1996 TOYOTA TERCEL head bolt

SF0X4-05
FI3271
New
O-Ring
New Grommet
P00159
CORRECT
WRONG
InjectorDelivery Pipe GrommetO-Ring
WRONG
P20295
Spacer
Insulator
Connector MF-22
- MFIINJECTOR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to an O-ring, and install it
to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Place the 2 spacers and 4 insulators in position on the cyl-
inder head.
(e) Place the injectors together with the delivery pipe on the
cylinder head.
(f) Check that the injectors rotate smoothly.
HINT:
If the injectors do not rotate smoothly, the probable cause is in-
correct installation of O-rings. Replace the O-rings.
(g) Position the injector connector upward.
(h) Install the 2 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
2. CONNECT ENGINE WIRE
(a) Connect the 4 injector connectors.
(b) Connect the engine wire to the surge tank stay.
3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Install 2 new gaskets and the inlet hose with the union
bolt.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
(b) Connect the engine wire clamp to the No.2 engine hang-
er.
4. CONNECT FUEL RETURN HOSE TO FUEL RETURN
PIPE
5. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR

IG08G-03
S06147
- IGNITIONIGNITION COIL
IG-7
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT HIGH-TENSION CORDS FROM IGNI-
TION COILS (See page IG-1)
2. REMOVE IGNITION COILS
(a) Disconnect the 2 connectors from the ignition coils.
(b) Remove the 2 bolts and 2 ignition coils from cylinder
head.
Torque: 8.5 N´m (85 kgf´cm, 70 in.´lbf)
HINT:
Arrange the ignition coils in correct order.

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

Q06552
Q08461
AB
C
CC
A
Q06446
Q08159
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-5
1996 TERCEL (RM440U)
14. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
(b) Remove the 2 bolts, springs and gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the bolt, clamp and gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Disconnect the 2 rings and remove the exhaust front pipe.
15. REMOVE STARTER
Disconnect the connector and wire and remove the starter.
16. DISCONNECT SPEEDOMETER CABLE
17. REMOVE ENGINE REAR MOUNTING INSULATOR
Remove the 6 bolts and insulator.
Torque:
Bolt A: 78 N´m (800 kgf´cm, 58 ft´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 90 N´m (920 kgf´cm, 67 ft´lbf)
18. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 36 ft´lbf)
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 4 bolts.
Torque:
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
10 mm head: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
21. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Install and torque the 7 bolts.
Torque:
Upper side mounting bolts: (See step 7)
Lower side mounting bolts: (See step 20)

MT0094
FIPG
Q08153
MT0093Align Alignment Mark
Q06515
C151 Only
N00045
MX-14
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
21. REMOVE REVERSE IDLER GEAR, THRUST WASHER
AND SHAFT
22. REMOVE REVERSE SHIFT ARM BRACKET
Remove the 2 bolts and bracket.
Torque: 17 N´m (175 kgf´cm, 13 ft´lbf)
HINT:
Install the reverse idler gear, thrust washer and shaft, as shown.
23. REMOVE SHIFT FORK AND SHIFT FORK SHAFT
(a) Using 2 screwdrivers and a hammer, tap out the 3 (C151)
or 2 (C141) snap rings.
(b) Remove the 3 set bolts.
Torque: 16 N´m (160 kgf´cm, 12 ft´lbf)
(c) C141:
Using a pin punch and hammer, remove the slotted spring
pin from the reverse shift fork.
(d) Remove the No.2 shift fork shaft and shift head.

SR17S-01
SR-16
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE SLIDING YOKE
Remove the bolt.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered-head bolts.
(b) Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.
3. REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT
BUSHING
(a) Using snap ring expander, remove the snap ring from the
shaft assembly.
(b) Using a plastic hammer, tap out the shaft assembly from
the column tube.
(c) Using snap ring expander, remove the snap ring from the
shaft assembly.
4. REMOVE STEERING SUPPORT
(a) Remove the set bolt and nut.
(b) Remove the 2 steering support No.1 collars.

SR17U-01
R11676
- STEERINGNON-TIL T STEERING COLUMN
SR-19
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL STEERING SUPPORT
(a) Install the 2 steering support No.1 collars.
(b) Torque the set bolt and nut.
Torque: 5.4 N´m (55 kgf´cm, 48 ft´lbf)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly to the column tube.
(c) Using snap ring expander, install a new snap ring to the
shaft assembly.
3. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
Tighten the 2 new tapered-head bolts until the bolts head break
off.
4. INSTALL SLIDING YOKE
Temporarily tighten the bolt.

SR0KS-01
SR-36
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE STEERING WHEEL PAD
(See page SR-13)
3. REMOVE STEERING WHEEL
(See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
6. DISCONNECT SLIDING YOKE
(See page SR-13)
7. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
8. REMOVE MANUAL STEERING GEAR ASSEMBLY
Remove the gear assembly from the LH side of the vehicle.