TOYOTA TERCEL 1996 Service Repair Manual

R11681R11753F02280
Front
RearSA23E-01
Z03382
SA3213
AB
C D
Front SA-4
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
820 Author
: Date
:
1996 TERCEL (RM440U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFrontRear
155SR13187.9 mm (7.40 in.)253.2 mm (9.97 in.)
Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
Rear measuring point:
Measure from the ground to the center of the axle beam mount-
ing bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not the specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instruction of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
Caster
Left-right error1°20' ± 45
45' (0.75°) or less
Steering axis inclination
Left-right error12°10' ± 45'
45' (0.75°) or less
HINT:
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damaged and/or worn out parts.
4. INSPECT TOE-IN
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe-in is not within the specification, adjust by the tie rod
end.

F03984
R15511



- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-5
821 Author
: Date
:
1996 TERCEL (RM440U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06' - 0°30'
(f) Tighten the nuts.
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
(g) Install the front wheels.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
HINT:

Try to adjust the camber to the center value.

Adjusting value for the set bolts is 6' - 30' (0.1° - 0.5°).

F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author
: Date
:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:

Try to adjust the toe-in to the center value.

Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.

SA0028
A: Inside
B: Outside AB
Front BA
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-7
823 Author
: Date
:
1996 TERCEL (RM440U)
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Inside wheel35°55' ± 2°
Reference: Outside wheel32°10'
If the wheel angles differ from the standard specifications, in-
spect the toe-in.

SA112-04
SA3213
AB
C D
Front
SA-8
- SUSPENSION AND AXLEREAR WHEEL ALIGNMENT
824 Author
: Date
:
1996 TERCEL (RM440U)
REAR WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SA-4)
NOTICE:
Before inspecting the weel alignment, adjust the vehicle
height to the specitication.
2. INSPECT CAMBER
Camber
Left-right error-0°30' ± 45'
45' (0.75°) or less
HINT:
Camber is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.
3. INSPECT TOE-IN
Toe-in
(total)A + B: 0.3° ± 0.3°
C - D: 3 ± 3 mm (0.12 ± 0.12 in.)
HINT:
Toe-in is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.

SA113-04
- SUSPENSION AND AXLEFRONT AXLE HUB
SA-9
825 Author
: Date
:
1996 TERCEL (RM440U)
FRONT AXLE HUB
COMPONENTS

SA114-03
R11682
F03986
F03987
SA-10
- SUSPENSION AND AXLEFRONT AXLE HUB
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. w/ ABS
REMOVE BOLT AND ABS SPEED SENSOR
Torque: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
3. REMOVE FRONT BRAKE CALIPER AND DISC
(a) Remove the 2 bolts and brake caliper from the steering
knuckle.
Torque: 88 N´m (900 kgf´cm, 65 in.´lbf)
(b) Support the brake caliper securely.
(c) Remove the disc.
4. CHECK BACKLASH IN BEARING SHAFT DIRECTION
Using a dial indicator, check the backlash near the center of the
axle hub, and check the backlash in the bearing shaft direction.
Maximum: 0.05 mm (0.0020 in.)
If the backlash exceeds the maximum, replace the bearing.
5. CHECK AXLE HUB DEVIATION
Using a dial indicator, check the deviation at the surface of the
axle hub outside the hub bolt.
Maximum: 0.05 mm (0.0020 in.)
If the deviation exceeds the maximum, replace the axle hub.
6. REMOVE DRIVE SHAFT LOCK NUT
(a) Install the brake disc and caliper.
(b) Remove the cotter pin and lock cap.
(c) With applying the brakes, remove the nut.
Torque: 216 N´m (2,200 kgf´cm, 159 ft´lbf)
(d) Remove the brake caliper and disc.
7. LOOSEN 2 NUTS ON LOWER SIDE OF SHOCK AB-
SORBER
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:

Do not remove the 2 bolts.

Coat the nut's thread with engine oil.

W00656
SST
R11683
- SUSPENSION AND AXLEFRONT AXLE HUB
SA-1 1
1996 TERCEL (RM440U)
8. DISCONNECT TIE ROD END FROM STEERING
KNUCKLE
(a) Remove the cotter pin and nut.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Using SST, disconnect the tie rod end from the steering
knuckle.
SST 09628-6201 1
9. DISCONNECT LOWER BALL JOINT FROM LOWER
SUSPENSION ARM
Remove the 2 nuts and bolt.
Torque: 80 N´m (820 kgf´cm, 59 ft´lbf)
10. REMOVE STEERING KNUCKLE WITH AXLE HUB
(a) Remove the 2 nuts and bolts on lower side of the shock
absorber.
(b) Remove the steering knuckle with the axle hub.
NOTICE:
Be careful not to damage the oil seal with the drive shaft.

SA115-01
SA3121
SST
R11685
SST
R11686
SST
N00182
SST SA-12
- SUSPENSION AND AXLEFRONT AXLE HUB
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE LOWER BALL JOINT
(a) Remove the clip and nut.
(b) Using SST, remove the lower ball joint.
SST 09628-6201 1
2. REMOVE INNER OIL SEAL
Using a screwdriver, remove the inner oil seal.
3. REMOVE DUST COVER SET BOLTS
Using a torx wrench (T30), remove the 3 bolts.
4. REMOVE AXLE HUB AND DUST COVER
(a) Using SST, remove the axle hub from the steering
knuckle.
SST 09520-00031
(b) Remove the dust cover.
5. REMOVE INNER RACE (OUTSIDE) FROM AXLE HUB
Using SST and a press, remove the inner race from the axle
hub.
SST 09631-12040, 09950-00020
6. REMOVE OUTER OIL SEAL
Using SST, remove the outer oil seal.
SST 09308-00010
7. REMOVE BEARING FROM STEERING KNUCKLE
(a) Using snap ring pliers, remove the snap ring.
(b) Place the inner race on the outside of the bearing.

R11687
SST
SST
- SUSPENSION AND AXLEFRONT AXLE HUB
SA-13
1996 TERCEL (RM440U)
(c) Using SST and a press, remove the bearing from the
steering knuckle.
SST 09223- 15020, 09950- 60010 (09951- 00650),
09950-70010 (09951-07150)