1996 TOYOTA TERCEL check oil

SR05Q-17
R11229
NormalAbnormal
R11025Engine Idling Engine Stopped5 mm (0.20 in.)
or less SR-6
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5)
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5)
(i) Check the fluid level.

Q10145
Attachment
Attachment
IN
OUT
Pressure Feed TubeSST
PS Vane Pump
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed
- STEERINGPOWER STEERING FLUID
SR-7
1996 TERCEL (RM440U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube from the PS vane
pump. (See page SR-24)
(b) Connect SST, as shown in the illustration below.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.

R12818Hexagon Wrench12°
R15481
SST
Z14313
Hexagon WrenchSST
R15482
Hexagon
Wrench SST
Fulcrum
Length
- STEERINGMANUAL STEERING GEAR
SR-43
1996 TERCEL (RM440U)
8. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (19 mm), torque the rack guide
spring cap.
Torque: 14.7 N´m (150 kgf´cm, 10.8 ft´lbf)
(c) Using a hexagon wrench (19 mm), return the cap 12°.
(d) Using SST, turn the pinion shaft right and left 1 or 2 times.
SST 09612-24014 (09616-10010)
(e) Using a hexagon wrench (19 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (19
mm), tighten the cap until the preload is within specifica-
tion.
SST 09612-24014 (09616-10010)
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
9. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant:
Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (19 mm), hold the rack guide
spring cap rotating and using SST, torque the nut.
SST 09922-10010
Torque: 41 N´m (419 kgf´cm, 30 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Recheck the total preload.
Preload (turning):
0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
(d) Remove the RH and LH rack ends.

SR0L0-02
R10072
Dial Indicator
R11358
Cylinder Gauge
Micrometer
Bushing
R11357
BushingSST Steel
Plate
R11359
Brass Bar
Oil Seal
- STEERINGPOWER STEERING GEAR
SR-53
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise, do not overtighten it.
1. INSPECT STEERING RACK
Using a dial indicator, check the rack for runout and teeth wear
and damage.
Maximum runout: 0.30 mm (0.0118 in.)
2. MEASURE OIL CLEARANCE BETWEEN CONTROL
VALVE ASSEMBLY AND BUSHING
Using a micrometer and a cylinder gauge, measure the oil clear-
ance.
Standard clearance:
0.050 - 0.083 mm (0.00197 - 0.00327 in.)
Maximum clearance: 0.125 mm (0.00492 in.)
3. IF NECESSARY, REPLACE BUSHING AND OIL SEAL
(a) Using SST and 2 steel plates, remove the bushing from
the rack housing.
SST 09612-65014 (09612-01030)
NOTICE:

As shown, from the opposite side of SST confirm that
its claw is firmly caught on the bushing.

Be careful not to damage the rack housing.
(b) Using a brass bar and a hammer, remove the oil seal from
the rack housing.
NOTICE:
Be careful not to damage the rack housing.
(c) Coat a new oil seal lip with power steering fluid.
(d) Using a socket wrench (24 mm), extension bar and ham-
mer, press in the oil seal.
NOTICE:
Make sure to install the oil seal facing the correct direction.

Z03128
Vinyl Tape
R11057
SST
SR4264
SST
- STEERINGPOWER STEERING GEAR
SR-57
1996 TERCEL (RM440U)
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. INSTALL BUSHING AND CYLINDER END STOPPER
(a) Install a new bushing to the stopper.
(b) Using SST, torque the stopper.
SST 09631-20090
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the stopper and rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
NOTICE:
Do not install union seats.
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Push the valve assembly into the rack housing.

W04432
Hexagon
Wrench
12°
W00840
SST
W00841
SST
Hexagon
Wrench
W01203SSTHexagon
Wrench Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-59
1996 TERCEL (RM440U)
13. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616-00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (21
mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616-00010
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
14. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (21 mm), hold the rack guide
spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 36 N´m (366 kgf´cm, 26 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 300 mm (11.81
in.).
(c) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
(d) Remove the RH and LH rack end.

N06460
N06461
N06462
BE4117
- BODY ELECTRICALWIPER AND WASHER SYSTEM
BE-31
1996 TERCEL (RM440U)
(b) Inspect the motor operation at high speed.
Connect the positive (+) lead from the battery to terminal
2 and the negative (-) lead from the battery to terminal 1,
and check that the motor operates at high speed.
If operation is not as specified, replace the motor.
(c) Inspect the motor operation when stopping it.
(1) Operate the motor at low speed and stop the motor
operation anywhere except at the stop position by
disconnecting positive (+) lead from terminal 3.
(2) Connect terminals 3 and 5.
(3) Connect the positive (+) lead from the battery to ter-
minal 6 and the negative (-) lead from the battery
to terminal 1, and check that the motor stops run-
ning at the stop position after the motor operates
again.
If operation is not as specified, replace the motor.
4. INSPECT WASHER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 2 and
the negative (-) lead to terminal 1, and check that the motor op-
erates.
NOTICE:
These tests must be performed quickly (within 20 seconds)
to prevent the coil from burning out.
If operation is not as specified, replace the motor.

I16684
No.Wiring Connector Side
1
2
3
4
5
6
7GAUGE Fuse
10
11
12
13
1
2
3
4
5
7
8
1
2
3
4
5
6
7
8
9
10Generator
IGN Fuse
SRS Fuse
Airbag Sensor Assembly
Seat Belt Buckle Switch
Low Oil Pressure Warning Switch
Igniter
TAIL Fuse
Door Courtesy Switch
DOME Fuse
Fuel Level Warning Switch
Engine Coolant Temperature Sender Gauge
ABS ECU
ECM
O/D Off Switch
Light Control Rheostat
Ground
Headlight Dimmer Switch
Turn Signal Switch (Left) Ground
Fuel Sender Gauge
Theft Deterrent ECU
Speed Control Unit
Ground
Starter Relay
Brake Fluid Level Warning Switch
and Parking Brake Switch
Turn Signal Switch (Right) A
B
C
F
E
T: Fuel Receiver Gauge
: Engine Coolant Temperature Receiver Gauge
: Tachometer
Hi-Grade
SRS Warning Illumination Open Door Warning Hi-Beam Indicator Security Indicator Left Turn Indicator Right Turn Indicator Discharge Warning Seat Belt Warning O/D Off Indicator Brake WarningBulb Check Relay Malfunction Indicator Low Oil Pressure Warning ABS Warning Fuel Lever Warning Speed Sensor
A5 B7 A12 C2 A2
A6
B5 C9 B4 A7 B3 B1 A10 B8 B9 C7 C4
A4 A11 A13C1 C5C3 C10A3 C8C6 A1TE F BE-36
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)