1996 TOYOTA TERCEL clutch

Q08079
Q08081
Q07892
Q08080A
BA
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-31
1996 TERCEL (RM440U)
16. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
(b) Remove the bolts and springs from the exhaust manifold
and front exhaust pipe.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the clamp.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Remove the front exhaust pipe and gaskets.
HINT:
Replace the used gaskets with new ones.
17. REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the converter cover.
(b) Turn the crankshaft to gain access and remove the 6 bolts
with holding the crankshaft pulley set bolt a wrench.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
18. SUPPORT TRANSAXLE WITH A TRANSMISSION
JACK
19. DISCONNECT LH ENGINE MOUNTING BRACKET
Remove the 2 mounting bolts.
Torque: 49 N´m (490 kgf´cm, 36 ft´lbf)
20. REMOVE ENGINE REAR MOUNTING
(a) Remove the rear mounting insulator through bolt.
Torque: 65 N´m (650 kgf´cm, 48 ft´lbf)
(b) Remove the 5 bolts and rear mounting insulator.
Torque:
Bolt A: 80 N´m (800 kgf´cm, 59 in´lbf)
Bolt B: 92 N´m (920 kgf´cm, 69 ft´lbf)

AX088-04
AT0943
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE UNIT
AX-33
1996 TERCEL (RM440U)
INSTALLATION
1. TORQUE CONVERTER CLUTCH
Using calipers and a straight edge, measure the distance from
the installed surface to the front surface of the transaxle hous-
ing.
Correct distance: More than 13.0 mm (0.512 in.)
2. TRANSAXLE INSTALLATION
Installation is in the reverse order of removal.
HINT:

After installation, adjust the shift cable and park/neutral
position switch (See page AX-2).

Fill ATF and check fluid level (See page AX-2).

Test drive the vehicle.

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.

AC1HH-04
AC-16
- AIR CONDITIONINGTROUBLESHOOTING
1168 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
No blower operation
2. Heater main relay
3. Blower motor
4. Blower resistor
5. Blower speed control switchAC-62
AC-55
AC-56
AC-71
No air temperature control1. Inspect engine coolant volume
2. A/C control lever-
AC-72
No compressor operation
1. Refrigerant volume
2. A/C Fuse
3. Magnetic clutch relay
4. Magnetic clutch
5. Compressor
6. Pressure switch
7. Heater main relay
8. A/C switch
9. Blower speed control switch
10.A/C amplifier
11. Thermistor
12.Wiring and wiring connectionsAC-3
-
AC-63
AC-40
AC-36
AC-59
AC-59
AC-62
AC-71
AC-66
AC-57
-
Compressor operates intermittently
1. Refrigerant volume
2. Refrigerant cooling system
3. Pressure switch
4. A/C amplifier
5. Thermistor
6. Wiring and wiring connectionsAC-3
-
AC-59
AC-66
AC-57
-
No condenser fan operation
1. Condenser fan fuse
2. Engine main relay
3. Cooling fan relay No.1
4. Cooling fan relay No.2
5. Cooling fan relay No.3
6. Magnetic clutch relay
7. Condenser fan motor
8. Pressure switch
9. Water temperature switch
10.A/C amplifier-
CO-33
AC-64
AC-64
AC-64
AC-63
AC-65
AC-59
-
AC-66
No cool air comes out
1. Refrigerant volume
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Refrigeration controlAC-3
AC-18
AC-40
AC-36
-
Cool air comes out intermittently
1. Refrigerant Volume
2. Drive belt
3. A/C amplifier
4. Expansion valve
5. Evaporator
6. Thermistor
7. Wiring and wiring connectionAC-3
AC-18
AC-66
AC-54
AC-52
AC-57
-
Cool air comes out only at high engine rpm
1. Refrigerant volume
2. Drive belt
3. Inspect refrigerant linesAC-3
AC-18
-

AC1C9-03
N12246
Upper Unit Case
Magnetic Clutch
Relay
Evaporator
Expansion Valve
Grommet
Blower Resistor Lower Unit Case
O-ring

O-ring

Packing
Packing

Non-reusable part
Wire Harness
A/C Amplifier
AC-26
- AIR CONDITIONINGCOOLING UNIT
1178 Author
: Date
:
1996 TERCEL (RM440U)
COOLING UNIT
COMPONENTS

AC2WI-01
AC-28
- AIR CONDITIONINGCOOLING UNIT
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE WIRE HARNESS
2. REMOVE MAGNETIC CLUTCH RELAY
3. REMOVE A/C AMPLIFIER
4. REMOVE BLOWER RESISTOR
5. SEPARATE UPPER CASE AND LOWER CASE
(a) Using a knife, cut off the each packing.
(b) Remove 2 clips and 2 screws.
(c) Separate the upper and lower unit case.
6. REMOVE EVAPORATOR
HINT:
If evaporator was replaced, add compressor oil to the compressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND-OIL 8 or equivalent
7. REMOVE THERMISTOR FROM EVAPORATOR
8. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Lubricate 4 new O-rings with compressor oil and install them to the tubes.

AC3IP-01
AC-38
- AIR CONDITIONINGCOMPRESSOR
1996 TERCEL (RM440U)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. DISCONNECT CONNECTOR FROM MAGNETIC CLUTCH
7. DISCONNECT 2 HOSES FROM COMPRESSOR SERVICE VALVE
NOTICE:
Cap the open fitting immediately to keep moisture or dirt out of the system
8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the compressor.

AC2WN-02
- AIR CONDITIONINGCOMPRESSOR
AC-39
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING BOLTS
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
2. INSTALL DRIVE BELT (See page AC-20)
3. CONNECT 2 HOSES TO COMPRESSOR SERVICE VALVES
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Lubricate 2 new O-rings with compressor oil and install the tubes.
4. CONNECT MAGNETIC CLUTCH LEAD WIRE TO WIRING HARNESS
5. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT
Specified amount:
600 ± 50 g (21.73 ± 1.76 oz.)
7. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
8. INSPECT A/C OPERATION