set clock TOYOTA TERCEL 1996 Service Repair Manual

IN07J-05
BO4111
Negative Cable
- INTRODUCTIONFOR ALL OF VEHICLES
IN-9
9 Author
: Date
:
1996 TERCEL (RM440U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The TERCEL is equipped with an SRS (Supplemental
Restraint System), such as the driver airbag and front
passenger airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the negative (-) terminal cable from
the battery (See page DI-148).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back-up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (-) terminal cable from the battery, the SRS
may deploy.)
When the negative (-) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back-up power supply from anoth-
er battery.

EM1OD-01
P20154
Oil Pan
P20153
Ground Strap
P20536
Timing Mark
P20159
EM-12
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. w/ A/C and/or w/ PS:
REMOVE DRIVE BELT
3. REMOVE GENERATOR DRIVE BELT
4. SLIGHTY JACK UP ENGINE
5. SLIGHTLY JACK UP ENGINE
Raise the engine enough to remove the weight from the engine
mounting on the right side.
6. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Remove the bolt and disconnect the ground strap.
(b) Remove the through bolt, 2 bolts, nut and mounting insu-
lator.
7. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, timing belt cover and gasket.
8. 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.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the hole of the camshaft timing pulley on the
side with the 5E mark is aligned with the timing mark of the
No.1 bearing cap.
If not, turn the crankshaft pulley 1 complete revolution (360°).
9. w/ A/C and/or w/ PS:
REMOVE NO.2 CRANKSHAFT PULLEY
Remove the 4 bolts and No.2 crankshaft pulley.

P21439
2 Revolutions
P20537
Timing Mark
P20552
P20745
P20157
SST
- ENGINE MECHANICALTIMING BELT
EM-19
1996 TERCEL (RM440U)
(b) Slowly turn the crankshaft pulley 2 revolutions from TDC
to TDC.
NOTICE:
Always turn the crankshaft clockwise.
(c) Check that each pulley aligns with the timing marks as
shown in the illustration.
If the timing marks do not align, remove the timing belt and rein-
stall it.
(d) Tighten the No.1 idler pulley bolt.
Torque: 18.5 N´m (185 kgf´cm, 13 ft´lbf)
(e) Remove the crankshaft pulley bolt.
8. INSTALL TIMING BELT GUIDE
Install the guide, facing the cup side outward.
9. INSTALL NO.1 TIMING BELT COVER
(a) Install the gasket to the belt cover.
(b) Install the belt cover with the 3 bolts.
10. INSTALL NO.3 TIMING BELT COVER
11. INSTALL CRANKSHAFT PULLEY
(a) Align the pulley set key with the key groove of the pulley,
and slide on the pulley.
(b) Using SST, install the pulley bolt.
SST 09213-14010, 09330-00021
Torque: 155 N´m (1,550 kgf´cm, 112 ft´lbf)

P20948
P20953
Timing Mark
Installation
Mark
P20746
P20748
P20749
- ENGINE MECHANICALCYLINDER HEAD
EM-49
1996 TERCEL (RM440U)
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with timing
mark º0º of the No.1 timing belt cover.
(b) Turn the camshaft, and align the hole of the camshaft tim-
ing pulley on the side with the 5E mark with the timing
mark of the bearing cap.
9. INSTALL TIMING BELT
(a) Starting from the right hand side of the pulley and instal-
ling the belt counterclockwise.
(b) Loosen the No.1 idler pulley mounting bolt until the pulley
is moved slightly by the spring tension.
(c) Turn the crankshaft pulley 2 revolutions from TDC to TDC.
NOTICE:
Always turn the crankshaft clockwise.

- MFITHROTTLE BODY
MF-31
1996 TERCEL (RM440U)
4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-
SOR
(a) Loosen the 2 set screws of the sensor.
(b) Insert a 0.60 mm (0.024 in.) feeler gauge between the
throttle stop screw and stop lever.
(c) Connect the tester probe of an ohmmeter to the terminals
IDL and E2 of the sensor.
(d) Gradually turn the sensor clockwise until the ohmmeter
deflects, and secure it with the 2 set screws.
(e) Recheck the continuity between terminals IDL and E2.
Clearance between
lever and stop screwContinuity (IDL - E2)
0.50 mm (0.020 in.)Continuity
0.70 mm (0.028 in.)No continuity

AT0952
SST
AX0RT-01
AT0953
SST
AT3306
Hold
TurnLock
Free
AT2821
AT2820
AX-30
- AUTOMATIC TRANSAXLE (A132L)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
782 Author
: Date
:
1996 TERCEL (RM440U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate. If installing a new drive plate, note the orientation of
spacers and tighten the bolts.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator, measure the torque converter
clutch sleeve runout.
Maximum runout: 0.30 mm (0.0018 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
Mark the position of the converter clutch to ensure the correct
installation.

AT0952
SST
AX0S7-01
AT0953
AT3306
Hold
TurnLock
Free
AT2821
AT2820
AX-34
- AUTOMATIC TRANSAXLE (A242L)TORQUE CONVERTER CLUTCH AND DRIVE PLATE
816 Author
: Date
:
1996 TERCEL (RM440U)
TORQUE CONVERTER CLUTCH
AND DRIVE PLATE
INSPECTION
1. INSPECT ONE-WAY CLUTCH
(a) Install SST in the inner race of the one-way clutch.
SST 09350-32014 (09351-32010)
(b) Install SST so that it fits in the notch of the converter clutch
hub and outer race of the one-way clutch.
SST 09350-32014 (09351-32020)
(c) With the torque converter clutch held upright, inspect the
clutch locks when turned counterclockwise, and rotates
freely and smoothly clockwise.
If necessary, clean the converter and retest the clutch. Replace
the converter clutch if the clutch still fails the test.
2. MEASURE DRIVE PLATE RUNOUT AND INSPECT
RING GEAR
Set up a dial indicator, and measure the drive plate runout.
Maximum runout: 0.20 mm (0.0079 in.)
If the runout is not within the specification, replace the drive
plate.
Torque: 88 N´m (900 kgf´cm, 65 ft´lbf)
3. MEASURE TORQUE CONVERTER CLUTCH SLEEVE
RUNOUT
Temporarily mount the torque converter clutch to the drive
plate. Set up a dial indicator.
Maximum runout: 0.30 mm (0.0118 in.)
If the runout is not within the specification, try to correct by reori-
enting the installation of the converter.
HINT:
Mark the position of the converter clutch to ensure the correst
installation.

W01455
Torx ScrewScrew Case
- STEERINGNON-TIL T STEERING COLUMN
SR-21
1996 TERCEL (RM440U)
11. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then rotate the cable clockwise about 2.5 turns to align
the green marks.
HINT:
The spiral cable turns clockwise about 2.5 turns to either left or
right of the center.
12. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and main
shaft assembly.
(b) Torque the steering wheel set nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the connector.
13. w/ Airbag:
INSTALL STEERING WHEEL PAD
NOTICE:

Make sure the wheel pad is installed with the speci-
fied torque.

If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.

When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and that they are
not pinched between other parts.
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
ence groove of the torx screws are caught on the screw
case.
(c) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
14. w/o Airbag:
INSTALL STEERING WHEEL PAD
15. CHECK STEERING WHEEL CENTER POINT

RS02V-04
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS-1
984 Author
: Date
:
1996 TERCEL (RM440U)
SRS AIRBAG
PRECAUTION
NOTICE:

The TERCEL is equipped with an SRS, which comprises a driver airbag and front passenger
airbag. Failure to carry out service operations in the correct sequence could cause the SRS to
unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mis-
take is made in servicing the SRS, it is possible the SRS may fail to operate when required. Be-
fore performing servicing (including removal or installation of parts, inspection or replace-
ment), be sure to read the following items carefully, then follow the correct procedure described
in the repair manual.

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting the SRS, always inspect the DTCs before dis-
connecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly and airbag sensor assembly should be inspected.
(See page RS-9, RS-22, RS-34)

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly or air-
bag sensor assembly in order to reuse it.

If the steering wheel pad, front passenger airbag assembly or airbag sensor assembly has been
dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace
them with new ones.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruction
on the notices.

After work on the SRS is completed, check the SRS warning light. (See page DI-148)

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a
back-up power source so that if work is started within 90 seconds of disconnecting the nega-
tive (-) terminal cable of the battery, the SRS may be deployed.)

When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a back-
up power supply from outside the vehicle.

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Do not expose the steering wheel pad, front passenger airbag assembly or airbag sensor as-
sembly directly to hot air or flames.