1996 TOYOTA TERCEL Service Repair Manual

- ENGINE MECHANICALENGINE UNIT
EM-67
1996 TERCEL (RM440U)
19. INSTALL CHARCOAL CANISTER
(a) Install the charcoal canister to the bracket.
(b) Connect the canister hoses.
20. 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)
21. CONNECT ACCELERATOR CABLE, AND ADJUST IT
22. INSTALL RADIATOR (See page CO-22)
23. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
24. FILL WITH TRANSAXLE OIL (FLUID)
25. FILL WITH ENGINE COOLANT
26. INSTALL ENGINE UNDER COVERS
27. INSTALL HOOD
28. START ENGINE AND CHECK FOR LEAKS
29. PERFORM ENGINE ADJUSTMENT
30. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points
and smooth operation.
31. RECHECK ENGINE COOLANT AND ENGINE OIL LEV-
ELS

EM0JP-05
EM-68
- ENGINE MECHANICALCYLINDER BLOCK
489 Author
: Date
:
1996 TERCEL (RM440U)
CYLINDER BLOCK
COMPONENTS

- ENGINE MECHANICALCYLINDER BLOCK
EM-69
490 Author
: Date
:
1996 TERCEL (RM440U)

EM0JQ-06
EM9411
EM9412
P20480
SST
P20478
SST
P20477
12 mm
Hexagon
Wrench EM-70
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
DISASSEMBLY
1. M/T:
REMOVE CLUTCH COVER AND DISC
2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
8. REMOVE WATER PUMP WITH WATER INLET PIPE
9. REMOVE GENERATOR BRACKET
10. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816-30010
11. REMOVE RH ENGINE MOUNTING BRACKET
12. REMOVE OIL FILTER
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
14. REMOVE OIL PUMP AND PRESSURE REGULATOR
VA LV E
15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.

EM9988
EM3441
P20487
EM9392
EM3444
- ENGINE MECHANICALCYLINDER BLOCK
EM-71
1996 TERCEL (RM440U)
16. REMOVE REAR OIL SEAL RETAINER
(a) Remove the 4 bolts.
(b) Using a screwdriver, remove the oil seal retainer by prying
the portions between the oil seal retainer and main bear-
ing cap.
17. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the rod back and forth.
Standard thrust clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in.)
Maximum thrust clearance:
0.45 mm (0.0177 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
18. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using a soft-faced hammer, lightly tap the connecting rod
bolt and lift the cap and lower bearing.
HINT:
Keep the lower bearing inserted with the connecting rod cap.

EM3445
EM9405
EM3447
Plastigage
EM3448
EM3449
EM-72
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin bearing is for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.
(h) Install the connecting rod cap (See page EM-85).
Torque: 40 N´m (400 kgf´cm, 29 ft´lbf)
NOTICE:
Do not turn the crankshaft.
(i) Remove the connecting rod cap
(See procedure (b) and (c) above).
(j) Measure the Plastigage at its widest point.
Standard oil clearance:
STD0.016 - 0.048 mm (0.0006 - 0.0019 in.)
U/S 0.250.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum oil clearance:
0.08 mm (0.0031 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

P20473
Mark
1,2 or 3
Mark
1,2 or 3
P20491
EM3445
- ENGINE MECHANICALCYLINDER BLOCK
EM-73
1996 TERCEL (RM440U)
HINT:
If using a standard bearing, replace with one having the same
number as marked on the bearing cap. There are 3 sizes of
standard bearings, marked
º1º, º2º and º3º accordingly.
Reference:
Connecting rod big end inside diameter
Standard sized
U/S 0.25
Mark 1
Mark 2
Mark 3
-46.000 - 46.007 mm (1.8110 - 1.8113 in.)
46.007 - 46.014 mm (1.8113 - 1.8116 in.)
46.014 - 46.021 mm (1.8116 - 1.8118 in.)
46.000 - 46.021 mm (1.8110 - 1.8118 in.)
Crankshaft crank pin diameter
Standard sized
U/S 0.25
-
-42.985 - 43.000 mm (1.6923 - 1.6929 in.)
42.745 - 42.755 mm (1.6829 - 1.6833 in.)
Bearing center wall thickness
Standard sized
U/S 0.25
Mark 1
Mark 2
Mark 3
-1.487 - 1.491 mm (0.0585 - 0.0587 in.)
1.491 - 1.495 mm (0.0587 - 0.0589 in.)
1.495 - 1.499 mm (0.0589 - 0.0590 in.)
1.609 - 1.615 mm (0.0633 - 0.0636 in.)
(k) Completely remove the Plastigage.
19. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Cover the rod bolts with a short piece of hose to protect
the crankshaft from damage.
(c) Push out the piston and connecting rod assembly and the
upper bearing though the top of the cylinder block.
HINT:

Keep the bearing, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in cor-
rect order.

P20547
P20190
481062
1
5
9
7
3
P20486
EM9403
EM-74
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
20. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.02 - 0.20 mm (0.0008 - 0.0079 in.)
Maximum thrust clearance:
0.3 mm (0.012 in.)
If the thrust clearance is greater than maximum, replace the
thrust washers as a set.
Thrust washer thickness:
STD2.430 - 2.480 mm (0.0957 - 0.0976 in.)
O/S 0.1252.493 - 2.543 mm (0.0981 - 0.1001 in.)
21. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts, in several passes, in the sequence shown.
(b) Using the removed main bearing cap bolts, pry the main
bearing cap back and forth, and remove the 5 main bear-
ing caps, 5 lower bearings and 2 lower thrust washers
(No.3 main bearing cap only).
HINT:

Keep the lower bearing inserted together with cap.

Arrange the main bearing caps and lower thrust washers
in correct order.
(c) Lift out the crankshaft.
HINT:
Keep the upper bearings and upper thrust washers together
with the cylinder block.