1996 TOYOTA TERCEL torque

SS061-41
- SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
SS-39
169 Author
: Date
:
1996 TERCEL (RM440U)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Steering wheel3435025
Steering wheel pad8.89078 in.´lbf
Front passenger airbag assembly1919514
Airbag sensor assembly2020014

SS0NJ-06
SS-42
- SERVICE SPECIFICATIONSBODY
172 Author
: Date
:
1996 TERCEL (RM440U)
BODY
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT SEAT
Seat track x Body3737527
REAR SEAT
Seat back x Body1818513
Seat x Seat center hinge1818513
Seat center hinge x Body7.88069 in.´lbf
Seat x Seat hinge1818513
Seat hinge x Body7.88069 in.´lbf
FRONT SEAT BELT
Shoulder anchor x Adjustable anchor4344032
Outer belt anchor x Body4344032
ELR x Body4344032
Adjustable anchor x Body4344032
Inner belt x Seat4344032
REAR SEAT BELT
Outer belt anchor x Body4344032
ELR x Body4344032
Center belt x Body4344032
CANADA:
CRS, tether anchor x Body
2121015

SS0MA-05
SS-44
- SERVICE SPECIFICATIONSAIR CONDITIONING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Compressor x Suction hose101007
Compressor x Discharge hose101007
Compressor x Compressor bracket2525018
Receiver x Liquid tube5.45548 in.´lbf
Condenser x Liquid tube5.45548 in.´lbf
Cooling unit x Liquid tube1414010
Cooling unit x Suction tube3233024
Expansion valve x Evaporator5.45548 in.´lbf
Revolution detecting sensor x Compressor1111 08
Pressure plate x Compressor1414010

EM0494
P20156
SST(A)
SST(B)
EM-6
- ENGINE MECHANICALVALVE CLEARANCE
427 Author
: Date
:
1996 TERCEL (RM440U)
(b) Determine the replacement adjusting shim size by the fol-
lowing Formula or Charts on the next 2 pages:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N = T + (A - 0.20 mm (0.008 in.))
Exhaust:
N = T + (A - 0.36 mm (0.014 in.))
Select a new shim with a thickness as close as possible
to the calculated value.
HINT:
Shims are available in 17 increments of 0.05 mm (0.0020 in.),
from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
(1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248-55040 (09248-05410, 09248-05020)
(d) Recheck the valve clearance.
7. REINSTALL 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
cap nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install oil filler cap.
8. REINSTALL IGNITION COILS AND HIGH-TENSION
CORDS
9. RECONNECT EGR VACUUM MODULATOR
10. RECONNECT PCV HOSES TO CYLINDER HEAD COV-
ER

EM1OE-01
P20743
P20742
P20744
P20390SST
P20915
Timing Mark
SST
Installation
Mark
- ENGINE MECHANICALTIMING BELT
EM-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CRANKSHAFT TIMING PULLEY
(a) Align the pulley set key with the key groove of the pulley.
(b) Slide on the timing pulley, facing the rotor side of the
crankshaft position sensor inward.
2. TEMPORARILY INSTALL NO.1 IDLER PULLEY AND
TENSION SPRING
(a) Install the tension spring to the idler pulley.
(b) Align the bracket pin hole with the pivot pin.
(c) Install the idler pulley with the bolt. Do not tighten the bolt
yet.
(d) Pry the idler pulley toward the left as far as it will go and
temporarily tighten the bolt.
(e) Check that the idler pulley moves smoothly.
3. INSTALL NO.2 IDLER PULLEY
(a) Install the idler pulley with the bolt.
Torque: 28 N´m (280 kgf´cm, 20 ft´lbf)
(b) Check that the idler pulley moves smoothly.
4. 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 on the timing
pulley.
(b) Using SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 51 N´m (510 kgf´cm, 37 ft´lbf)
5. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Using SST, align the hole of the camshaft timing pulley on
the side with the 5E mark with the timing mark of the bear-
ing cap.
SST 09960-10010 (09962-01000, 09963-01000)

P21439
2 Revolutions
P20537
Timing Mark
P20552
P20745
P20157
SST
- ENGINE MECHANICALTIMING BELT
EM-19
1996 TERCEL (RM440U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) 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.
(d) Tighten the No.1 idler pulley bolt.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
(e) Remove the crankshaft pulley bolt.
8. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
9. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 3 bolts.
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-14010, 09330-00021
Torque: 155 N´m (1,550 kgf´cm, 112 ft´lbf)

P20159
P20153
Ground Strap EM-20
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
12. w/ A/C and/or w/ PS:
INSTALL NO.2 CRANKSHAFT PULLEY
Install the No.2 crankshaft pulley with the 4 bolts.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
13. INSTALL NO.2 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 4 bolts.
14. INSTALL RH ENGINE MOUNTING INSULATOR
(a) Attach the RH mounting insulator to the mounting bracket
and body, and temporarily install the through bolt, 2 bolts
and nut.
(b) Torque the 2 bolts, nut and through bolt of the RH mount-
ing insulator.
Torque:
Through bolt
73 N´m (740 kgf´cm, 54 ft´lbf)
Others
64 N´m (650 kgf´cm, 47 ft´lbf)
(c) Connect the ground strap with the bolt.
15. INSTALL GENERATOR DRIVE BELT (See page
CH-2)
16. w/ A/C and/or w/ PS:
INSTALL DRIVE BELT
(See page AC-18 and SR-3)
17. INSTALL RH ENGINE UNDER COVER

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.)