1996 TOYOTA TERCEL Service Repair Manual

BO5836
N13783
N13784
N13785
H00475
Mandrel
BO-18
- BODYREAR DOOR
1996 TERCEL (RM440U)
10. REMOVE WINDOW REGULATOR (See page BO-1 1)
HINT:
Apply MP grease to the sliding surface and gears of the window
regulator.
NOTICE:
Do not apply MP grease to the spring of the window regula-
tor.
11. REMOVE REAR DOOR PANEL REINFORCEMENT
(a) Remove the door lock control knob from the link.
(b) Remove the clip.
(c) Remove the link from the clip.
(d) Using a drill of less than 5.2 mm (1.20 in.), drill out the rivet
heads and pull out the rear door panel reinforcement for-
ward from the link.
HINT:
Do not drill the door inner hole.
(e) Using a vacuum cleaner, remove the drilled rivets and
their dust from the inside of the door.
HINT:
Using a air riveter, strike rivets into the door frame to install the
rear door panel reinforcement.
NOTICE:
If the rivet is not positioned perpendicularly it will bend the
mandrel. When the trigger is then pulled, it may damage the
air riveter.

N15432
20 mm
(0.79 in.)
Z16245
N12305
- BODYREAR DOOR
BO-19
1996 TERCEL (RM440U)
CAUTION:
To avoid personal injury and shorting of the wiring when
installing (6.4 mm) rivets keep your hands and wire har-
ness out of the (20 mm) radius that caulked (6.4 mm) rivet
will cover.
12. REMOVE DOOR LOCK
(a) Disconnect the link from the outside handle.
(b) Remove the 3 screws.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Apply adhesive to the 3 screws.
Part No.08833-00090, THREE BOND 1324 or equiva-
lent.
HINT:
Apply MP grease to the sliding and rotating parts of the door
lock.
13. REMOVE OUTSIDE HANDLE

BO33M-01
Z16246
178.4 mm
(7.024 in.) BO-20
- BODYREAR DOOR
1996 TERCEL (RM440U)
REPLACEMENT
1. REMOVE GLASS CHANNEL WITH SCREWDRIVER
OR LIKE OBJECT
2. APPLY SOAPY WATER TO INSIDE OF WEATH-
ERSTRIP
3. INSTALL CHANNEL BY TAPPING IT WITH PLASTIC
HAMMER

BO33L-01
Z15107
Z15108
- BODYREAR DOOR
BO-21
1996 TERCEL (RM440U)
ADJUSTMENT
1. ADJUST DOOR IN FORWARD/REARWARD AND VER-
TICAL DIRECTIONS
(a) Upper Side:
Loosen the body side hinge nuts to adjust.
(b) Lower Side:
Loosen the body side hinge bolts to adjust.
2. ADJUST DOOR IN LEFT/RIGHT AND VERTICAL
DIRECTIONS
Loosen the door side hinge bolts to adjust.
3. ADJUST DOOR LOCK STRIKER (See page BO-14)

BO33N-01
BO-22
- BODYREAR DOOR
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO-17).

N15358
BO33O-01
H04284
SST
- BODYLUGGAGE COMPARTMENT DOOR
BO-23
111 7 Author
: Date
:
1996 TERCEL (RM440U)
LUGGAGE COMPARTMENT DOOR
REMOVAL
1. REMOVE TORSION BAR FROM LUGGAGE
COMPARTMENT DOOR HINGE
(a) Install SST to the torsion bar of the hinge side.
SST 09804-24010
(b) Push down on SST, and pull the luggage compartment
door hinge from the torsion bar.
(c) Slowly lift SST, and remove the torsion bar with SST from
the torsion bar bracket.
(d) Remove the torsion bar from the center bracket.
(e) Do the same for the other side.
2. REMOVE LUGGAGE COMPARTMENT DOOR

BO33P-01
H04285
BO1474
BO-24
- BODYLUGGAGE COMPARTMENT DOOR
1996 TERCEL (RM440U)
ADJUSTMENT
1. ADJUST LUGGAGE COMPARTMENT DOOR
(a) For forward/rearward and left/right adjustments, loosen
the bolts.
(b) For vertical adjustment of front end of door, increase or
decrease the number of washers.
2. ADJUST LOCK AND STRIKER
Loosen the mounting bolts to adjust the lock and striker.

BO33Q-01
- BODYLUGGAGE COMPARTMENT DOOR
BO-25
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page BO-23).