1996 TOYOTA TERCEL tow

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)

P20361
P20532
Shop
Rag
Tape
P20363
P20357
P20364
EM-26
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
22. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, No.2 timing belt cover and gasket.
23. REMOVE GENERATOR DRIVE BELT
Loosen the pivot nut and adjusting bolt, and remove the gener-
ator drive belt.
24. REMOVE NO.3 TIMING BELT COVER FROM NO.1 TIM-
ING BELT COVER
25. SET NO.1 CYLINDER TO TDC/COMPRESSION (See
page EM-12)
26. REMOVE TIMING BELT FROM CAMSHAFT TIMING
PULLEY
(a) Loosen the mount bolt of the No.1 idler pulley and shift
pulley toward the left as far as it will go and then tempo-
rarily tighten it.
NOTICE:
Be careful not to damage the timing belt.
(b) Remove the timing belt from the camshaft timing pulley.
27. REMOVE NO.2 IDLER PULLEY
Remove the bolt and idler pulley.
NOTICE:

Support the timing belt, so the meshing of the crank-
shaft timing pulley and timing belt does not shift.

Be careful not to drop anything inside the timing belt
cover.

Do not allow the belt to come into contact with oil, wa-
ter or duct.
28. REMOVE CAMSHAFT TIMING PULLEY
Secure the hexagonal portion of the camshaft, and remove the
bolt and pulley.

P20412
Service Bolt Hole
P20409
P20415
Main Gear
Sub-Gear Service
Bolt
- ENGINE MECHANICALCYLINDER HEAD
EM-27
1996 TERCEL (RM440U)
29. REMOVE INTAKE AND EXHAUST CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be held level while it is being removed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Set the intake camshaft as shown in the illustration so that
the service bolt holes of the intake camshaft gears are di-
rectly above.
HINT:
This helps to lift the exhaust camshaft levelly and evenly by
pushing No.2 and No.4 cylinder cam lobes of the intake cam-
shaft toward their valve lifters.
(b) Remove the 4 bolts, No.1 and No.2 bearing caps.
(c) Remove the oil seal and housing plug.
(d) Secure the intake camshaft sub-gear to the main gear
with a service bolt.
Recommended service bolt:
Thread diameter6 mm
Thread pitch1.0 mm
Bolt length16 - 20 mm (0.63 - 0.79 in.)
HINT:
When removing the camshaft, make sure that the torsional
spring force of the sub-gear has been eliminated by the above
operation.

P20418
Main Gear
Sub-GearSST
P00400
No.3 Cylinder
No.4 Cylinder
P20378
8
6 13
24
57
- ENGINE MECHANICALCYLINDER HEAD
EM-45
1996 TERCEL (RM440U)
(e) Using snap ring pliers, install the snap ring.
(f) Using SST, align the holes of the camshaft main gear and
sub-gear by turning camshaft sub-gear clockwise, and
install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
4. INSTALL INTAKE AND EXHAUST CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the
camshaft must be kept level while it is being installed. If the
camshaft is not kept level, the portion of the cylinder head
receiving the shaft thrust may crack or be damaged, caus-
ing the camshaft to seize or break. To avoid this, the follow-
ing steps should be carried out.
(a) Apply engine oil to the thrust portion of intake camshaft.
(b) Place the intake camshaft as shown in the illustration so
that the service bolt of the intake camshaft gears are di-
rectly above.
HINT:
This helps to lift the intake camshaft in a level and uniform man-
ner by pushing No.3 and No.4 cylinder cam lobes of the intake
camshaft toward their vale lifters.
(c) Install the 4 bearing caps in their proper locations.
(d) Temporarily tighten the bearing cap bolts uniformly and
alternately, in several passes, in the sequence shown un-
til the bearing caps are snug with the cylinder head.

P19552
TOYOTA Hand-Held Tester
DLC3
P20392
SF1PR-02
P20176
P20391
- MFIFUEL PUMP
MF-5
529 Author
: Date
:
1996 TERCEL (RM440U)
FUEL PUMP
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn the ignition switch ON and TOYOTA hand-held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(d) Select the active test mode on the TOYOTA hand-held
tester.
(e) Please refer to the TOYOTA hand-held tester operator's
manual for further details.
If you have no TOYOTA hand-held tester, connect the positive
(+) and negative (-) leads from the battery to the fuel pump con-
nector (See step 6).
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check the fusible link, H-fuse, fuses, EFI
main relay, circuit opening relay, fuel pump, ECM and wiring
connections.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 11 V.
(b) Disconnect the negative (-) terminal cable from the bat-
tery.
(c) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter.Slowly loosen the
union bolt.

CO1206
Dimension B
Punch Assembly
Overhaul HandleStopper BoltPartSST
P21094
8 7
65
43
2
1
P21095
Stopper
BoltSSTTank
Lock
Plate
P21096
RibBracket
Claw
Z15037
CO-20
- COOLINGRADIATOR
1996 TERCEL (RM440U)
4. ASSEMBLE SST
SST 09230-01010
(a) Install the punch assembly to the overhaul handle, insert-
ing it in the hole in part A as shown in the illustration.
(b) While gripping the handle, adjust the stopper bolt so that
dimension B shown in the diagram is 7.7 mm (0.30 in.)
5. CAULK LOCK PLATE
(a) Lightly press SST against the lock plate in the order
shown in the illustration. After repeating this a few times,
fully caulk the lock plate by squeezing the handle until
stopped by the stopper plate.
SST 09230-01010
HINT:

Do not stake the areas protruding around the ports,brack-
et or tank ribs.

The oil cooler (A/T only) and the points attowed in the il-
lustlation cannot be staked with the SST. Use a plier or like
object and be careful not to damage the core plates.

ST1086
Z03210
(3)
(2)
(1)
Z15980
ST0659
ST0647
Hollow
Protrusion
ST-18
- STARTINGSTARTER (Planetary Type)
1996 TERCEL (RM440U)
5. REMOVE DRIVE LEVER AND STARTER CLUTCH
WITH SHOCK ABSORBER FROM STARTER HOUS-
ING
6. REMOVE PLANETARY GEARS
Remove these parts from the shock absorber:
(1) Plate
(2) 3 planetary gears
(3) Plate washer
7. REMOVE STARTER CLUTCH
(a) Using a screwdriver, tap in the stop collar towards the
starter clutch.
(b) Using a screwdriver, pry off the snap ring.
(c) Remove the rear collar from the starter clutch.
8. REMOVE PLANET CARRIER SHAFT AND INTERNAL
GEAR
(a) Using snap ring pliers, remove the snap ring and plate
washer.
(b) Remove the planet carrier shaft and plate washer.
(c) Align the hollow of the internal gear with the protrusion in-
side the shock absorber, and remove the internal gear.

ST1090
P25513
Terminal 30
Terminal 50
Ammeter
- STARTINGSTARTER (Planetary Type)
ST-29
1996 TERCEL (RM440U)
(b) Move the pinion gear toward the armature to remove
slack and measure the clearance between the pinion
gear end and stop collar.
Standard clearance: 1 - 5 mm (0.04 - 0.20 in.)
5. DO NO-LOAD PERFORMANCE TEST
(a) Connect the field coil lead to terminal C. Make sure the
lead is not grounded.
(b) Connect the battery and ammeter to the starter as shown.
(c) Check that the starter rotates smoothly and steadily with
the clutch pinion gear moving out. Check that the amme-
ter reads the specified current.
Specified current: At 11.5 V: 90 A or less