1996 Toyota COROLLA automecanico

1996 Toyota Corolla Automecanico-Free PDF

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e Using snap ring pliers install the snap ring, f Insert service bolts A and B into the service hole of the. camshaft sub gear, g Using a screwdriver align the holes of the camshaft main. gear and sub gear by turning the camshaft sub gear. clockwise and install service bolt C,Be careful not to damage the camshaft. 3 INSTALL INTAKE AND EXHAUST CAMSHAFTS, 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 Install the exhaust camshaft.
1 Apply MP grease to the thrust portion of the cam. Knock Pin shaft, 2 Place the exhaust camshaft so the knock pin is lo. cated slightly counterclockwise from the vertical,axis of the camshaft. The above angle allows the No 1 and No 3 cylinder cam lobes. P06756 of the exhaust camshaft to push their valve lifters evenly. 3 Remove any old packing FIPG material, 4 Apply seal packing to the cylinder head as shown. in the illustration,Seal packing,Part No 08826 00080 or equivalent. Seal Packing, 5 Install the 5 bearing caps in their proper locations.
6 Apply a light coat of engine oil on the threads and. under the heads of the bearing cap bolts, 7 Install and uniformly tighten the 10 bearing cap. 7 bolts in several passes in the sequence shown,2 Torque 13 N m 130 kgf cm 9 ft lbf. 6 8 Apply MP grease to a new oil seal lip,9 Using SST tap in the oil seal. SST 09223 4601 1, Do not install the oil seal with the lip facing the wrong. Insert the oil seal into the deepest part of the cylinder. b Install the intake camshaft, 1 Set the exhaust camshaft so that the knock pin is.
slightly above the top of the cylinder head, Installation Mark 2 Apply MP grease to the thrust portion of the cam. Installation Mark,Timing Mark,3 Engage the intake camshaft gear to the exhaust. camshaft gear by matching the assembly installa,tion marks on each gear. There are also timing marks for TDC on each gear as. shown in the illustration Do not use these marks,4 Roll down the intake camshaft onto the bearing. journals while engaging gears with each other,P06658 HINT.
The above angle allows the No 1 and No 3 cylinder cam lobes. of the intake camshaft to push their valve lifters evenly. 5 Install the 4 bearing caps in their proper locations. 6 Apply a light coat of engine oil on the threads and. under the heads of bearing cap bolts, 7 7 Install and uniformly tighten the 8 bearing cap bolts. 3 8 in several passes in the sequence shown,1 Torque 13 N m 130 kgf cm 9 ft lbf. 5 2 8 Remove the service bolt, 6 9 Install the No 1 bearing cap with the arrow mark fac. ing forward,P06657 NOTICE, If the No 1 bearing cap does not fit properly push the cam. shaft gear backwards by prying apart the cylinder head and. camshaft gear with a screwdriver, 10 Apply a light coat of engine oil on the threads and.
under the heads of bearing cap bolts, 11 Install and alternately tighten the 2 bolts in several. Torque 13 N m 130 kgf cm 9 ft lbf, 12 Turn the exhaust camshaft clockwise and set it with. the knock pin facing upward, Installation Mark 13 Check that the timing marks of the camshaft gears. are aligned,The assembly installation marks are on the upside. 4 CHECK AND ADJUST VALVE CLEARANCE See page, Turn the camshaft and position the cam lobe upward and.
check adjust the valve clearance,Timing Mark,P06647 Valve clearance Cold. 0 15 0 25 mm 0 006 0 010 in,0 25 0 35 mm 0 010 0 014 in. 5 INSTALL WATER INLET NO 2,a Connect the water inlet to the water inlet hose. b Install the water inlet with the 2 nuts,Torque 15 N m 150 kgf cm 11 ft lbf. 6 INSTALL OIL DIPSTICK GUIDE AND DIPSTICK,a Install a new O ring to the dipstick guide.
b Apply a small amount of engine oil to the O ring. c Push in the dipstick guide together with the dipstick. d Install the dipstick guide and bracket with the bolt. Torque 9 N m 95 kgf cm 82 in lbf, e Connect the crankshaft position sensor connector to the. dipstick guide,7 INSTALL GENERATOR BRACKET,Install the bracket with the 3 bolts. Torque 26 N m 270 kgf cm 20 ft lbf,8 INSTALL CAMSHAFT TIMING PULLEY See page. 9 INSTALL TIMING BELT, a Align the matchmarks of the timing belt and camshaft tim. ing pulley, b Remove any oil or water on the camshaft timing pulley.
and keep it clean, c Install the timing belt checking the tension between the. crankshaft timing pulley and camshaft timing pulley. 10 CHECK VALVE TIMING,a Loosen the idler pulley bolt 1 2 turn. b Turn the crankshaft pulley 2 revolutions from TDC to TDC. 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. d Tighten the idler pulley bolt,Torque 37 N m 375 kgf cm 27 ft lbf.
11 REFERENCE,INSTALL TIMING BELT DEFLECTION, Check that there is belt tension at the position indicated in the. illustration,Deflection,At 20 N 2 kgf 4 4 lbf 5 6 mm 0 20 0 24 in. If the deflection is not as specified adjust with the idler pulley. 12 INSTALL NO 2 AND NO 3 TIMING BELT COVERS, Install the No 2 and No 3 timing belt covers with the 6 bolts. Torque 7 4 N m 75 kgf cm 65 in lbf,13 INSTALL SPARK PLUGS. 14 INSTALL SEMI CIRCULAR PLUG,a Remove any old packing FIPG material.
Seal Packing b Apply seal packing to the circular plug. Seal packing,Part No 08826 00080 or equivalent, c Install the semi circular plug to the cylinder head. 15 INSTALL CYLINDER HEAD COVER, Seal Packing a Remove any old packing FIPG material. b Apply seal packing to the cylinder head as shown in the. illustration,Seal packing,Part No 08826 00080 or equivalent. c Install the gasket to the head cover, d Install the head cover with the 4 seal washers and cap. P06763 nuts,Torque 5 9 N m 60 kgf cm 52 in lbf,16 INSTALL RH ENGINE MOUNTING INSULATOR See.
page EM 25,17 INSTALL INTAKE MANIFOLD, a Place a new intake manifold gasket to the cylinder head. b Place a new EGR inlet gasket to the cylinder head facing. the protrusion downward, c Install the intake manifold with the 7 bolts ground strap. and 4 nuts, d Uniformly tighten the bolts and nuts in several passes. A 19 N m 195 kgf cm 14 ft lbf,Others 19 N m 195 kgf cm 14 ft lbf. 18 CONNECT ENGINE WIRE, a Connect the engine wire with the bolt and 2 nuts.
b Connect the engine wire to cylinder head cover and. install the engine wire cover with the 2 bolts,Connect the A C compressor connector. d Connect the oil pressure switch connector, e Connect the crankshaft position sensor connector. 19 INSTALL INJECTORS AND DELIVERY PIPE See page,20 INSTALL AIR INTAKE CHAMBER See page SF 27. 21 INSTALL THROTTLE BODY See page SF 38,22 INSTALL AIR PIPE. a Install the air pipe and fuel hose clamp with the 2 bolts and. Attach the clamp claw of the fuel hose to the intake manifold. b Connect the fuel return hose to pressure regulator. c Connect the air hose from IAC valve to air pipe,23 INSTALL INTAKE MANIFOLD STAY.
12 mm head bolt 19 N m 195 kgf cm 14 ft lbf,14 mm head bolt 39 N m 400 kgf cm 29 ft lbf. INSTALL EGR VSV,25 CONNECT HOSES,a Connect the MAP sensor hose. b Connect the brake booster vacuum hose,Connect the air hose from air pipe. 26 CONNECT GROUND STRAP CONNECTOR,27 INSTALL WATER INLET WITH HOUSING. a Remove any old packing material and be careful not to. drop any oil on the contact surfaces of the water inlet. housing and cylinder head, Using a razor blade and gasket scraper remove all the.
packing FIPG material from the gasket surfaces, Do not use a solvent which will affect painted surfaces. b Apply seal packing to the water inlet housing as shown in. the illustration,Seal packing,Part No 08826 00100 or equivalent. Install a nozzle that has been cut to a 2 3 mm 0 08. 0 12 in opening,Avoid applying an excessive amount to the surface. Parts must be assembled within 15 minutes of ap,plication Otherwise the material must be removed. and reapplied,Immediately remove the nozzle from the tube and.
reinstall the cap, c Install the water inlet and inlet housing assembly with the. bolt and 2 nuts,Torque 20 N m 200 kgf cm 14 ft lbf. d Connect the radiator outlet hose,e Connect the 2 water bypass hoses. f Connect the 2 heater water hoses,g Connect the 2 EVAP TVV vacuum hoses. h Connect the ECT sensor connector,i Connect the ECT switch connector.
e j Connect the IAC valve connector,28 INSTALL WATER OUTLET. a Remove any old packing FIPG material and be careful. not to drop any oil on the contact surfaces of the water. outlet and cylinder head, 1 Using a razor blade and gasket scraper remove all. the oil packing FIPG material from the gasket sur,faces and sealing groove. 2 Thoroughly clean all components to remove all the. loose material,3 Using a non solvent clean both sealing surfaces. Seal Diameter b Apply seal packing to the water outlet groove. 2 3 mm 0 08 0 12 in Seal packing,Part No 08826 00100 or equivalent.
Seal Packing,1 Install a nozzle that has been cut to a 2 3 mm. 0 08 0 12 in opening,Avoid applying an excessive amount to the surface. 2 Parts must be assembled within 15 minutes of ap, EM4897 plication Otherwise the material must be removed. and reapplied, 3 Immediately remove nozzle from the tube and rein. c Install the water outlet with the 2 bolts,Torque 19 5 N m 200 kgf cm 14 ft lbf.
29 INSTALL EXHAUST MANIFOLD, a Install the lower heat insulator to the exhaust manifold. with the 3 bolts, b Install a new gasket and the exhaust manifold with the 5. nuts Uniformly tighten the bolts in several passes. Torque 34 N m 350 kgf cm 25 ft lbf, c Install the manifold stay with the 3 bolts Alternately tight. en the bolts,Torque 59 N m 600 kgf cm 46 ft lbf, d Install the upper heat insulator with the 5 bolts. 30 INSTALL FRONT EXHAUST PIPE, a Place 2 new gaskets to the front and rear of the front ex.
haust pipe, b Using a 14 mm deep socket wrench install the front ex. haust pipe with 2 new nuts,Torque 62 N m 630 kgf cm 46 ft lbf. c Install the 2 bolts and support bracket holding the front ex. haust pipe to the TWC,Torque 43 N m 440 kgf cm 32 ft lbf. d Install the 2 bolts holding the front exhaust pipe bracket. to the mounting bracket,Torque 19 N m 195 kgf cm 14 ft lbf. e Connect the oxygen sensor connector,31 INSTALL DISTRIBUTOR See page IG 13.
32 INSTALL GENERATOR See page CH 22,33 CONNECT ACCELERATOR CABLE BRACKET TO. THROTTLE BODY,34 INSTALL AIR CLEANER HOSE AND CAP, a Connect the air cleaner hose and install the air cleaner. cap with the 4 clips,b Tighten the air cleaner hose clamp bolt. c Connect the IAT sensor connector to the air cleaner cap. 35 FILL RADIATOR WITH ENGINE COOLANT,36 START ENGINE AND CHECK FOR LEAKS. Warm up the engine and inspect for leaks,37 INSTALL RH ENGINE UNDER COVER.
38 CHECK IGNITION TIMING See page EM 12,39 PERFORM ROAD TEST. Check for abnormal noise shock slippage correct shift points. and smooth operation,40 RECHECK ENGINE COOLANT LEVEL AND OIL LEV. 1 Apply a light coat of engine oil on the threads and Length A B under the heads of the cylinder head bolts 2 Using SST install and uniformly tighten the 10 cylin der head bolts in several passes in the sequence shown SST 09205 16010 Torque 29 N m 300 kgf cm 22 ft lbf A A A A A 8 7 1 3 9 HINT

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