belt TOYOTA TERCEL 1996 Service Workshop Manual

BO1HB-03
N15574
2-Door:

Precoated partDoor Glass Run
Door Belt Moulding
Outside Handle
Door Lock Cylinder
Door Glass
Rear View Mirror
Inner Cover
Door Hinge
Door Hinge Control Link Door Lock
Front Lower Frame
Service Hole Cover
Grommet
Inside Handle
Door Trim
Plate
Snap Ring Armrest Door Trim
Armrest
Cover w/ Power Window:w/ Power Window: w/ Power Door Lock:


Speaker
Window Regulator Door Lock
Door CheckerWindow Regulator
Armrest Panel
Regulator Handle
- BODYFRONT DOOR
BO-9
1103 Author
: Date
:
1996 TERCEL (RM440U)
FRONT DOOR
COMPONENTS

N15573
4-Door:
Door Glass RunFront Door Belt Moulding
Outside Handle Door Lock Cylinder
Door Glass
Rear View Mirror
Inner Cover
Door Hinge Control Link Door Lock
Front Lower
Frame
Service Hole Cover
Window Regulator
Inside Handle
Snap Ring Armrest Door Trim
Armrest Cover w/ Power Window:
w/ Power Window: w/ Power Door Lock:
Speaker
Plate Door Trim

Precoated partRegulator HandleGrommetDoor Hinge Door Checker Door Lock
Window Regulator

Armrest Panel
BO-10
- BODYFRONT DOOR
1104 Author
: Date
:
1996 TERCEL (RM440U)

BO47Y-01
BO0020
N00132
N12057
BO2455
Cotton
TapePanel
Cover
N12580
4 Door: 6 Clips
2 Door: 7 Clips
2 Door only
- BODYFRONT DOOR
BO-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. w/o Power Window:
REMOVE REGULATOR HANDLE
Pull off the snap ring with a shop rag and remove the regulator
handle and plate.
2. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the inside handle forward.
(b) Disconnect the inside handle from the control link and re-
move the inside handle.
3. REMOVE OUTSIDE REAR VIEW MIRROR
(a) w/ Manual Remote Control Mirror:
Remove the screw and the knob.
(b) Using a screwdriver, pry off the cover, as shown.
HINT:
Tape the screwdriver tip before use.
NOTICE:
Make sure you pry off the cover from the correct position.
(c) Remove the 3 nuts and the mirror.
4. w/ Power Window:
REMOVE ARMREST PANEL
5. REMOVE ARMREST COVER
6. REMOVE DOOR TRIM
7. REMOVE SPEAKER
8. REMOVE SERVICE HOLE COVER
Remove the 2 grommets.
HINT:
Bring out the links through the service hole cove.
9. REMOVE DOOR BELT MOULDING
Pry out the clips from the edge of the weatherstrip and remove
the weatherstrip.
10. REMOVE DOOR GLASS RUN
11. REMOVE DOOR GLASS
12. REMOVE FRONT LOWER FRAME

BO1HF-04
N15575
Precoated partRegulator HandleDoor Glass
Door Belt Moulding
Outside HandleDoor Glass Run
Door Hinge Control Link
Door Lock
Grommet
Inside Handle
Door Trim
Plate
Snap Ring Armrest
Coverw/ Power Window: w/ Power Door Lock:
Door Lock
Door HingeDoor Checker
Window Regulator Rear Door Panel Reinforcement
Service Hole CoverDoor Glass DIvision Bar


Weatherstrip
Quarter Window
Glass
Power Window
Switch
w/ Power Window: BO-16
- BODYREAR DOOR
111 0 Author
: Date
:
1996 TERCEL (RM440U)
REAR DOOR
COMPONENTS

BO33K-01
N00132
N12579
5 Clips
BO2455
Cotton
TapePanel
Cover
- BODYREAR DOOR
BO-17
1996 TERCEL (RM440U)
DISASSEMBLY
1. w/o Power Window:
REMOVE REGULATOR HANDLE (See page BO-1 1)
2. REMOVE DOOR INSIDE HANDLE
(a) Remove the screw and slide the handle forward.
(b) Disconnect the handle from the control link and remove
the handle.
3. REMOVE ARMREST COVER
4. REMOVE DOOR TRIM
5. REMOVE SPEAKER
6. REMOVE DOOR BELT MOULDING
Pry out the clips from the edge of the weatherstrip and remove
it.
7. REMOVE SERVICE HOLE COVER
Remove the 2 grommets.
HINT:
Bring out the links through the service hole cover.
8. REMOVE DOOR GLASS AND DOOR GLASS RUN
Disconnect the glass from the regulator arm and remove the
glass by pulling it upward.
HINT:
Insert a shop rag inside the panel to prevent scratching the
glass.
9. REMOVE QUARTER WINDOW GLASS WITH WEATH-
ERSTRIP

BO1I3-02
N15578
Rear Seatback
Rear Seat Cushion
Front Seat
Outer Belt
Front Door Scuff PlatePackage Tray Trim Side Cover
Rear Seat Outer Belt
Roof Side Inner Garnish
Quarter Trim Board
Quarter Window Glass
BO-38
- BODYQUARTER WINDOW GLASS
1132 Author
: Date
:
1996 TERCEL (RM440U)
QUARTER WINDOW GLASS
COMPONENTS

BO342-01
Z16117
: 4 Clips
Z16118
: 2 Clips
: 5 Clips
N12584
N12581
N12585
- BODYQUARTER WINDOW GLASS
BO-39
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE REAR SEAT CUSHION
2. REMOVE REAR SEATBACK
3. REMOVE FRONT SEAT OUTER BELT
4. REMOVE PACKAGE TRAY TRIM SIDE COVER
5. REMOVE REAR SEAT OUTER BELT
6. REMOVE QUARTER TRIM BOARD
7. REMOVE FRONT DOOR SCUFF PLATE
8. REMOVE ROOF SIDE INNER GARNISH
9. REMOVE QUARTER WINDOW GLASS
(a) Push piano wire through between body and glass from
the interior.
(b) Tie both wire ends to wooden blocks or similar object.
HINT:
Apply adhesive tape to the outer surface to keep the surface
from being scratched.
NOTICE:
When separating the glass, take care not to damage the
paint and exterior.
(c) Cut the adhesive by pulling the piano wire around it.
HINT:
Cut the adhesive areas as shown in the illustration, leaving the
adhesive where the pins are.
(d) Using piano wire, as shown in the illustration, cut off the
rest of the adhesive.
(e) Remove the glass.
NOTICE:
Leave as much of the adhesive on the body as possible
when cutting off the glass.

N12283
a - a b - bab
H ab
H
- BODYQUARTER WINDOW GLASS
BO-41
1996 TERCEL (RM440U)
6. APPLY ADHESIVE
(a) Cut off the tip of the cartridge nozzle. Fill the cartridge with
adhesive.
(b) Load the cartridge into the sealer gun.
(c) Coat the glass with adhesive, as shown.
H: 12 mm (0.47 in.)
7. INSTALL QUARTER WINDOW GLASS
(a) Install the glass to the body.
(b) Use adhesive tape to keep the glass tight against the
body.
8. INSPECT FOR LEAKS AND REPAIR
(a) Perform a leak test after the hardening time has elapsed.
(b) Seal any leak with sealant.
Part No.08833-00030 or equivalent.
9. INSTALL ROOF SIDE INNER GARNISH
10. INSTALL FRONT DOOR SCUFF PLATE
11. INSTALL QUARTER TRIM BOARD
12. INSTALL REAR SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
13. INSTALL PACKAGE TRAY TRIM SIDE COVER
14. INSTALL FRONT SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
15. INSTALL REAR SEAT BECK
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
16. INSTALL REAR SEAT CUSHION

BO345-01
N12301
- BODYBACK WINDOW GLASS
BO-43
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT DEFOGGER CONNECTOR
2. REMOVE REAR SEAT CUSHION AND SEATBACK
3. REMOVE REAR SEAT BELT
4. REMOVE FRONT DOOR SCUFF PLATE
5. REMOVE QUARTER TRIM BOARD
6. REMOVE FRONT SEAT BELT
7. REMOVE HIGH MOUNTED STOP LIGHT
8. REMOVE PACKAGE TRAY GARNISH
9. REMOVE BACK WINDOW MOULDING
Using a knife, cut off the body.
NOTICE:
Do not damage the body with the knife.
10. REMOVE BACK WINDOW GLASS
Remove the glass in the same manner as windshield (See page
BO-34).

BO346-01
N12302
BO-44
- BODYBACK WINDOW GLASS
1996 TERCEL (RM440U)
INSTALLATION
1. CLEAN AND SHAPE CONTACT SURFACE OF BODY
(See page BO-35)
2. CLEAN REMOVED GLASS (See page BO-35)
3. POSITION GLASS (See page BO-35)
4. CLEAN CONTACT SURFACE GLASS (See page
BO-35)
5. COAT CONTACT SURFACE OF BODY WITH PRIMER
ºMº (See page BO-35)
6. COAT CONTACT SURFACE OF GLASS WITH PRIMER
ºGº (See page BO-35)
7. MIX ADHESIVE COATING (See page BO-35)
8. APPLY ADHESIVE (See page BO-35)
9. INSTALL GLASS (See page BO-35)
10. INSTALL BACK WINDOW MOULDING
Place the moulding onto the body and tap it by hand.
11. INSPECT FOR LEAKS AND REPAIR (See page
BO-35)
12. INSTALL PACKAGE TRAY GARNISH
13. INSTALL HIGH MOUNTED STOP LIGHT
14. INSTALL FRONT SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
15. INSTALL QUARTER TRIM BOARD
16. INSTALL FRONT DOOR SUCFF PLATE
17. INSTALL REAR SEAT OUTER BELT
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
18. INSTALL REAR SEATBACK
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
19. INSTALL REAR SEAT CUSHION
20. CONNECT DEFOGGER CONNECTOR