TOYOTA TERCEL 1996 Service Repair Manual

SS0NH-03
- SERVICE SPECIFICATIONSCHARGING
SS-21
151 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING
SERVICE DATA
BatterySpecific gravity at 20°C (68°F)1.25 - 1.29
Drive beltTension New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Type A at 20°C (68°F)
Type B at 20°C (68°F)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V 70 A, 60 A
2.2 - 2.4 W
2.8 - 3.0 W
14.2 - 14.4 mm (0.559 - 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage regulatorRegulating voltage at 25°C (77°F)
at 115°C (239°F)13.9 - 15.1 V
13.5 - 14.3 V

SS0NI-03
SS-22
- SERVICE SPECIFICATIONSCHARGING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Generator x Generator bracket4142030
Generator x Adjusting lever121209
Bearing retainer x Drive end frame2.62723 in.´lbf
Rectifier end frame x Drive end frame Type A, B4.54640 in.´lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame Type A, B1.962017 in.´lbf
Rear end cover x Rectifier holder Type A, B4.44540 in.´lbf
Terminal insulator x Rectifier holder4.14236 in.´lbf

SS0KR-04
- SERVICE SPECIFICATIONSCLUTCH
SS-23
153 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH
SERVICE DATA
Pedal height from ashalt sheet143.0 - 151.0 mm (5.944 - 5.945 in.)
Push rod play at pedal top1.0 - 5.0 mm (0.039 - 0.197 in.)
Pedal freeplay5.0 - 15.0 mm (0.197 - 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON-OFF stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 - 3.5 mm (0.059 - 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runout Max.0.8 mm (0.031 in.)
Flywheel runoutMax.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)Dia hragm s ring finger wear Max. de th
Max. width
0.6 mm (0.024 in.)
5.0 mm (0.197 in.)
Diaphragm spring tip non-alignment Max.0.5 mm (0.020 in.)

SS0KS-01
SS-24
- SERVICE SPECIFICATIONSCLUTCH
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch line union1515511
Master cylinder installation nut121209
Bleeder plug8.38574 in.´lbf
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209

SS0KP-02
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-25
155 Author
: Date
:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SERVICE DATA
Input shaft roller bearing journal diameterMin.24.970 mm (0.9831 in.)
Input shaft 3rd gear journal diameterMin.30.970 mm (1.2193 in.)
Input shaft 4th gear journal diameterMin.28.970 mm (1.1405 in.)
Input shaft 5th gear journal diameter (for C151)Min.24.870 mm (0.9791 in.)
Input shaft runoutMax.0.05 mm (0.0020 in.)
Output shaft roller bearing journal diameterMin.32.970 mm (1.2980 in.)
Output shaft 1st gear journal diameterMin.37.970 mm (1.4949 in.)
Output shaft 2nd gear journal diameterMin.31.970 mm (1.2587 in.)
Output shaft runoutMax.0.05 mm (0.0020 in.)
Gear thrust clearance 1st STD
Max.0.10 - 0.40 mm (0.0039 - 0.0157 in.)
0.45 mm (0.0177 in.)
Gear thrust clearance 2nd STD
Max.0.10 - 0.45 mm (0.0039 - 0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 3rd STD
Max.0.10 - 0.35 mm (0.0039 - 0.0138 in.)
0.40 mm (0.0157 in.)
Gear thrust clearance 4th STD
Max.0.10 - 0.55 mm (0.0039 - 0.0217 in.)
0.60 mm (0.0236 in.)
Gear thrust clearance 5th (for C151) STD
Max.0.10 - 0.57 mm (0.0039 - 0.0224 in.)
0.65 mm (0.0256 in.)
1st, 2nd, 3rd, 4th and 5th (for C151) gear radial clearance STD
Max.0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance Min.0.6 mm (0.024 in.)
Drive in depth
Input shaft front oil seal
Speedometer driven gear oil seal
Control shaft cover oil seal
Select inner lever slotted spring pin
No. 1 shift inner lever slotted spring pin
No. 2 shift inner lever slotted spring pin
Transmission case oil seal
Transaxle case oil seal
15.8 ± 0.2 mm (0.622 ± 0.008 in.)
25 mm (0.98 in.)
1.0 - 2.0 mm (0.039 - 0.079 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
2.4 ± 0.3 mm (0.094 ± 0.012 in.)
1.9 ± 0.3 mm (0.075 ± 0.012 in.)
Differential side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Differential side gear thrust washer thickness1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
Differential side bearing preload (at starting) (for use with SST)
New bearing
Reused bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)

SS-26
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
156 Author
: Date
:
1996 TERCEL (RM440U) Input shaft snap ring thickness
No. 2 clutch hub Mark 0
1
2
3
4
5
No. 3 clutch hub (for C151) Mark A
B
C
D
E
F
G
Input shaft rear bearing Mark A
B
C
D
E
F
2.30 mm (0.0906 in.)
2.36 mm (0.0929 in.)
2.42 mm (0.0953 in.)
2.48 mm (0.0976 in.)
2.54 mm (0.1000 in.)
2.60 mm (0.1024 in.)
2.25 mm (0.0886 in.)
2.31 mm (0.0909 in.)
2.37 mm (0.0933 in.)
2.43 mm (0.0957 in.)
2.49 mm (0.0980 in.)
2.55 mm (0.1004 in.)
2.61 mm (0.1028 in.)
2.29 mm (0.0902 in.)
2.35 mm (0.0925 in.)
2.41 mm (0.0949 in.)
2.47 mm (0.0972 in.)
2.53 mm (0.0996 in.)
2.59 mm (0.1020 in.)
Output shaft snap ring thickness
No. 1 clutch hub Mark A
B
C
D
E
F
2.50 mm (0.0984 in.)
2.56 mm (0.1008 in.)
2.62 mm (0.1031 in.)
2.68 mm (0.1055 in.)
2.74 mm (0.1079 in.)
2.80 mm (0.1102 in.)
Differential side bearing adjusting shim thickness Mark A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
T
U2.10 mm (0.0827 in.)
2.15 mm (0.0846 in.)
2.20 mm (0.0866 in.)
2.25 mm (0.0886 in.)
2.30 mm (0.0906 in.)
2.35 mm (0.0925 in.)
2.40 mm (0.0945 in.)
2.45 mm (0.0965 in.)
2.50 mm (0.0984 in.)
2.55 mm (0.1004 in.)
2.60 mm (0.1024 in.)
2.65 mm (0.1043 in.)
2.70 mm (0.1063 in.)
2.75 mm (0.1083 in.)
2.80 mm (0.1102 in.)
2.85 mm (0.1122 in.)
2.90 mm (0.1142 in.)
2.95 mm (0.1161 in.)
3.00 mm (0.1181 in.)

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)

SS0LL-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
SS-29
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug4950036
Oil pan4.95043 in.´lbf
Detent spring101007
Valve body x Oil pipe clamp101007
Valve body x Oil strainer101007
Valve body x Apply pipe bracket101007
Valve body x Transaxle101007
Park/neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/neutral position switch (nut)6.97061 in.´lbf
Transaxle control shaft lever x Park/neutral position switch131309
Transaxle control shaft lever x Transaxle control cable121209
Drive plate x Crankshaft8890065
Torque converter clutch x Drive plate2728020
Starter3940029
Transaxle housing x Engine (upper side)6465047
Transaxle housing x Engine (lower side) Bolt A
Bolt B
Bolt C
Bolt D7.4
25
46
6475
250
470
65065 in.´lbf
18
34
47
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Oxygen sensor4445032
Exhaust pipe clamp1919014
LH engine mounting x Body4949036
Engine rear mounting bracket x Engine rear mounting insulator6565048
Engine rear mounting insulator x Body Bolt A
Bolt B80
92800
92059
69

SS0LI-04
SS-30
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
160 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
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)
196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 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 depth LH side
RH side5.3 ± 0.5 mm (0.209 ± 0.020 in.)
3.1 ± 0.5 mm (0.122 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth25.0 mm (0.98 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
Throttle valve fully closed 3 O/D
L position
Throttle valve fully closed 2 " 1
45 - 61 km/h (28 - 38 mph)
89 - 106 km/h (55 - 66 mph)
83 - 102 km/h (52 - 63 mph)
83 - 43 km/h (19 - 27 mph)
19 - 33 km/h (12 - 21 mph)
44 - 56 km/h (27 - 35 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
65 - 76 km/h (40 - 47 mph)
61 - 72 km/h (38 - 45 mph)