check engine TOYOTA TERCEL 1996 Service Repair Manual

P13734
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
at 25°C (77°F)13.9 - 15.1 V
at 115°C (239°F)13.5 - 14.3 V
If the voltmeter reading is greater than standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

CL05O-03
- CLUTCHTROUBLESHOOTING
CL-1
696 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Engine mounting (Loosen)-1.Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
CL-14
2.Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
CL-14
CL-14
Clutch grabs/chatters
3.Clutch disc (Oily)
4. Clutch disc (Worn out)
CL-14
CL-14Clutch grabs/chatters4.Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged)
CL-14
CL-145.Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed)
CL 14
CL-146.Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)
CL 14
CL-14
1. Clutch line (Air in line)-
Clutch pedal spongy
1.Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
CL-4
Clutch edal s ongy2.Master cylinder cu (Damaged)
3. Release cylinder cup (Damaged)
CL 4
CL-9
1. Release bearing (Worn, dirty, or damaged)CL-14
Clutch noisy
1.Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or damaged)
CL-14
-Clutch noisy2.In ut shaft bearing (Worn or damaged)
3. Clutch disc torsion rubber (Damaged)CL-14
1. Clutch pedal (Free play out of adjustment)CL-21.Clutch edal (Free lay out of adjustment)
2. Clutch disc (Oily)
CL-2
CL-14
Cl t h li
2.Clutch disc (Oily)
3. Clutch disc (Worn out)
CL-14
CL-14Clutch slips3.Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
CL 14
CL-144.Dia hragm s ring (Damaged)
5. Pressure plate (Distortion)
CL 14
CL-145. Pressure late (Distortion)
6. Flywheel (Distortion)
CL 14
-
1 Clutchpedal (Freeplay out of adjustment)CL-21.Clutch pedal (Free play out of adjustment)
2 Clutch line (Air in line)CL-2
-2.Clutch line (Air in line)
3 Master cylinder cu
p(Damaged)
-
CL-43.Master cylinder cup (Damaged)
4. Release cylinder cu
p(Damaged)
CL-4
CL
-94.Release cylinder cup (Damaged)
5
. Input shaft bearing (Worn or damaged)
CL-9
-5.In ut shaft bearing (Worn or damaged)
6. Clutch disc (Out of true)
-
CL-14
Cl t h d t di
6.Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
CL-14
CL-14Clutch does not disengage7.Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
CL-14
CL-148.Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned)
CL-14
CL-149.Clutch disc (Dirty or burned)
10.Clutch disc (Oily)
CL 14
CL-1410.Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
CL 14
CL-1711. Clutch disc (Lack of s line grease)
12.Diaphragm spring (Damaged)
CL 17
CL-14gg(g)
13.Diaphragm spring (Out of tip alignment)CL-17gg( g)
14.Pressure plate (Distortion)CL-14

CL0649
Push Rod Play and Freeplay Adjust Point
Pedal Height
Adjust Point
Push Rod Play
Pedal HeightCL05P-04
CL0102
Pedal Freeplay
CL0512
25 mm (0.98 in.) or More
Full Stroke
End PositionRelease Point
CL-2
- CLUTCHCLUTCH PEDAL
697 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH PEDAL
INSPECTION
1. CHECK THAT PEDAL HEIGHT IS CORRECT
Pedal height from dash panel:
143.0 - 151.0 mm (5.629 - 5.944 in.)
2. IF NECESSARY, ADJUST PEDAL HEIGHT
Loosen the lock nut and turn the stopper bolt until the height is
correct. Tighten the lock nut.
3. CHECK PEDAL FREEPLAY AND PUSH ROD PLAY
Push in on the pedal until the beginning of clutch resistance is
felt.
Pedal freeplay: 5.0 - 15.0 mm (0.196 - 0.591 in.)
Gently push on the pedal until the resistance begins to in-
crease.
Push rod play at pedal top:
1.0-5.0 mm (0.039-0.196 in.)
4. IF NECESSARY, ADJUST PEDAL FREEPLAY AND
PUSH ROD PLAY
(a) Loosen the lock nut and turn the push rod until the free-
play and push rod play are correct.
(b) Tighten the lock nut.
(c) After adjusting the pedal freeplay, check the pedal height.
(d) Connect the air duct and install the lower finish panel.
5. CHECK CLUTCH RELEASE POINT
(a) Pull the parking brake lever and install wheel stopper.
(b) Start and idle the engine.
(c) Without depressing the clutch pedal, slowly shift the shift
lever into reverse position until the gears contact.
(d) Gradually depress the clutch pedal and measure the
stroke distance from the point that the gear noise stops
(release point) up to the full stroke end position.
Standard distance:
25 mm (0.98 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following opera-
tions.

Inspect pedal height.

Inspect push rod play and pedal freeplay.

Bleed the clutch line.

Inspect the clutch cover and disc.

CL0650
Clutch Start Switch
CL0525
5.0 - 0.5 mm (0.196 + 0.020 in.)
- CLUTCHCLUTCH PEDAL
CL-3
698 Author
: Date
:
1996 TERCEL (RM440U)
6. CHECK CLUTCH START SYSTEM
(a) Check that the engine does not start when the clutch ped-
al is released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, adjust or replace the clutch start switch.
7. CHECK CONTINUITY OF CLUTCH START SWITCH
Check the continuity between terminals when the switch is ON
and OFF.
Switch positionCondition
ON (pushed)Continuity
OFF (free)No continuity
If continuity is not as specified, replace the switch.

CL063-03
Q06681
Flywheel Side
CL0291
1.4
MatchmarksSST 7 3
6
2.58
Q06392
SST
N00415
CL0653
- CLUTCHCLUTCH UNIT
CL-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them.
SST 09301-00210
(b) Align the matchmark on the clutch cover and flywheel.
(c) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333-00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887-01706 (100 g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(See page MX-6)

AX0RI-02
(b) Check the idle speed.
(e) Check the shift linkage. (d) Check the throttle cable mark.
(f) Check the park/neutral position switch.
Check the engine and the torque converter clutch. (c) Check the fluid level and fluid condition.
STALL TEST
TIME LAG TEST PRELIMINARY CHECK
ROAD TEST HYDRAULIC TEST
MATRIX CHART (a) Check the tire inflation.
Measure the line pressure and make a basic check of fluid circuit.
Check if trouble lies within automatic transaxle. If noise or vibration occurs, the possible cause could
be with the compressor, engine, drive shaft and tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-10) AX-2
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
TROUBLESHOOTING
1. GENERAL INFORMATION
(a) Troubles occurring with the automatic transaxle can be caused by either the engine or the transaxle
itself. These two areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty, but first de-
termine whether the trouble lies within the engine or transaxle.
(c) Proceed with the inspection as follows:

Q02129
AT2802
OK if hot
Add if hot
Q02558
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-3
1996 TERCEL (RM440U)
2. PRELIMINARY CHECK
(a) Check the fluid level.
HINT:
The vehicle mjst have been driven so that the engine and trans-
saxle are at normaloperating temperature.
ATF temperature: 70 - 80 °C (158 - 176 °F)
(1) Park the vehicle on the level surface and set the
parking brake.
(2) With the engine idling, shift the selector into each
gear from the P to L position and return to the P
position.
(3) Pull out the transaxle dipstick and wipe it clean.
(4) Push it back fully into the pipe.
(5) Pull it out and check that the fluid level is in the HOT
range. If the level is at the low side of the hot range,
add new fluid.
Fluid type: ATF DEXRON®ll
NOTICE:
Do not overfill.
(b) Check the fluid condition.
If the fluid smells burnt or is black, replace it.
(c) Replace the ATF.
NOTICE:
Do not overfill.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF DEXRON®ll
Dry fill: 5.5 liters (5.8 US qts, 4.8 lmp.qts)
Drain and refill: 2.5 liters (2.6 US qts, 2.2 lmp.qts)

Z13623
RPMidle
AT5867Drain plug Filler plug
MT0613
Filler Hole
Fluid Level
0 - 5 mm
e
Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
BE1485
8 423
5 761
9 AX-4
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Start the engine and shift the selector into all posi-
tions from the P position through the L position and
then shift it into the P position.
(5) With the engine idling, check the fluid level. Add the
fluid up to the COOL level on the dipstick.
(6) Check the fluid level at the normal operating tem-
perature 70 - 80 °C (158 - 176 °F) and add as nec-
essary.
NOTICE:
Do not overfill.
(d) If necessary, replace the differential fluid.
(1) Using a hexagon wrench, remove the drain plug
and drain the fluid.
(2) Using a hexagon wrench, install the drain plug se-
curely.
(3) Remove the filler plug.
(4) Add new fluid until it begins to run out of the filler
hole.
Fluid type: ATF D-ll or DEXRON®lll (DEXRON®ll)
Capacity: 1.4 liters (1.5 US qts, 1.2 lmp.qts)
(e) Check the differential fluid level.
Remove the filler plug and check the differential fluid lev-
el.
(f) Inspect and adjust the throttle cable.
(1) Depress the accelerator pedal all the way and
check that the throttle valve opens fully.
HINT:
If the throttle valve does not open fully, adjust the accelerator
link.
(2) Fully depress the accelerator.
(3) Loosen the adjustment nuts.
(4) Adjust the outer cable so that the distance between
the end of the boot and the stopper on the cable is
the standard.
Standard boot and cable stopper distance:
0 - 1 mm (0 - 0.04 in.)
(5) Tighten the adjusting nuts.
(6) Recheck the adjustment.
(g) Inspect the park/neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-15).

AT8103
Neutral Basic Line
Groove
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-5
1996 TERCEL (RM440U)
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
(h) Adjust the shift control cable.
(1) Remove the engine under cover.
(2) Loosen the nut on the control shaft lever.
(3) Push the control shaft lever fully toward the right
side of the vehicle.
(4) Return the lever 2 notches to the NEUTRAL posi-
tion.
(5) Set the shift lever to the N position.
(6) While holding the lever lightly toward the ºRº posi-
tion side, tighten the swivel nut.
(i) Adjust the park/neutral position switch.
If the engine will start with the shift selector in any position other
than the N or P position, adjustment is required.
(1) Loosen the park/neutral position switch bolts and
set the shift selector to the N position.
(2) Align the groove with neutral basic line.
(3) Hold the switch in the position and tighten the bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
(j) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)
3. MEASURE STALL TEST
The object of this test is to check the overall performance of the transaxle and the engine by measuring the
maximum engine speeds in the D and R positions.
NOTICE:
Do the test at normal operating fluid temperature 50 - 80°C (122 - 176 °F).
Do not continuously run this test longer than 5 seconds.
(1) Check the front and rear wheels.
(2) Connect the tachometer to the engine.
(3) Fully apply the parking brake.

AX-6
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
(4) Keep your left foot pressing firmly on the brake pedal.
(5) Start the engine.
(6) Shift it into the D position. Press all the way down on the accelerator pedal with your right foot.
Quickly read the stall speed at this time.
Stall speed: 2,300 ± 200 rpm
(7) Do the same test in the R position.
Stall speed: 2,300 ± 200 rpm
EVALUATION
ProblemPossible cause
(a) Stall speed low in D and R positions. Engine output may be insufficient
 Stator one-way clutch is not operating properly
(b) Stall speed high in D position.
 Line pressure too low
 Forward clutch slipping
 No.2 one-way clutch not operating properly
(c) Stall speed high in R position.
 Line pressure too low
 Direct clutch slipping
 1st and reverse brake slipping
(d) Stall speed high in D and R positions. Line pressure too low
 Improper fluid level
4. MEASURE TIME LAG TEST
When the shift lever is shifted while the engine is idling, there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the condition of the forward clutch, direct clutch and 1st and re-
verse brake.
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176°F).
Make sure to allow 1 minute interval tests.
Make 3 measurements and take the average value.
(1) Fully apply the parking brake.
(2) Start the engine and check the idle speed.
Idling speed: 750 ± 50 rpm (In N position and A/C OFF)
(3) Shift the shift lever from the N to D position. Using a stop watch, measure the time it takes from
shifting the lever to the shock is felt.
Time lag: Less than 1.2 seconds
(4) In the same way, measure the time lag for N " R.
Time lag: Less than 1.5 seconds
EVALUATION (If N " D time lag are longer than than specified):
ProblemPossible cause
NDti l i l
 Line pressure too low
 Forward clutch worn
N " D time lag is longer Forward clutch worn
 Direct clutch worn
 1st and reverse brake worn