lug nut TOYOTA TERCEL 1996 Service Repair Manual

MA02M-05
- MAINTENANCEBODY
MA-9
47 Author
: Date
:
1996 TERCEL (RM440U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten the front seat-to-body mounting bolts.
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing nuts and bolts on the steering system,
drive train, suspension system, fuel tank mounts, engine
mounts, etc.
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operates properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding-down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle does not wander or pull to
one side.

Check that the brakes work properly and do not
drag.
(b) Be sure to deliver a clean car.
Especially check the steering wheel, shift lever knob, all
switch knobs, door handles and seats.

SS0NA-03
SS-14
- SERVICE SPECIFICATIONSCOOLING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Drain plug x Cylinder block2525018
Water pump x Cylinder block17.517513
Oil dipstick guide x RH engine mounting bracket18.518514
Water inlet pipe x Cylinder block7.57565 in.´lbf
Intake manifold stay x Cylinder block2020015
Water inlet x Water outlet housing5.05043 in.´lbf
Radiator upper support x Body121209
Oil cooler x Radiator lower tank Nut A
Nut B, C15.0
8.5150
8511
75 in.´lbf
No. 1 cooling fan x Radiator7.07061 in.´lbf
No. 2 cooling fan x Radiator7.07061 in.´lbf

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

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

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

SS0LJ-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
SS-31
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug1717513
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 C7.4
64
4675
650
47065 in.´lbf
47
34
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

SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf

DI4N0-02
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-217
1996 TERCEL (RM440U)
PRE-CHECK
1. SETTING OF THE THEFT DETERRENT SYSTEM
Setting Conditions
(a) Close all the doors.
(b) Close the engine hood and luggage compartment door.
(c) Remove the ignition key from the ignition key cylinder.
Setting Operation
When any of the following operations (a), (b) or (c) is performed, the theft deterrent indicator light will light
up as described.
(1) Lock the left or right front door using the key
(All doors are locked by key-interlinked lock operation).
(2) Lock all the doors using the wireless door lock control system.
(3) With the rear doors locked and with one of the front doors locked, lock the other front door without
using the key (keyless door lock).
Elapsed time after operationIndicator light
Within about 30 secondsLight up
After about 30 secondsBlinks *1
*1: 1 sec. or, 1 sec. off
HINT:
When the theft deterrent system is set, doors cannot be locked or unlocked with the door lock control switch
and the luggage compartment door cannot be unlocked with the luggage compartment door opener switch.
2. CANCELING OF THE THEFT DETERRENT SYSTEM IN THE SET CONDITION
Check if the theft deterrent indicator light is blinking.
Canceling Operation
When any of the following operations (a), (b), (c) or (d) is performed, the theft deterrent system is canceled
and indicator light will go off.
Condition
(1) Unlock the left or right front door using the key.
(2) Unlock all the doors using the wireless door lock control system.
(3) Insert the ignition key in the ignition key cylinder and turn it to the ACC or ON position
(This is operative only when the theft deterrent system has never operated).
(4) Unlock the luggage compartment door with the key. *1
*1: The theft deterrent system is temporarily canceled only while the luggage compartment door is open.
Approximately 2 seconds after the luggage compartment door is closed, the theft deterrent system is reset.
3. CHECK OF THE THEFT DETERRENT SYSTEM OPERATION
Check if the theft deterrent indicator light is blinking.
When any of the following operations (a) or (b) is performed, the system sounds the horns and theft deterrent
horn and flashes the headlights and taillights for about one minute to alert. At the same time, the system
disconnects the starter motor circuit and locks all doors (if all doors are not locked, the system repeats door
locking operation every 2 seconds during the one minute alert time).
(1) Open the engine hood using the engine hood opener lever.
(2) Unlock any of the front or rear doors without key operation.

EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author
: Date
:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)

EG0023
EM-24
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. w/ A/C and w/o PS:
REMOVE IDLER PULLEY BRACKET
(a) Loosen the idler pulley mounting nut and adjusting bolt,
and remove the drive belt.
(b) Remove the 3 bolts and idler pulley bracket.
10. REMOVE IGNITION COILS AND SPARK PLUGS
11. DISCONNECT VACUUM HASES
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the 3 vacuum hoses from the throttle body.
(c) Disconnect the vacuum hose from the TVV (to charcoal
canister).
(d) Disconnect the vacuum hose from the TVV (to throttle
body).
(e) Disconnect the vacuum hose from the EGR VSV.
12. REMOVE THROTTLE BODY (See page MF-28)
13. REMOVE EGR PIIPE
Loosen the union nut, and remove the 2 nuts, EGR pipe and
gasket.
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt and disconnect the vacuum modulator.
(b) Remove the 2 nuts, EGR valve, EGR vacuum modulator
with the bracket and gasket.
15. REMOVE EGR VSV AND CAMSHAFT POSITION SEN-
SOR
(a) Disconnect the EGR VSV and camshaft position sensor
connector.
(b) Remove the bbolt and EGR VSV.
(c) Remove the bolt, camshaft position sensor and O-ring.