1996 TOYOTA TERCEL Service Repair Manual

P21099
P21032
- LUBRICATIONOIL PUMP
LU-9
1996 TERCEL (RM440U)
(b) Using a soft-faced hammer, carefully tap off the oil pump.
(c) Remove the oil pump body and O-ring.
(d) Using a vise, remove the nut and oil pump pulley.

LU08E-01
LU0106
LU-10
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
DISASSEMBLY
REMOVE PRESSURE REGULATOR VALVE
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the retainer, spring and pressure regulator valve
piston.

LU08F-04
LU0144
P21820
P21819
LU1165
- LUBRICATIONOIL PUMP
LU-1 1
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT PRESSURE REGULATOR VALVE
Coat the valve piston with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If necessary, replace the valve.
2. INSPECT ROTOR BODY CLEARANCE
Using a feeler gauge, measure the clearance between the driv-
en rotor and pump body.
Standard clearance:
0.10 - 0.16 mm (0.0039 - 0.0063 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.
3. INSPECT TIP CLEARANCE
Using a feeler gauge, measure the clearance between both ro-
tor tips.
Standard clearance:
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
Maximum clearance:
0.20 mm (0.0079 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set.
4. INSPECT SIDE CLEARANCE
Using a feeler gauge and flat block, measure the side clearance
as shown.
Standard clearance:
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
Minimum clearance:
2.90 mm (0.1142 in.)
If the clearance is greater than maximum, replace the oil pump
rotor set and/or pump body.

LU08G-03
EM9964
LU1170
Flush LU-12
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
REPLACEMENT
1. REMOVE OIL SEAL
Using a screwdriver, pry out the oil seal.
2. INSTALL OIL SEAL
(a) Using a socket wrench and hammer, tap in a new oil seal
until its suface is flush with the oil pump body edge.
(b) Apply MP grease to the oil seal lip.
3. REPLACE CRANKSHAFT FRONT OIL SEAL
(See page EM-83)

LU08H-01
- LUBRICATIONOIL PUMP
LU-13
1996 TERCEL (RM440U)
REASSEMBLY
INSTALL PRESSURE REGULATOR VALVE
(a) Insert the pressure regulator valve piston, spring and retainer.
(b) Using snap ring pliers, install the snap ring.

LU08I-05
EG0099
P21101
Marks
P21885
EG0097
Seal Diameter
2 - 3 mm
(0.08 - 0.12 in.)
A - AB -B
A
AB
B LU-14
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL OIL PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pump
and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the contact
surfaces and sealing grooves.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Place the driven rotors into the pump body with the marks
facing the front.
(c) Align the pully and oil pump drive shaft.
(d) Using a vise, install the oil pump pully and nut.
Torque: 37 N´m (370 kgf´cm, 27 ft´lbf)
(e) Apply seal packing to the oil pump as shown in the illustra-
tion.
Seal packing:
Part No. 08826-00080 or equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Z14807
Oil Pump
Oil PanFIPG
A' - A
Front
Seal Diameter
a: 7mm
b: 4mm
c: 5mmB' - B C' - C ab
bc
B'
BC'
C
- LUBRICATIONOIL PUMP
LU-15
1996 TERCEL (RM440U)

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.
(f) Place a new O-ring into the cylinder block side groove.
(g) Install the oil pump and tension spring bracket with the 9
bolts.
Torque: 7.5 N´m (75 kgf´cm, 65 in.´lbf)
2. INSTALL PRESSURE REGULATOR VALVE
Torque: 30 N´m (300 kgf´cm, 22 ft´lbf)
3. INSTALL OIL STRAINER
(a) Apply a little engine oil to a new O-ring.
(b) Install the O-ring to the oil strainer.
(c) Install the oil strainer with the 3 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
4. INSTALL OIL PAN
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the oil pan,
oil pump, rear oil seal retainer and cylinder block.

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

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
NOTICE:
Do not use a solvent which will affect the painted surfaces.
(b) Apply seal packing to the oil pump, rear oil seal retainer
and oil pan as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
Seal diameter:
7 mm ( 0.28 in.) for a
4 mm ( 0.16 in.) for b
5 mm ( 0.17 in.) for c

Install a nozzle that has been cut to a 4 mm ( 0.16
in.) or 7 mm (0.28 in.) or 5 mm (0.17 in.) opening.
HINT:
Avoid applying an excess amount to the surface.

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 after use.
(c) Install the oil pan with the 10 bolts.
Torque: 13 N´m (130 kgf´cm, 10 ft´lbf)
5. CONNECT FRONT EXHAUST PIPE

LU-16
- LUBRICATIONOIL PUMP
1996 TERCEL (RM440U)
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe to the exhaust manifold with 2
compresson springs and 2 bolts.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
6. w/ A/C:
INSTALL A/C COMPRESSOR AND MOUNTING
BRACKET
(a) Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (270 kgf´cm, 20 ft´lbf)
(b) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Connect the A/C compressor connector.
7. INSTALL CRANKSHAFT TIMING PULLEY (See page
EM-17)
8. INSTALL TIMING BELT (See page EM-17)
9. INSTALL OIL DIPSTICK
10. FILL WITH ENGINE OIL
11. START ENGINE AND CHECK FOR LEAKS
12. CHECK ENGINE OIL LEVEL
13. INSTALL HOOD