1996 TOYOTA TERCEL Service Repair Manual

Z07818
75
60° (IN only)
45°
1.0 - 1.4 mm
P20352
EM0988
Deviation
EM0801
EM0281
- ENGINE MECHANICALCYLINDER HEAD
EM-35
1996 TERCEL (RM440U)
(2) If the seating is too low on the valve face, use 75°,
60° (IN only) and 45° cutters to correct the seat.
(e) Hand-lap the valve and valve seat with an abrasive com-
pound.
(f) After hand-lapping, clean the valve and valve seat.
8. INSPECT VALVE SPRINGS
(a) Using a steel square, measure the deviation of the valve
spring.
Maximum deviation: 2.0 mm (0.079 in.)
If the deviation is greater than maximum, replace the valve
spring.
(b) Using a vernier caliper, measure the free length of the
valve spring.
Free length: 53.58 mm (2.1094 in.)
If the free length is not as specified, replace the valve spring.
(c) Using a spring tester, measure the tension of the valve
spring at the specified installed length.
Installed tension:
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
at 31.8 mm (1.252 in.)
If the installed tension is not as specified, replace the valve
spring.

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.

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.