: 41 N´m (420 kgf´cm, 30 ft´lbf)
Adjusting bolt: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. REMOVE GENERATOR
(a) Remove the pivot bolt, nut and adjusting bolt.
(b) Remove the generator.

SR05N-06
SR-2
- STEERINGTROUBLESHOOTING
922 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Power steering fluid level (Low)
3. Drive belt (Loose)
4. Front wheel alignment (Incorrect)
5. Steering system joints (Worn)
6. Suspension arm ball joints (Worn)
7. Steering column (Binding)
8. Power steering gearSA-2
SR-6
SR-3
SA-4
-
SA-36
-
SR-46
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gearSA-2
SA-4
-
SR-46
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear-
SA-36
-
SA-10
SR-46
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering gearSR-6
-
SR-46