TOYOTA TERCEL 1996 Service Repair Manual

SA119-05
SA-24
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
840 Author
: Date
:
1996 TERCEL (RM440U)
FRONT SHOCK ABSORBER
COMPONENTS

SA1W8-02
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-25
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. REMOVE FLEXIBLE HOSE
Remove the bolt and disconnect the flexible hose from the shock absorber.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
3. w/ ABS:
DISCONNECT ABS SPEED SENSOR WIRE HARNESS
Remove the bolt and disconnect the ABS speed sensor wire harness from the shock absorber.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
4. DISCONNECT SHOCK ABSORBER FROM STEERING KNUCKLE
Remove the 2 nuts and bolts and disconnect the shock absorber from steering knuckle,
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
HINT:
Coat the nut's threads with engine oil.
5. REMOVE SHOCK ABSORBER AND COIL SPRING
(a) Remove the 3/4 nuts on the upper side of the shock absorber.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Remove the shock absorber with the coil spring.

F02799
SST
SA1W9-01
W03398
SST SA-26
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
DISASSEMBLY
REMOVE COIL SPRING
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install 2 nuts and bolt to the bracket at the lower part of
the shock absorber and secure it in a vise.
(c) Using SST, to hold the spring seat, remove the nut.
SST 09729-22031
(d) Remove these parts:

Suspension support.

Dust seal.

Spring seat.

Upper insulator.

Coil spring.

Spring bumper.

Lower insulator.

SA11C-02
R11754
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-27
1996 TERCEL (RM440U)
INSPECTION
INSPECT SHOCK ABSORBER
Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual operation sound.
If there is any abnormality, replace the shock absorber with a
new one.
NOTICE:
When disposing of the shock absorber, use the following
procedure.

SA11D-02
R11755
SA-28
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
DISPOSAL
1. FULLY EXTEND SHOCK ABSORBER ROD
2. DRILL HOLE TO REMOVE GAS FROM CYLINDER
Using a drill, make a hole in the cylinder, as shown to remove
the gas inside.
CAUTION:
The gas coming out is harmless, but be careful of chips
which may fly up when drilling.

SA1WA-01
W03399
SST
W03400
MP Grease
SST
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
SA-29
1996 TERCEL (RM440U)
REASSEMBLY
1. INSTALL LOWER INSULATOR ONTO SHOCK AB-
SORBER
2. INSTALL COIL SPRING AND SUSPENSION SUPPORT
(a) Using SST, compress the coil spring.
SST 09727-30021
NOTICE:
Do not use an impact wrench. It will damage the SST.
(b) Install the spring bumper to the piston rod.
(c) Install the coil spring to the shock absorber.
HINT:
Fit the lower end of the coil spring into the gap of the spring seat
of shock absorber.
(d) Install the spring seat with the upper insulator.
(e) Install the dust seal and suspension support.
(f) Using SST, to hold the spring seat, install a new nut.
SST 09729-22031
Torque: 47 N´m (475 kgf´cm, 39 ft´lbf)
(g) Remove the SST.
(h) Pack the suspension support with MP grease.
(i) Install the cap.

SA11F-02
SA-30
- SUSPENSION AND AXLEFRONT SHOCK ABSORBER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-25).
HINT:
After installation, check front wheel alignment (See page SA-2).

SA11G-04
- SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA-31
847 Author
: Date
:
1996 TERCEL (RM440U)
FRONT LOWER SUSPENSION ARM
COMPONENTS

SA11H-04
R11688
Z14904
SA-32
- SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
2. DISCONNECT LOWER SUSPENSION ARM FROM
LOWER BALL JOINT
Remove the 2 nuts and bolt.
Torque: 80 N´m (820 kgf´cm, 59 ft´lbf)
3. REMOVE LOWER SUSPENSION ARM
Remove the 3 bolts, lower suspension arm.
Torque:
A: 142 N´m (1,450 kgf´cm, 105 ft´lbf)
B: 74 N´m (750 kgf´cm, 55 ft´lbf)
HINT:
After stabilizing the suspension, torque the bolts.

SA11I-02
- SUSPENSION AND AXLEFRONT LOWER SUSPENSION ARM
SA-33
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page SA-32).
HINT:
After installation, check front wheel alignment (See page SA-4).