wheel alignment TOYOTA TERCEL 1996 Service Repair Manual

SS0KR-04
- SERVICE SPECIFICATIONSCLUTCH
SS-23
153 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH
SERVICE DATA
Pedal height from ashalt sheet143.0 - 151.0 mm (5.944 - 5.945 in.)
Push rod play at pedal top1.0 - 5.0 mm (0.039 - 0.197 in.)
Pedal freeplay5.0 - 15.0 mm (0.197 - 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON-OFF stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 - 3.5 mm (0.059 - 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runout Max.0.8 mm (0.031 in.)
Flywheel runoutMax.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)Dia hragm s ring finger wear Max. de th
Max. width
0.6 mm (0.024 in.)
5.0 mm (0.197 in.)
Diaphragm spring tip non-alignment Max.0.5 mm (0.020 in.)

CL05O-03
- CLUTCHTROUBLESHOOTING
CL-1
696 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
1. Engine mounting (Loosen)-1.Engine mounting (Loosen)
2. Clutch disc (Runout is excessive)
-
CL-14
2.Clutch disc (Runout is excessive)
3. Clutch disc (Oily)
CL-14
CL-14
Clutch grabs/chatters
3.Clutch disc (Oily)
4. Clutch disc (Worn out)
CL-14
CL-14Clutch grabs/chatters4.Clutch disc (Worn out)
5. Clutch disc torsion rubber (Damaged)
CL-14
CL-145.Clutch disc torsion rubber (Damaged)
6. Clutch disc (Glazed)
CL 14
CL-146.Clutch disc (Glazed)
7. Diaphragm spring (Out of tip alignment)
CL 14
CL-14
1. Clutch line (Air in line)-
Clutch pedal spongy
1.Clutch line (Air in line)
2. Master cylinder cup (Damaged)
-
CL-4
Clutch edal s ongy2.Master cylinder cu (Damaged)
3. Release cylinder cup (Damaged)
CL 4
CL-9
1. Release bearing (Worn, dirty, or damaged)CL-14
Clutch noisy
1.Release bearing (Worn, dirty, or damaged)
2. Input shaft bearing (Worn or damaged)
CL-14
-Clutch noisy2.In ut shaft bearing (Worn or damaged)
3. Clutch disc torsion rubber (Damaged)CL-14
1. Clutch pedal (Free play out of adjustment)CL-21.Clutch edal (Free lay out of adjustment)
2. Clutch disc (Oily)
CL-2
CL-14
Cl t h li
2.Clutch disc (Oily)
3. Clutch disc (Worn out)
CL-14
CL-14Clutch slips3.Clutch disc (Worn out)
4. Diaphragm spring (Damaged)
CL 14
CL-144.Dia hragm s ring (Damaged)
5. Pressure plate (Distortion)
CL 14
CL-145. Pressure late (Distortion)
6. Flywheel (Distortion)
CL 14
-
1 Clutchpedal (Freeplay out of adjustment)CL-21.Clutch pedal (Free play out of adjustment)
2 Clutch line (Air in line)CL-2
-2.Clutch line (Air in line)
3 Master cylinder cu
p(Damaged)
-
CL-43.Master cylinder cup (Damaged)
4. Release cylinder cu
p(Damaged)
CL-4
CL
-94.Release cylinder cup (Damaged)
5
. Input shaft bearing (Worn or damaged)
CL-9
-5.In ut shaft bearing (Worn or damaged)
6. Clutch disc (Out of true)
-
CL-14
Cl t h d t di
6.Clutch disc (Out of true)
7. Clutch disc (Runout is excessive)
CL-14
CL-14Clutch does not disengage7.Clutch disc (Runout is excessive)
8. Clutch disc (Lining broken)
CL-14
CL-148.Clutch disc (Lining broken)
9. Clutch disc (Dirty or burned)
CL-14
CL-149.Clutch disc (Dirty or burned)
10.Clutch disc (Oily)
CL 14
CL-1410.Clutch disc (Oily)
11. Clutch disc (Lack of spline grease)
CL 14
CL-1711. Clutch disc (Lack of s line grease)
12.Diaphragm spring (Damaged)
CL 17
CL-14gg(g)
13.Diaphragm spring (Out of tip alignment)CL-17gg( g)
14.Pressure plate (Distortion)CL-14

CL063-03
Q06681
Flywheel Side
CL0291
1.4
MatchmarksSST 7 3
6
2.58
Q06392
SST
N00415
CL0653
- CLUTCHCLUTCH UNIT
CL-17
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL CLUTCH DISC AND CLUTCH COVER ON
FLYWHEEL
(a) Insert SST in the clutch disc, and then set them.
SST 09301-00210
(b) Align the matchmark on the clutch cover and flywheel.
(c) Torque the bolts on the clutch cover in the order shown.
Torque: 19 N´m (195 kgf´cm, 14 ft´lbf)
HINT:
Temporarily tighten the No.1 and No.2 bolts.
2. CHECK DIAPHRAGM SPRING TIP ALIGNMENT
Using a dial indicator with roller instrument, check the dia-
phragm spring tip alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
If alignment is not as specified, using SST, adjust the dia-
phragm spring tip alignment.
SST 09333-00013
3. APPLY MOLYBDENUM DISULPHIDE LITHIUM BASE
GREASE (NLGI NO.2)
(a) Apply release hub grease to these parts:

Release fork and hub contact point

Release fork and push rod contact point

Release fork pivot point
(b) Apply clutch spline grease.
Clutch disc spline
HINT:
Recommended grease part number 08887-01706 (100 g).
4. INSTALL RELEASE BEARING AND FORK TO TRANS-
AXLE
Install the bearing to the release fork, and then install them to
the transaxle.
5. INSTALL TRANSAXLE TO ENGINE
(See page MX-6)

MX07G-02
MX-6
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal.
HINT:
After installation, check and inspect items as follows.

Front wheel alignment (See page SA-4).

Do the road test.

SA10Z-04
- SUSPENSION AND AXLETROUBLESHOOTING
SA-1
817 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table to help you find the cause of the problem. The numbers indicate the priority of the likely case
of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
Wander/pulls
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Steering linkage (Loosen or worn)
4. Hub bearings (Worn)
5. Steering gear (Out of adjustment or broken)
6. Suspension parts (Worn)SA-2
SA-4
SA-8
-
SA-10
SA-39
SR-34
SR-46
-
Bottoming
1. Vehicle (Overloaded)
2. Spring (Weak)
3. Shock absorber (Worn)-
SA-24
SA-44
SA-24
SA-44
Sways/pitches
1. Tire (Worn or improperly inflated)
2. Stabilizer bar (Rear axle beam)
3. Shock absorber (Worn)SA-2
SA-54
SA-24
SA-44
Front wheel shimmy
1. Tire (Worn or improperly inflated)
2. Wheels (Out of balance)
3. Shock absorber (Worn)
4. Wheel alignment (Incorrect)
5. Ball joint (Worn)
6. Hub bearing (Worn)
7. Steering linkage (Loosen or worn)
8. Steering gear (Out of adjustment or broken)SA-2
SA-2
SA-24
SA-4
SA-34
SA-10
-
SR-34
SR-46
Abnormal tire wear
1. Tire (Worn or improperly inflated)
2. Wheel alignment (Incorrect)
3. Suspension parts (Worn)
4. Shock absorber (Worn)SA-2
SA-4
SA-8
-
SA-24
SA-44

R11681R11753F02280
Front
RearSA23E-01
Z03382
SA3213
AB
C D
Front SA-4
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
820 Author
: Date
:
1996 TERCEL (RM440U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFrontRear
155SR13187.9 mm (7.40 in.)253.2 mm (9.97 in.)
Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
Rear measuring point:
Measure from the ground to the center of the axle beam mount-
ing bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not the specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instruction of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
Caster
Left-right error1°20' ± 45
45' (0.75°) or less
Steering axis inclination
Left-right error12°10' ± 45'
45' (0.75°) or less
HINT:
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damaged and/or worn out parts.
4. INSPECT TOE-IN
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe-in is not within the specification, adjust by the tie rod
end.

F03984
R15511



- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-5
821 Author
: Date
:
1996 TERCEL (RM440U)
5. ADJUST CAMBER
NOTICE:
After the camber has been adjusted, inspect the toe-in.
(a) Remove the front wheels.
(b) Remove the 2 nuts on the lower side of the shock absorb-
er.
(c) Coat the threads of the nuts with engine oil.
(d) Temporarily install the 2 nuts.
(e) Adjust the camber by pushing or pulling the lower side of
the shock absorber in the direction in which the camber
adjustment is required.
Adjusting value: 0°06' - 0°30'
(f) Tighten the nuts.
Torque: 245 N´m (2,500 kgf´cm, 181 ft´lbf)
(g) Install the front wheels.
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
(h) Check the camber.
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
HINT:

Try to adjust the camber to the center value.

Adjusting value for the set bolts is 6' - 30' (0.1° - 0.5°).

F01195
Bolt
Adjusting
ValueSet Bolt
15'
30'Adjusting Bolt90105-15001 90105-15004 90105-15005 90105-15006
45'
1°00'
1°15'
1°30'121212121 Dot 2 Dots 3 Dots
W00533
W00533
SA-6
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
822 Author
: Date
:
1996 TERCEL (RM440U)
If the camber is not within the specification, using the table be-
low, estimate of how much additional camber adjustment will be
required, and select the camber adjusting bolt.
(i) Follow the above mentioned steps again. Between step
(b) and (c), exchange 1 or 2 selected bolts.
HINT:
When exchanging the 2 bolts, exchange 1 bolt for each time.
6. ADJUST TOE-IN
(a) Remove the boot clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the left and right rack ends an equal amount to adjust
the toe-in.
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
HINT:

Try to adjust the toe-in to the center value.

Make sure that the lengths of the left and right rack ends
are the same.
Tie rod end length difference: 1.5 mm (0.059 in.) or
less
(d) Torque the tie rod end lock nuts.
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
(e) Place the boots on the seat and install the clamps to them.
HINT:
Make sure that the boots are not twisted.

SA0028
A: Inside
B: Outside AB
Front BA
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
SA-7
823 Author
: Date
:
1996 TERCEL (RM440U)
7. INSPECT WHEEL ANGLE
Turn the steering wheel fully, and measure the turning angle.
Inside wheel35°55' ± 2°
Reference: Outside wheel32°10'
If the wheel angles differ from the standard specifications, in-
spect the toe-in.

SA112-04
SA3213
AB
C D
Front
SA-8
- SUSPENSION AND AXLEREAR WHEEL ALIGNMENT
824 Author
: Date
:
1996 TERCEL (RM440U)
REAR WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT (See page SA-4)
NOTICE:
Before inspecting the weel alignment, adjust the vehicle
height to the specitication.
2. INSPECT CAMBER
Camber
Left-right error-0°30' ± 45'
45' (0.75°) or less
HINT:
Camber is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.
3. INSPECT TOE-IN
Toe-in
(total)A + B: 0.3° ± 0.3°
C - D: 3 ± 3 mm (0.12 ± 0.12 in.)
HINT:
Toe-in is not adjustable, if the measurement is not within the
specification, inspect and replace the suspension parts as nec-
essary.