engine TOYOTA TERCEL 1996 Service Repair Manual

- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE SYSTEM (A132L)
AX-1 1
1996 TERCEL (RM440U)Symptom
Suspect AreaSee page
Slip
(Forward & Reverse)1. Torque converter clutch
2. Pressure relief valve
3. Oil strainerAX-30


AX-12
Slip (ºRº position)Direct clutch (C2)

Slip
(1st)1. Forward clutch (C1)
2. No.2 one-way clutch (F
2)




Slip
(2nd)1. Forward clutch (C1)
2. 2nd brake (B
2)
3. No.1 one-way clutch (F
1)






Slip
(3rd)1. Forward clutch (C1)
2. Direct clutch (C
2)
3. 2nd brake (B
2)






No engine braking (1st ºLº position)1st & reverse brake (B3)

No engine braking (2nd º2º position)2nd coast brake (B1)

No kick-down1. 1 - 2 shift valve
2. 2 - 3 shift valve



Poor accelerationTorque converter clutchAX-30
No lock-up
1. Lock-up relay
2. Lock-up signal valve
3. Torque converter clutch



AX-30

: Refer to A131L, A132L Automatic Transaxle Repair Manual (Pub. No. RM386U).

Q06544
N00513
N00515
0.8 - 1.5 mm
200 mm
AX0RL-01
- AUTOMATIC TRANSAXLE (A132L)THROTTLE CABLE
AX-15
767 Author
: Date
:
1996 TERCEL (RM440U)
THROTTLE CABLE
ON-VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Disconnect the transaxle control cable from the transaxle
control shaft lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Remove the nut and transaxle control shaft lever.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Using a screwdriver, pry off the nut stopper.
(d) Remove the nut and nut stopper.
Torque: 6.9 N´m (70 kgf´cm, 61 in.´lbf)
(e) Remove the 2 bolts and park/neutral position switch.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
3. REMOVE VALVE BODY (See page AX-12)
4. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
HINT:
New cables does not habe a cable stopper staked.
(c) Bend the cable so that there is a radius of about 200 mm
(7.87 in.).
(d) Pull the inner cable lightly nutil a slight resistance is felt,
and hold it there.
(e) Stake the stoppe, 0.8-1.5 mm (0.031-0.059 in.) from the
end of outer cable.

AT8106
SSTAX0RP-01
- AUTOMATIC TRANSAXLE (A132L)DIFFERENTIAL OIL SEAL
AX-19
771 Author
: Date
:
1996 TERCEL (RM440U)
DIFFERENTIAL OIL SEAL
ON-VEHICLE REPAIR
1. REMOVE ENGINE UNDER COVER
2. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
3. REMOVE SIDE OIL SEAL
Using SST, drive out the oil seals on both sides.
SST 09308-00010

AX0RQ-01
D01628
SST
SST LH Side
RH Side
AX-20
- AUTOMATIC TRANSAXLE (A132L)DIFFERENTIAL OIL SEAL
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL SIDE OIL SEAL
(a) Using SST, drive in a new oil seal until its surface is flush
with the case surface.
SST 09350-32014 (09351-32150, 09351-32130)
Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)
(b) Coat the lip of the oil seal with MP grease.
2. INSTALL LH AND RH DRIVE SHAFTS
(See page SA-18)
3. INSTALL ENGINE UNDER COVER
4. FILL AND CHECK FLUID LEVEL
(See page AX-2)

AX08M-03
Q07634
RH Drive Shaft

Snap
RingSpeedometer
Cable
Rear Engine
Mounting InsulatorAir Cleaner
Assembly

Snap RingTie Rod End
LH Drive Shaft
Nut Cap Plug for Governor Pressure Test
Oxygen Sensor
Front Exhaust Pipe Torque Converter
Clutch
Clip
Control Cable

Gasket
Compression Spring
Engine Under Cover
Cotter Pin Starter

Gasket
Clamp x 6
Plug for Line
Pressure Test

Non-reusable partx 5
Converter
Cover
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-25
777 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE UNIT
COMPONENTS

AX08N-03
Q06547
Q06548
Q07635
Q08079
AX-26
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY
2. REMOVE AIR CLEANER ASSEMBLY
3. REMOVE THROTTLE CABLE
4. REMOVE UPPER SIDE MOUNTING BOLTS
Torque: 64 N´m (650 kgf´cm, 47 ft´lbf)
5. REMOVE STARTER
(a) Disconnect the cable and connector.
(b) Remove the starter with the 2 bolts.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
6. REMOVE GROUND CABLES AND BRACKET
7. INSTALL ENGINE SUPPORT FIXTURE
8. RAISE VEHICLE
9. REMOVE ENGINE UNDER COVER
10. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-18)
11. DISCONNECT SPEEDOMETER CABLE
12. DISCONNECT CONTROL CABLE
(a) Remove the clip from the control cable.
(b) Disconnect the control cable from the lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
13. DISCONNECT PARK/NEUTRAL POSITION SWITCH
CONNECTOR
14. DISCONNECT OIL COOLER HOSE FROM PIPE
15. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)

Q06735
Q06553
Q06554
Q08080
ABA
- AUTOMATIC TRANSAXLE (A132L)AUTOMATIC TRANSAXLE UNIT
AX-27
1996 TERCEL (RM440U)
(d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
16. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt with a wrench.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
17. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
18. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Torque: 49 N´m (490 kgf´cm, 36 ft´lbf)
19. REMOVE ENGINE REAR MOUNTING
(a) Remove the rear mounting insulator through bolt.
Torque: 65 N´m (650 kgf´cm, 48 ft´lbf)
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N´m (800 kgf´cm, 59 ft´lbf)
Bolt B: 92 N´m (920 kgf´cm, 69 ft´lbf)

AX0RV-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
MATRIC 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, and drive shaft tires, etc. Check the automatic transaxle (each clutch, brake and gear) for wear.
(See page AX-13) AX-2
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
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 2 areas should be checked before proceeding with troubleshooting.
(b) Troubleshooting should begin with the simplest operation, working up in order of difficulty degree but
first determine whether the trouble lies within the engine or the transaxle.
(c) Proceed with the inspection as follows:

Q02129
AT3417
OK if hot
Add if hot
OR0028
Z13623
RPMidle
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-3
1996 TERCEL (RM440U)
2. PRELIMINARY CHECK
(a) Check the fluid level.
HINT:
The vehicle must have been driver so that the engine and trans-
axle are at normal operating.
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 position to the 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) Remove the drain plug and drain the fluid.
(2) Install the drain plug securely.
(3) Add new fluid through the filler pipe.
Fluid type: ATF DEXRON®ll
Dry fill: 7.2 liters (7.6 US qts, 6.3 lmp.qts)
Drain and refill: 3.1 liters (3.3 US qts, 2.7 lmp.qts)
(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.

Z15674
Adjusting Nut
Outer Cable Rubber Boot
Cable Stopper0 - 1 mm
Q06559
Q01095
AX-4
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
1996 TERCEL (RM440U)
NOTICE:
Do not overfill.
(d) 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.
(e) Adjust the shift control cable.
When shifting the shift lever from the N position to other
positions, check that the lever can be shifted smoothly
and accurately to each position and that the position indi-
cator correctly indicates the position.
(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.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(f) 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)
(g) Inspect the idle speed.
Idle speed:
750 ± 50 rpm (In the N position and A/C OFF)