lock TOYOTA TERCEL 1996 Service Owner's Manual

PP19C-01
PP-28
- PREPARATIONSTARTING
1996 TERCEL (RM440U)
EQUIPMENT
Caliper gaugeCenter bearing for planetary type
Dial indicatorCommutator
Magnetic finger
MicrometerPlanet carrier shaft for planetary type
PressReduction type
Pull scaleBrush spring
SandpaperCommutator
Torque wrench
V-block
Vernier calipersCommutator, Brush

SS0N5-03
- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-5
135 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,275 kPa (13.0 kgf/cm2, 185 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) No. 02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
340.15 - 0.25 mm (0.006 - 0.010 in.)
0.31 - 0.41 mm (0.012 - 0.016 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC110° BTDC @ idle
Idle speed-750 ± 50 rpm
Idler pulley tension
springFree length
Installed load at 47.4 mm (1.866 in.)38.4 mm (1.512 in.)
32 N (3.3 kgf, 7.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve guide bore diameter STD
O/S 0.05
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
11.000 - 11.027 mm (0.4331 - 0.4342 in.)
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
30°, 45°, 60°, 75°
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 - 6.030 mm (0.2366 - 0.2374 in.)
11.048 - 11.059 mm (0.4350 - 0.4354 in.)
11.098 - 11.109 mm (0.4369 - 0.4374 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum93.45 mm (3.6791 in.)
93.89 mm (3.6965 in.)
92.95 mm (3.6594 in.)
93.39 mm (3.6768 in.)
44.5°
5.970 - 5.985 mm (0.2350 - 0.2356 in.)
5.965 - 5.980 mm (0.2348 - 0.2354 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 - 1.2 mm (0.031 - 0.047 in.)
0.5 mm (0.020 in.)

SS-6
- SERVICE SPECIFICATIONSENGINE MECHANICAL
136 Author
: Date
:
1996 TERCEL (RM440U) Valve spring
Deviation Maximum
Free length
Installed tension at 31.8 mm (1.252 in.)2.0 mm (0.079 in.)
53.58 mm (2.1094 in.)
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
CamshaftThrust clearance STD
Maximum
Cam lobe height STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter Exhaust No. 1
Others
Journal oil clearance STD
Maximum
Circle runout
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.045 - 0.100 mm (0.0018 - 0.0039 in.)
0.12 mm (0.0047 in.)
41.514 - 41.614 mm (1.6344 - 1.6383 in.)
41.011 - 41.111 mm (1.6146 - 1.6185 in.)
41.35 mm (1.6279 in.)
40.85 mm (1.6083 in.)
24.949 - 24.965 mm (0.9822 - 0.9829 in.)
22.949 - 22.965 mm (0.9035 - 0.9041 in.)
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
0.10 mm (0.0039 in.)
0.04 mm (0.0016 in.)
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0118 in.)
22.5 - 22.9 mm (0.886 - 0.902 in.)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum27.975 - 27.985 mm (1.1014 - 1.1018 in.)
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
0.015 - 0.046 mm (0.0006 - 0.0018 in.)
0.10 mm (0.0039 in.)
ManifoldWarpageMaximum Intake
Exhaust0.1 mm (0.004 in.)
0.5 mm (0.020 in.)
Spark tubeProtrusion47.5 - 48.5 mm (1.870 - 1.909 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter Mark 1
2
3
Maximum
Main journal bore diameter (Reference) Mark 1
2
30.05 mm (0.0020 in.)
74.000 - 74.010 mm (2.9134 - 2.9138 in.)
74.011 - 74.020 mm (2.9138 - 2.9142 in.)
74.021 - 74.030 mm (2.9142 - 2.9146 in.)
74.23 mm (2.9244 in.)
54.018 - 54.024 mm (2.1267 - 2.1269 in.)
54.025 - 54.030 mm (2.1270 - 2.1272 in.)
54.031 - 54.036 mm (2.1272 - 2.1274 in.)
Piston and piston
ringPiston diameter Mark 1
2
3
Piston oil clearance STD
Maximum
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil73.900 - 73.910 mm (2.9094 - 2.9098 in.)
73.910 - 73.920 mm (2.9098 - 2.9102 in.)
73.920 - 73.930 mm (2.9102 - 2.9106 in.)
0.09 - 0.11 mm (0.0035 - 0.0043 in.)
0.13 mm (0.0051 in.)
0.04 - 0.08 mm (0.0016 - 0.0031 in.)
0.03 - 0.07 mm (0.0012 - 0.0028 in.)
0.26 - 0.48 mm (0.0102 - 0.0189 in.)
0.30 - 0.57 mm (0.0118 - 0.0224 in.)
0.13 - 0.50 mm (0.0059 - 0.0197 in.)
1.07 mm (0.0421 in.)
1.02 mm (0.0354 in.)
1.10 mm (0.0433 in.)

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

SS0N8-03
SS-12
- SERVICE SPECIFICATIONSMFI
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Fuel line Union bolt type
Flare nut type29
30290
30022
23
Fuel inlet hose x Fuel filter2929022
Fuel outlet pipe x Fuel pump bracket2929022
Fuel tank x Fuel pump set bolt3.43530 in.´lbf
Fuel pressure regulator x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Fuel pressure regulator2020014
Delivery pipe x Cylinder head1919014
Fuel inlet hose x Delivery pipe3030023
Fuel pump bracket x Fuel cut-off valve1.51513 in.´lbf
Fuel tank x Fuel tank filler pipe3.43530 in.´lbf
Fuel tank x Body3334025
Throttle body x Intake manifold19.519514
Main heated oxygen sensor x Exhaust manifold4444032
Sub heated oxygen sensor x Exhaust pipe4444032
Knock sensor x Cylinder block4545033

SS0NA-03
SS-14
- SERVICE SPECIFICATIONSCOOLING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug x Cylinder block2525018
Water pump x Cylinder block17.517513
Oil dipstick guide x RH engine mounting bracket18.518514
Water inlet pipe x Cylinder block7.57565 in.´lbf
Intake manifold stay x Cylinder block2020015
Water inlet x Water outlet housing5.05043 in.´lbf
Radiator upper support x Body121209
Oil cooler x Radiator lower tank Nut A
Nut B, C15.0
8.5150
8511
75 in.´lbf
No. 1 cooling fan x Radiator7.07061 in.´lbf
No. 2 cooling fan x Radiator7.07061 in.´lbf

SS0NC-01
SS-16
- SERVICE SPECIFICATIONSLUBRICATION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch release cylinder x Transaxle case M/T only121209
Drain plug x Oil pan2525018
Oil pump x Oil pump pulley3737027
Oil pump x Cylinder block7.57565 in.´lbf
Pressure regulator valve x Cylinder block3030022
Oil strainer x Cylinder block101007
Oil pan x Cylinder block1313010
Oil pan x Oil pump1313010
Front exhaust pipe x Exhaust manifold6263046
Compressor mounting bracket x Cylinder block2727020
A/C compressor x Compressor mounting bracket2525018

SS0NG-06
SS-20
- SERVICE SPECIFICATIONSSTARTING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
End cover x Brush holder1.51513 in.´lbf
End cover x Starter housing Planetary type
Reduction type5.9
9.360
9552 in.´lbf
82 in.´lbf
Magnetic switch x Starter housing Planetary type
Reduction type8.3
9.385
9573 in.´lbf
82 in.´lbf
Lead wire of field frame x Magnetic switch Planetary type
Reduction type9.8
5.9100
6087 in.´lbf
52 in.´lbf
Intake manifold x Intake manifold stay17.517513
Cylinder block x Intake manifold stay17.517513
Starter wire x Terminal 30 of starter8.89078 in.´lbf
Starter x Transaxle3737027
Terminal nut x Terminal C of starter1717312
Terminal nut x Terminal 30 of starter1717312
Magnetic switch end cover x Magnetic switch3.63632 in.´lbf

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513

SS0LK-02
SS-28
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
158 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
186 - 265 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth0 ± 0.5 mm (0 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth19 mm (0.75 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
L position
Throttle valve fully closed 2 " 1
47 - 62 km/h (29 - 39 mph)
91 - 107 km/h (57 - 66 mph)
85 - 104 km/h (53 - 65 mph)
36 - 46 km/h (22 - 29 mph)
39 - 49 km/h (24 - 30 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
63 - 72 km/h (39 - 45 mph)
59 - 68 km/h (37 - 42 mph)