1996 TOYOTA TERCEL Service Repair Manual

R12213
A
B
Matchmarks
Manual Steering: SR-14
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
4. REMOVE CENTER UPPER INSTRUMENT CLUSTER
FINISH PANEL
(a) Remove the screw.
(b) Remove the 3 clips.
5. REMOVE UPPER AND LOWER COLUMN COVERS
Remove the 6 screws.
6. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Remove the clip and trim.
7. REMOVE LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Remove the 2 opening covers from the instrument cover.
(b) Remove the 2 screws and disconnect the hood lock re-
lease lever from the instrument cover.
(c) Remove the 4 panel cover set bolts.
(d) Remove the lower pad insert from the instrument cover.
8. REMOVE NO.2 HEATER TO REGISTER DUCT
(a) Disconnect the junction block No.1 with the 3 screws.
(b) Remove the clip.
9. REMOVE COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Disconnect the 3 connectors.
(b) w/ Airbag:
Disconnect the airbag connector.
(c) w/ Airbag:
Remove the 3 screws.
10. REMOVE SPIRAL CABLE (See page BE-14)
NOTICE:
Do not disassemble the cable or apply oil to it.
11. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
12. DISCONNECT SLIDING YOKE
(a) Place matchmarks on the yoke and steering pinion shaft/
control valve shaft.
(b) Loosen bolt A and remove bolt B.

R12213Matchmarks A
B
- STEERINGNON-TIL T STEERING COLUMN
SR-15
1996 TERCEL (RM440U)
13. REMOVE STEERING COLUMN ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 4 column assembly set nuts.

SR17S-01
SR-16
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. REMOVE SLIDING YOKE
Remove the bolt.
2. REMOVE COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
(a) Using a centering punch, mark the center of the 2 ta-
pered-head bolts.
(b) Using a 3 - 4 mm (0.12 - 0.16 in.) drill, drill into the 2 bolts.
(c) Using a screw extractor, remove the 2 bolts.
3. REMOVE MAIN SHAFT ASSEMBLY AND MAIN SHAFT
BUSHING
(a) Using snap ring expander, remove the snap ring from the
shaft assembly.
(b) Using a plastic hammer, tap out the shaft assembly from
the column tube.
(c) Using snap ring expander, remove the snap ring from the
shaft assembly.
4. REMOVE STEERING SUPPORT
(a) Remove the set bolt and nut.
(b) Remove the 2 steering support No.1 collars.

SR17T-02
- STEERINGNON-TIL T STEERING COLUMN
SR-17
1996 TERCEL (RM440U)
INSPECTION
NOTICE:
When using a vise do not overtighten it.
1. INSPECT STEERING LOCK OPERATION
Check that the steering lock mechanism operates properly.
2. IF NECESSARY, REPLACE KEY CYLINDER
(a) Place the ignition key at the ACC position.
(b) Push down the stop pin with a thin rod, and pull out the
key cylinder.
(c) Install a new cylinder.
HINT:
Make sure the ignition key is at the ACC position.
3. INSPECT IGNITION SWITCH (See page BE-1 1)
4. IF NECESSARY, REPLACE IGNITION SWITCH
(a) Remove the 2 screws.
(b) Install a new ignition switch with the 2 screws.
5. INSPECT KEY UNLOCK WARNING SWITCH
(See page BE-1 1)
6. IF NECESSARY, REPLACE KEY UNLOCK WARNING
SWITCH
(a) Remove the 2 screws.
(b) Install a new switch with the 2 screws.
7. A/T:
INSPECT KEY INTERLOCK SOLENOID
A132L A/T: (See page AX-24)
A242L A/T: (See page AX-28)
8. A/T:
IF NECESSARY, REPLACE KEY INTERLOCK SOLE-
NOID
(a) Remove the 2 screws.
(b) Install a new solenoid with the 2 screws.
9. INSPECT BEARING
Check the bearing rotation condition and check for abnormal
noise.
If the bearing is worn or damaged, replace the column tube.

SR-18
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
10. IF NECESSARY, REPLACE BUSHING
(a) Using a screwdriver, depress the projections on the bush-
ing to release the bushing, then remove the bushing from
the column tube.
(b) Coat the inside of new bushing with molybdenum disul-
fide lithium base grease.
(c) Align the projections on the bushing with the holes in the
column tube. Install the bushing until the projections are
firmly engaged in the holes in the column tube.

SR17U-01
R11676
- STEERINGNON-TIL T STEERING COLUMN
SR-19
1996 TERCEL (RM440U)
REASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. INSTALL STEERING SUPPORT
(a) Install the 2 steering support No.1 collars.
(b) Torque the set bolt and nut.
Torque: 5.4 N´m (55 kgf´cm, 48 ft´lbf)
2. INSTALL MAIN SHAFT ASSEMBLY
(a) Using snap ring expander, install a new snap ring to the
shaft assembly.
(b) Install the shaft assembly to the column tube.
(c) Using snap ring expander, install a new snap ring to the
shaft assembly.
3. INSTALL COLUMN UPPER BRACKET AND COLUMN
UPPER CLAMP
Tighten the 2 new tapered-head bolts until the bolts head break
off.
4. INSTALL SLIDING YOKE
Temporarily tighten the bolt.

SR17V-02
R12213
A
B
Matchmarks
Manual Steering: SR-20
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 4 column assembly set nuts.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(b) Connect the connector.
2. CONNECT SLIDING YOKE
(a) Align the matchmarks on the sliding yoke and steering
pinion shaft/control valve shaft.
(b) Torque the bolt B.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(c) Torque the bolt A.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
3. INSTALL COLUMN HOLE COVER
Torque the 4 nuts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
4. w/ Airbag:
INSTALL SPIRAL CABLE (See page BE-14)
5. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Tighten the 3 screws.
(b) w/ Airbag:
Connect the airbag connector.
(c) Connect the 3 connectors.
6. INSTALL NO.2 HEATER TO REGISTER DUCT
(a) Install the clip.
(b) Connect the junction block No.1 with the 3 screws.
7. INSTALL LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Install the pad insert to cover.
(b) Tighten the 4 panel set bolts.
(c) Connect the hood lock release lever with the 2 screws.
(d) Install the 2 opening covers.
8. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Install the clip and trim.
9. INSTALL UPPER AND LOWER COLUMN COVERS
Tighten the 6 screws.
10. INSTALL CENTER UPPER INSTRUMENT CLUSTER
FINISH PANEL
(a) Connect the connector.
(b) Tighten screw.

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