1996 TOYOTA TERCEL Cylinder head

P20411
P20365
8
613
4
2 57
9
10
EM0050
MP Grease
P20407
P20247
Seal Packing
- ENGINE MECHANICALCYLINDER HEAD
EM-47
1996 TERCEL (RM440U)
(n) Place the No.2 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.
(o) Temporarily tighten the bearing cap bolts, alternately
tightening the left and right bolts uniformly.
(p) Install the camshaft housing plug.
(q) Install and uniformly tighten the 10 bearing cap bolts, in
several passes, in the sequence shown.
Torque: 13 N´m (13 kgf´cm, 9 ft´lbf)
(r) Apply MP grease to a new camshaft oil seal lip.
(s) Install the oil seal as far as the deepest part of the cylinder
head.
(t) Clean the installed surfaces of the No.1 bearing cap and
cylinder head with cleaner.
(u) Apply seal packing to the No.1 bearing cap as shown.
Seal packing:
Part No. 08826-00080 or equivalent

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8
6
13 4
2
57
9 10
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Timing Mark
EXIN
Other Timing Mark
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- 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.

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Timing Mark
Installation
Mark
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- ENGINE MECHANICALCYLINDER HEAD
EM-49
1996 TERCEL (RM440U)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
(b) Turn the camshaft, and align the hole of the camshaft tim-
ing pulley on the side with the 5E mark with the timing
mark of the bearing cap.
9. INSTALL TIMING BELT
(a) Starting from the right hand side of the pulley and instal-
ling the belt counterclockwise.
(b) Loosen the No.1 idler pulley mounting bolt until the pulley
is moved slightly by the spring tension.
(c) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.

P20538
Timing Mark
Installation Mark
P20361
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Seal Packing
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EM-50
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(d) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(e) Tighten the mounting bolt of the No.1 idler pulley.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL GENERATOR DRIVE BELT (See page
CH-2)
12. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 4 bolts.
13. INSTALL CHARCOAL CANISTER (See page EM-17)
14. INSTALL 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
nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install the oil filler cap.
15. INSTALL INTAKE MANIFOLD
(a) Install air pipe a new gasket and the intake manifold with
the 2 bolts and 3 nuts.
Torque: 19.5 N´m (195 kgf´cm, 14 ft´lbf)

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Seal PackingCORRECT WRONG
- ENGINE MECHANICALCYLINDER HEAD
EM-51
1996 TERCEL (RM440U)
(b) Install the manifold stay with the bolt and nut.
Torque: 20 N´m (200 kgf´cm, 15 ft´lbf)
(c) Connect the engine wire clamps to the intake manifold
stay.
16. CONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
17. INSTALL INJECTORS AND DELIVERY PIPE (See page
MF-22)
18. INSTALL EXHAUST MANIFOLD
(a) Install a new gasket and the exhaust manifold with the 6
nuts. Uniformly tighten the nuts in several passes.
Torque: 48 N´m (480 kgf´cm, 35 ft´lbf)
(b) Place the exhaust manifold stay snug against the cylinder
block and exhaust manifold.
(c) First, tighten the bolt (A) and then the 2 nuts.
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
(d) Install the heat insulator with the 3 bolts.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
19. INSTALL WATER INLET AND OUTLET HOUSING
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contacting surfaces of the water
outlet housing and cylinder head.

Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the gasket sur-
faces.

Thoroughly clean all components to remove all the
loose material.

Clean both sealing surfaces with a non-residue sol-
vent.
(b) Apply seal packing to the water outlet housing as shown
in the illustration.
Seal packing:
Part No. 08826-00100, THREE BOND 1282B
or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

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- ENGINE MECHANICALCYLINDER HEAD
EM-53
1996 TERCEL (RM440U)
22. INSTALL EGR PIPE
Install a new gasket, sleeve ball and the EGR pipe with the
union nut and 2 nuts.
Torque:
Union nut
40 N´m (400 kgf´cm, 29 in.´lbf)
Nut
30 N´m (300 kgf´cm, 22 in.´lbf)
23. INSTALL THROTTLE BODY (See page MF-32)
24. CONNECT VACUUM HOSES
(a) Connect the vacuum hose from the EGR valve.
(b) Connect the 3 vacuum hoses from the throttle body.
(c) Connect the vacuum hose from TVV (to charcoal canis-
ter).
(d) Connect the vacuum hose from the TVV (to throttle body).
(e) Connect the vacuum hose from the EGR VSV.
25. INSTALL IGNITION COILS AND SPARK PLUGS
26. w/ A/C and w/o PS:
INSTALL IDLER PULLEY BRACKET
(a) Install the idler pulley bracket with the 3 bolts.
Torque:
12 mm head bolt
27 N´m (275 kgf´cm, 20 ft´lbf)
14 mm head bolt
37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Install and adjust the drive belt (See page AC-18).
27. w/ PS:
INSTALL PS PUMP BRACKET AND PS PUMP
(a) Install the PS pump bracket with the 3 bolts.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(b) Temporarily install the PS pump and drive belt with the 2
bolts (See page SR-33).
(c) Adjust the belt tension (See page SR-3).
28. CONNECT FUEL HOSE
Connect the fuel inlet hose with the union bolt and 2 new gas-
kets.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
29. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
30. INSTALL ACCELERATOR CABLE, AND ADJUST IT
31. A/T:
CONNECT THROTTLE CABLE, AND ADJUST IT

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EM-54
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
32. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with
the 2 compression spring and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
33. INSTALL RH ENGINE UNDER COVER
34. FILL WITH ENGINE COOLANT (See page CO-2)
35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT
37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
38. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS