1996 TOYOTA TERCEL light

P20908
CORRECT
WRONG
S06255
P21178
Ohmmeter
S06256
Push
P04690
CORRECT
WRONG IG-2
- IGNITIONIGNITION SYSTEM
633 Author
: Date
:
1996 TERCEL (RM440U)
2. INSPECT HIGH-TENSION CORDS
(a) Disconnect the high-tension cords from the spark plugs.
(1) Disconnect the high-tension cords at the rubber
boot. Do not pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(2) Disconnect the high-tension cords from the clamp.
(b) Disconnect the high-tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high-tension cord at the grommet.
(3) Do not pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside. Do not wipe any of the oil from the grommet after the
high-tension cord is disconnected.
(c) Reconnect the high-tension cords to the ignition coils.
Maximum resistance: 25 kW per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high-tension cord.
(d) Reinstall the high-tension cords.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and distributor cap as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(4) Connect the high-tension cords to the clamp.
(e) Reconnect high-tension cords to spark plugs.

N00280
DENSO
Borroughs
CH0087
CORRECTWRONG WRONG
P13685
CH0732
Disconnect Wire
from Terminal B
Generator
Voltmeter BatteryAmmeter
B
- CHARGINGCHARGING SYSTEM
CH-3
1996 TERCEL (RM440U)
(b) Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020)
Borroughs No. BT-33-73F
Drive belt tension:
New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
If the belt tension is not as specified, adjust it.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing a belt, check that it fits properly in the
ribbed grooved.

Check by hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.

After installing a new belt, run the engine for about 5 min-
utes and recheck the belt tension.
4. VISUALLY CHECK GENERATOR WIRING AND
LISTEN FOR ABNORMAL NOISES
(a) Check that the wiring is in good condition.
(b) Check that there is no abnormal noise from the generator
while the engine is running.
5. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Warm up the engine and then turn it off.
(b) Turn off all accessories.
(c) Turn the ignition switch ºONº. Check that the charge warn-
ing light is lit.
(d) Start the engine. Check that the light goes off.
If the light does not go off as specified, troubleshoot the charge
light circuit.
6. INSPECT CHARGING CIRCUIT WITHOUT LOAD
HINT:
If a battery/generator tester is available, connect the tester to
the charging circuit as per manufacturer's instructions.
(a) If a tester is not available, connect a voltmeter and amme-
ter to the charging circuit as follows:

Disconnect the wire from terminal B of the generator
and connect it to the negative (-) tester probe of the
ammeter.

P13734
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
at 25°C (77°F)13.9 - 15.1 V
at 115°C (239°F)13.5 - 14.3 V
If the voltmeter reading is greater than standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

Q06552
Q08461
AB
C
CC
A
Q06446
Q08159
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
MX-5
1996 TERCEL (RM440U)
14. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor.
(b) Remove the 2 bolts, springs and gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
(c) Remove the bolt, clamp and gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(d) Disconnect the 2 rings and remove the exhaust front pipe.
15. REMOVE STARTER
Disconnect the connector and wire and remove the starter.
16. DISCONNECT SPEEDOMETER CABLE
17. REMOVE ENGINE REAR MOUNTING INSULATOR
Remove the 6 bolts and insulator.
Torque:
Bolt A: 78 N´m (800 kgf´cm, 58 ft´lbf)
Bolt B: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt C: 90 N´m (920 kgf´cm, 67 ft´lbf)
18. DISCONNECT ENGINE LEFT MOUNTING BRACKET
FROM ENGINE LEFT MOUNTING INSULATOR
Remove the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 36 ft´lbf)
19. JACK UP TRANSAXLE SLIGHTLY
Using a transmission jack, support the transaxle.
20. REMOVE TRANSAXLE LOWER SIDE MOUNTING
BOLT
Remove the 4 bolts.
Torque:
14 mm head: 46 N´m (470 kgf´cm, 34 ft´lbf)
10 mm head: 7.4 N´m (75 kgf´cm, 65 in.´lbf)
21. REMOVE TRANSAXLE
Lower the engine left side and remove the transaxle from the
engine.
HINT:

Align the input shaft with the clutch disc and install the
transaxle to the engine.

Install and torque the 7 bolts.
Torque:
Upper side mounting bolts: (See step 7)
Lower side mounting bolts: (See step 20)

Z18912
Oil Receiver Pipe
Straight Screw Plug (C141)


Slotted Spring Pin (C151)
Outer Race
Plate Washer Reverse Restrict Pin (C151)
Oil Receiver Pipe
x13 Transmission Case
 Lock Ball Assembly (C151)


Back-Up Light Switch
Lock Bolt
Breather Plug
Shift and Select Lever
Shaft Assembly
Selecting Bellcrank Assembly
Oil Seal
x9
Transmission Case
Cover (C141) Drain Plug
 Non-reusable part

Precoated partTransmission Case
Cover (C151)
x9
Gasket Gasket
Filler Plug


Straight Screw Plug
Straight Screw Plug (C141)
Gasket MX-8
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
720 Author
: Date
:
1996 TERCEL (RM440U)

MX0B1-02
Q07828
FIPG
N00038
N00039
MX-10
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RELEASE FORK AND BEARING
HINT:
Apply molybdenum disulphide lithium base grease
(See page CL-17).
2. REMOVE SPEEDOMETER DRIVEN GEAR
Remove the driven gear lock plate set bolt and driven gear.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
3. REMOVE BACK-UP LIGHT SWITCH
Torque: 40 N´m (410 kgf´cm, 30 ft´lbf)
4. REMOVE CONTROL LEVER HOUSING SUPPORT
BRACKET
Remove the 3 bolts and bracket.
Torque: 11 N´m (115 kgf´cm, 8 ft´lbf)
5. REMOVE SELECTING BELLCRANK ASSEMBLY
Remove the 2 bolts and selecting bellcrank assembly.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
6. REMOVE TRANSMISSION CASE COVER
(a) Remove the 9 bolts.
Torque: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Carefully tap the projection of the transmission case cov-
er with a brass bar and hammer and remove the cover.
FIPG:
Part No. 08826-00090, THREE BOND 1281 or equiva-
lent
7. C151:
INSPECT 5TH GEAR THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 - 0.57 mm (0.0039 - 0.0224 in.)
Maximum clearance: 0.65 mm (0.0256 in.)
8. C151:
INSPECT 5TH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance.
Standard clearance:
0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.

WM0064
MX07J-03
WM0065
WM0066
N00053
SST MX-16
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
1996 TERCEL (RM440U)
INSPECTION
1. C151:
INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine
lapping compound between the synchronizer ring and gear
cone.
(c) Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(d) Check again the braking effect of the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. C151:
INSPECT SHIFT FORK AND HUB SLEEVE CLEAR-
ANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
3. REMOVE TRANSAXLE CASE RECEIVER
Remove the bolt and transaxle case receiver.
4. IF NECESSARY, REPLACE INPUT SHAFT FRONT
BEARING AND OIL SEAL
(a) Using SST, remove the bearing.
SST 09612-65014