TOYOTA TERCEL 1996 Service Repair Manual

N15573
4-Door:
Door Glass RunFront Door Belt Moulding
Outside Handle Door Lock Cylinder
Door Glass
Rear View Mirror
Inner Cover
Door Hinge Control Link Door Lock
Front Lower
Frame
Service Hole Cover
Window Regulator
Inside Handle
Snap Ring Armrest Door Trim
Armrest Cover w/ Power Window:
w/ Power Window: w/ Power Door Lock:
Speaker
Plate Door Trim

Precoated partRegulator HandleGrommetDoor Hinge Door Checker Door Lock
Window Regulator

Armrest Panel
BO-10
- BODYFRONT DOOR
1104 Author
: Date
:
1996 TERCEL (RM440U)

BO47Y-01
BO0020
N00132
N12057
BO2455
Cotton
TapePanel
Cover
N12580
4 Door: 6 Clips
2 Door: 7 Clips
2 Door only
- BODYFRONT DOOR
BO-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.
2. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the inside handle forward.
(b) Disconnect the inside handle from the control link and re-
move the inside handle.
3. REMOVE OUTSIDE REAR VIEW MIRROR
(a) w/ Manual Remote Control Mirror:
Remove the screw and the knob.
(b) Using a screwdriver, pry off the cover, as shown.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Make sure you pry off the cover from the correct position.
(c) Remove the 3 nuts and the mirror.
4. w/ Power Window:
REMOVE ARMREST PANEL
5. REMOVE ARMREST COVER
6. REMOVE DOOR TRIM
7. REMOVE SPEAKER
8. REMOVE SERVICE HOLE COVER
Remove the 2 grommets.
HINT:
Bring out the links through the service hole cove.
9. REMOVE DOOR BELT MOULDING
Pry out the clips from the edge of the weatherstrip and remove
the weatherstrip.
10. REMOVE DOOR GLASS RUN
11. REMOVE DOOR GLASS
12. REMOVE FRONT LOWER FRAME

N12284
N12285
N09263
N12286
H00475
Mandrel
BO-12
- BODYFRONT DOOR
1996 TERCEL (RM440U)
13. REMOVE WINDOW REGULATOR
(a) Using a hammer, tap out the mandril from the inside to the
outside of the vehicle.
(b) Using a drill of less than 6.8 mm (0.28 in.), drill out the rivet
heads and remove the window regulator.
HINT:
Do not drill the door inner hole.
(c) Remove the regulator through the service hole.
(d) Using a vacuum cleaner, remove the drilled rivets and
their dust from the inside of the door.
HINT:
At the time of reassembly, refer to following pocedures.

Apply MP grease to the sliding surface and gears of the
window regulator.

Using a air riveter, strike rivets into the door frame to install
the window regulator the door frame.
NOTICE:
If the rivet is not positioned perpendicularly it will bend the
mandrel. When the trigger is then pulled, it may damage the
air riveter.

N15432
20 mm
(0.79 in.)
N12570
N00133
(4 Door)
(2 Door)
- BODYFRONT DOOR
BO-13
1996 TERCEL (RM440U)
CAUTION:
To avoid personal injury and shorting of the wiring when
installing (6.4 mm) rivets deep your hands and wire har-
ness out of the (20 mm) radius that caulked (6.4 mm) rivet
will cover.
14. REMOVE DOOR LOCK
(a) Remove the door lock control knob from the link.
(b) Disconnect the 2 links from the outside handle and the
door lock cylinder.
(c) Remove the 3 screws.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
At the time of reassembly, refer to following pocedures.

Apply adhesive to the 3 screws.
Part No.08833-00090, THREE BOND 1324 or equiva-
lent.

Apply MP grease to the sliding and rotating parts of the
door lock.
15. REMOVE OUTSIDE HANDLE
16. REMOVE DOOR LOCK CYLINDER

BO1HD-02
N00130
N00131
BO2556
BO-14
- BODYFRONT DOOR
1996 TERCEL (RM440U)
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
Using SST, adjust the door by loosening the body side hinge
bolts.
SST 09812-00010
2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL
DIRECTIONS
Adjust the door by loosening the door side hinge bolts to adjust.
HINT:
Substitute the bolt with washer for the centering bolt (See page
BO-8).
3. ADJUST DOOR LOCK STRIKER
(a) Check that the door fit and door lock linkages are adjusted
correctly.
(b) Loosen the striker mounting screws to adjust.
(c) Using a plastic hammer, tap the striker to adjust it.

BO33J-01
- BODYFRONT DOOR
BO-15
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO-1 1).

BO1HF-04
N15575
Precoated partRegulator HandleDoor Glass
Door Belt Moulding
Outside HandleDoor Glass Run
Door Hinge Control Link
Door Lock
Grommet
Inside Handle
Door Trim
Plate
Snap Ring Armrest
Coverw/ Power Window: w/ Power Door Lock:
Door Lock
Door HingeDoor Checker
Window Regulator Rear Door Panel Reinforcement
Service Hole CoverDoor Glass DIvision Bar


Weatherstrip
Quarter Window
Glass
Power Window
Switch
w/ Power Window: BO-16
- BODYREAR DOOR
111 0 Author
: Date
:
1996 TERCEL (RM440U)
REAR DOOR
COMPONENTS

BO33K-01
N00132
N12579
5 Clips
BO2455
Cotton
TapePanel
Cover
- BODYREAR DOOR
BO-17
1996 TERCEL (RM440U)
DISASSEMBLY
1. w/o Power Window:
REMOVE REGULATOR HANDLE (See page BO-1 1)
2. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the handle forward.
(b) Disconnect the handle from the control link and remove
the handle.
3. REMOVE ARMREST COVER
4. REMOVE DOOR TRIM
5. REMOVE SPEAKER
6. REMOVE DOOR BELT MOULDING
Pry out the clips from the edge of the weatherstrip and remove
it.
7. REMOVE SERVICE HOLE COVER
Remove the 2 grommets.
HINT:
Bring out the links through the service hole cover.
8. REMOVE DOOR GLASS AND DOOR GLASS RUN
Disconnect the glass from the regulator arm and remove the
glass by pulling it upward.
HINT:
Insert a shop rag inside the panel to prevent scratching the
glass.
9. REMOVE QUARTER WINDOW GLASS WITH WEATH-
ERSTRIP

BO5836
N13783
N13784
N13785
H00475
Mandrel
BO-18
- BODYREAR DOOR
1996 TERCEL (RM440U)
10. REMOVE WINDOW REGULATOR (See page BO-1 1)
HINT:
Apply MP grease to the sliding surface and gears of the window
regulator.
NOTICE:
Do not apply MP grease to the spring of the window regula-
tor.
11. REMOVE REAR DOOR PANEL REINFORCEMENT
(a) Remove the door lock control knob from the link.
(b) Remove the clip.
(c) Remove the link from the clip.
(d) Using a drill of less than 5.2 mm (1.20 in.), drill out the rivet
heads and pull out the rear door panel reinforcement for-
ward from the link.
HINT:
Do not drill the door inner hole.
(e) Using a vacuum cleaner, remove the drilled rivets and
their dust from the inside of the door.
HINT:
Using a air riveter, strike rivets into the door frame to install the
rear door panel reinforcement.
NOTICE:
If the rivet is not positioned perpendicularly it will bend the
mandrel. When the trigger is then pulled, it may damage the
air riveter.

N15432
20 mm
(0.79 in.)
Z16245
N12305
- BODYREAR DOOR
BO-19
1996 TERCEL (RM440U)
CAUTION:
To avoid personal injury and shorting of the wiring when
installing (6.4 mm) rivets keep your hands and wire har-
ness out of the (20 mm) radius that caulked (6.4 mm) rivet
will cover.
12. REMOVE DOOR LOCK
(a) Disconnect the link from the outside handle.
(b) Remove the 3 screws.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Apply adhesive to the 3 screws.
Part No.08833-00090, THREE BOND 1324 or equiva-
lent.
HINT:
Apply MP grease to the sliding and rotating parts of the door
lock.
13. REMOVE OUTSIDE HANDLE