1996 TOYOTA TERCEL flywheel

IN-32
- INTRODUCTIONTERMS
32 Author
: Date
:
1996 TERCEL (RM440U) CW
Curb Weight
DCDirect Current
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLIDistributorless Ignition
DOHCDouble Over Head Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
EBDElectronic Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro-Deposited Coating
EDICElectric Diesel Injection Control
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGR-VMExhaust Gas Recirculation-Vacuum Modulator
ELREmergency Locking Retractor
ENGEngine
ESAElectronic Spark Advance
ETCSElectronic Throttle Control System
EVPEvaporator
E-VR VElectric Vacuum Regulating Valve
EXHExhaust
FEFuel Economy
FFFront-Engine Front-Wheel-Drive
F/GFuel Gage
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront-Engine Rear-Wheel-Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront-Wheel-Drive
GASGasoline
GSAGear Shift Actuator
GNDGround
HACHigh Altitude Compensator

PP18T-03
- PREPARATIONENGINE MECHANICAL
PP-7
1996 TERCEL (RM440U)
SSM (Special Service Materials)
08826-00080Seal Packing Black or equivalent
(FIPG)Camshaft bearing cap (No. 1 and
No. 2)
Cylinder head cover
Rear oil seal retainer
08826-00100Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)Water outlet housing
08833-00070Adhesive 1324,
THREE BOND 1324 or equivalentSpark plug tube
Flywheel or drive plate bolt
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentOil pressure switch

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015

SS0KR-04
- SERVICE SPECIFICATIONSCLUTCH
SS-23
153 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH
SERVICE DATA
Pedal height from ashalt sheet143.0 - 151.0 mm (5.944 - 5.945 in.)
Push rod play at pedal top1.0 - 5.0 mm (0.039 - 0.197 in.)
Pedal freeplay5.0 - 15.0 mm (0.197 - 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON-OFF stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 - 3.5 mm (0.059 - 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runout Max.0.8 mm (0.031 in.)
Flywheel runoutMax.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)Dia hragm s ring finger wear Max. de th
Max. width
0.6 mm (0.024 in.)
5.0 mm (0.197 in.)
Diaphragm spring tip non-alignment Max.0.5 mm (0.020 in.)

SS0KS-01
SS-24
- SERVICE SPECIFICATIONSCLUTCH
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch line union1515511
Master cylinder installation nut121209
Bleeder plug8.38574 in.´lbf
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209

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.

P20750
P20480
SST
P20545
EM9412
EM7333
EM-90
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
15. INSTALL RH ENGINE MOUNTING BRACKET
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
16. INSTALL KNOCK SENSOR
Using SST, install the knock sensor.
SST 09816-30010
Torque: 45 N´m (450 kgf´cm, 33 ft´lbf)
17. INSTALL GENERATOR BRACKET
Torque: 24 N´m (240 kgf´cm, 18 ft´lbf)
18. INSTALL WATER PUMP WITH WATER INLET PIPE
19. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
20. INSTALL CYLINDER HEAD
21. INSTALL TIMING BELT AND PULLEYS
22. REMOVE ENGINE STAND
23. INSTALL REAR END PLATE
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
24. M/T:
INSTALL FLYWHEEL
(a) Apply adhesive to 2 or 3 threads of new mounting bolt
end.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or
equivalent

EM9410
1
2 3
45
6
- ENGINE MECHANICALCYLINDER BLOCK
EM-91
1996 TERCEL (RM440U)
(b) Install the flywheel on the crankshaft.
(c) Install and uniformly tighten the mounting bolts, in several
passes, in the sequence shown.
Torque: 90 N´m (900 kgf´cm, 65 ft´lbf)
25. A/T:
INSTALL DRIVE PLATE (See step 24)
26. M/T:
INSTALL CLUTCH DISC AND COVER