engine TOYOTA TERCEL 1996 Service Repair Manual

MX07O-02
D02999
Engine Side
Z08629
N00067
N00068
- MANUAL TRANSAXLEINPUT SHAFT
MX-25
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL 3RD GEAR, NEEDLE ROLLER BEARING,
SYNCHRONIZER RING AND NO.2 HUB SLEEVE AS-
SEMBLY TO INPUT SHAFT
(a) Apply gear oil to the needle roller bearings.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Using a press, install the 3rd gear and No.2 hub sleeve
assembly.
3. INSTALL SNAP RING
(a) Select a snap ring that allows the minimum axial play.
MarkThickness mm (in.)MarkThickness mm (in.)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
(b) Using a screwdriver and hammer, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
(See page MX-21)

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.

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

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-7
1996 TERCEL (RM440U)
5. HYDRAULIC TEST
(a) Measure the line pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00150, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80°C (122 - 176 °F).
(3) Fully apply the parking brake and check the 4 wheels.
(4) Start the engine and check the idle speed.
(5) Shift into the D position,step down strongly on the brake pedal with your left foot and while manip-
ulating the accelerator pedal with the right foot, measure the line pressure at the engine speeds
specified in the toble.
(6) In the same manner, do the test in the R position.
Specified line pressure:
D positionIdling
Stall363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
R position Idling
Stall530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
(7) If the measured pressures are not up to specified values, recheck the throttle cable adjustment
and retest it (see step 2).
EVALUATION
ProblemPossible cause
If the measured values at all positions are higher.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
If the measured values at all positions are lower.
 Throttle cable out of adjustment
 Throttle valve defective
 Regulator valve defective
 Oil pump defective
If pressure is low in the D position only. D position circuit fluid leakage
 Forward clutch defective
If pressure is low in the R position only.
 R position circuit fluid leakage
 Direct clutch defective
 1st and reverse brake defective
(b) Measure the governor pressure.
(1) Warm up the transaxle fluid.
(2) Remove the transaxle case test plug and mount SST (See page AX-25).
SST 09992-00094 (09992-00230, 09992-00270)
NOTICE:
Do the test at normal operating fluid temperature 50 - 80 °C (122 - 176 °F).
(3) Check the parking brake to see that it is not applied.
(4) Start the engine.
(5) Shift into the D position and measure the governor pressures at the speeds specified in the table.

AX-8
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
1996 TERCEL (RM440U)
EVALUATION
ProblemPossible cause
If governor pressure defect.
 Line pressure defect
 Fluid leakage in governor pressure circuit
 Governor valve operation defect
Vehicle speed (Reference)Governor pressure
30 km/h (19 mph)59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
60 km/h (37 mph)186 - 365 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
90 km/h (56 mph)353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
6. ROAD TEST
NOTICE:
Do this test at normal fluid temperature 50 - 80 °C (122 - 176 °F).
(a) D position test.
Shift into the D position and while driving with the accelerator pedal held constant at the throttle valve
fully open, check on the following points:
(1) Check to seethat the 1"2 and 2"3 up-shifts take placeand also that the shift points conform
to those shown in the automatic shift schedule (See page SS-28).
EVALUATION
ProblemPossible cause
If there is no 1 - 2 up-shift. Governor valve is defective
 1 - 2 shift valve is stuck
If there is no 2 - 3 up-shift. 1 - 2 shift valve is stuck
If the shift point is defective.Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(2) In the same way, check the shock and slip at 1 " 2 and 2 " 3 up-shifts.
EVALUATION
ProblemPossible cause
If the shock is severe.
 Line pressure is too high
 Accumulator is defective
 Check ball is defective
(3) Run in the 3rd gear of the D position, check the abnormal noise and vibration.
HINT:
Check for the cause of abnormal noise and vibration must be made with extreme care as they could also
be due to imbalance in the drive shaft, differential, tires and torque converter clutch, etc.
(4) While running in the 3rd gear of the D position, check that the possible kick-down vehicle speed
limits for the 3 " 1 and 3 " 2 kick-down conform to those indicated in the automatic shift sched-
ule (See page SS-28).
EVALUATION
ProblemPossible cause
If the possible kick-down vehicle speed limit is defective. Throttle cable out of adjustment
 Throttle valve, 1 - 2 shift valve, 2 - 3 shift valve, etc. are defective
(5) Check the abnormal shock and slip at kick-down.
(6) While running at about 60 km/h (37 mph) in the 3rd gear of the D position, release your foot from
the accelerator pedal and shift into the L position. Then check if the 2 "1 down-shift point con-
forms to that indicated in the automatic shift schedule (See page SS-28).
(b) Inspect the lock-up mechanism.
(1) Drive in the D position at a steady speed (Lock-up ON) of about 65 km/h (40 mph).
(2) Lightly depress the accelerator pedal and check that the engine speed does not change abruptly.

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-9
1996 TERCEL (RM440U)
If there is a big jump in engine RPM, there is no lock-up.
(c) 2 position test.
(1) While running in the 2nd gear of the 2 position, release the accelerator pedal and check the en-
gine braking effect.
EVALUATION
ProblemPossible cause
If these is no engine braking effect. 2nd coast brake is defective.
(2) Check the abnormal noise during acceleration and deceleration.
(3) Check the shock during up-shift and down-shift.
(d) L position test.
(1) While running in the L position, check that there is no up-shift to 2nd gear.
(2) While running in the L position, release the accelerator pedal and check the engine braking ef-
fect.
EVALUATION
ProblemPossible cause
If these is no engine braking effect. 1st coast brake is defective.
(3) Check for abnormal noise during acceleration and deceleration.
(e) R position test.
Shift into the R position and, while running at full throttle, check for slipping.
(f) P position test.
Stop the vehicle on a gradient (more than 5°) and, after shifting into the P position, release the parking
brake. Then check to see that the parking lock pawl prevents the vehicle from moving.