1996 TOYOTA TERCEL Service Repair Manual

SS0NB-01
- SERVICE SPECIFICATIONSLUBRICATION
SS-15
145 Author
: Date
:
1996 TERCEL (RM440U)
LUBRICATION
SERVICE DATA
Oil presuureat idle speed
at 3,000 rpm29 kPa (0.3 kgf/cm2, 43 psi) or more
245 - 490 kPa (2.5 - 5.0 kgf/cm2, 36 - 71 psi)
Oil pumpBody clearance STD
Maximum
Tip clearance STD
Maximum
Side clearance STD
Minimum0.10 - 0.16 mm (0.0039 - 0.0063 in.)
0.20 mm (0.0079 in.)
0.03 - 0.14 mm (0.0012 - 0.0055 in.)
0.20 mm (0.0079 in.)
2.91 - 2.97 mm (0.1145 - 0.1169 in.)
2.90 mm (0.1142 in.)

SS0NC-01
SS-16
- SERVICE SPECIFICATIONSLUBRICATION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch release cylinder x Transaxle case M/T only121209
Drain plug x Oil pan2525018
Oil pump x Oil pump pulley3737027
Oil pump x Cylinder block7.57565 in.´lbf
Pressure regulator valve x Cylinder block3030022
Oil strainer x Cylinder block101007
Oil pan x Cylinder block1313010
Oil pan x Oil pump1313010
Front exhaust pipe x Exhaust manifold6263046
Compressor mounting bracket x Cylinder block2727020
A/C compressor x Compressor mounting bracket2525018

SS0ND-04
- SERVICE SPECIFICATIONSIGNITION
SS-17
147 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION
SERVICE DATA
High-tension cordResistance Maximum25 kW per cord
Spark plugRecommended spark plug ND
NGK
Correct electrode gapK16TR11
BKR5EKB-1 1
1.1 mm (0.043 in.)
Ignition coilPrimary coil resistance at cold
at hot
Secondary coil resistance at cold
at hot0.67 - 1.05 W
0.85 - 1.23 W
9.3 - 16.0 kW
11.7 - 18.8 kW
Camshaft position
sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W
Crankshaft
position sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W

SS0NE-01
SS-18
- SERVICE SPECIFICATIONSIGNITION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Spark plug x Cylinder head1818013
Ignition coil x Cylinder head8.58575 in.´lbf
Camshaft position sensor x Cylinder head88069 in.´lbf
Crankshaft position sensor x Oil pump88069 in.´lbf

SS0NF-07
- SERVICE SPECIFICATIONSSTARTING
SS-19
149 Author
: Date
:
1996 TERCEL (RM440U)
STARTING
SERVICE DATA
Starter
(Planetary type)Rated voltage and output power
No-load characteristics Current
rpm
Center bearing oil clearance STD
Maximum
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum12 V 0.8 kW
At 11.5 V 90 A or less
3,000 rpm or more
0.03 mm (0.0012 in.)
0.1 mm (0.004 in.)
14.0 mm (0.551 in.)
9.0 mm (0.354 in.)
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
8.8 N (0.9 kgf, 2.0 lbf)
28.0 mm (1.102 in.)
27.0 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
Starter
(Reduction type)Rated voltage and output power
No-load characteristics Current
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum
Magnetic switch
Contact plate for wear Maximum12 V 1.0 kW
At 11.5 V 90 A or less
3,000 rpm or more
13.5 mm (0.531 in.)
8.5 mm (0.334 in.)
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
11.8 N (1.2 kgf, 2.6 lbf)
30.0 mm (1.181 in.)
29.0 mm (1.412 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

SS0NG-06
SS-20
- SERVICE SPECIFICATIONSSTARTING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
End cover x Brush holder1.51513 in.´lbf
End cover x Starter housing Planetary type
Reduction type5.9
9.360
9552 in.´lbf
82 in.´lbf
Magnetic switch x Starter housing Planetary type
Reduction type8.3
9.385
9573 in.´lbf
82 in.´lbf
Lead wire of field frame x Magnetic switch Planetary type
Reduction type9.8
5.9100
6087 in.´lbf
52 in.´lbf
Intake manifold x Intake manifold stay17.517513
Cylinder block x Intake manifold stay17.517513
Starter wire x Terminal 30 of starter8.89078 in.´lbf
Starter x Transaxle3737027
Terminal nut x Terminal C of starter1717312
Terminal nut x Terminal 30 of starter1717312
Magnetic switch end cover x Magnetic switch3.63632 in.´lbf

SS0NH-03
- SERVICE SPECIFICATIONSCHARGING
SS-21
151 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING
SERVICE DATA
BatterySpecific gravity at 20°C (68°F)1.25 - 1.29
Drive beltTension New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Type A at 20°C (68°F)
Type B at 20°C (68°F)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V 70 A, 60 A
2.2 - 2.4 W
2.8 - 3.0 W
14.2 - 14.4 mm (0.559 - 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage regulatorRegulating voltage at 25°C (77°F)
at 115°C (239°F)13.9 - 15.1 V
13.5 - 14.3 V

SS0NI-03
SS-22
- SERVICE SPECIFICATIONSCHARGING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Generator x Generator bracket4142030
Generator x Adjusting lever121209
Bearing retainer x Drive end frame2.62723 in.´lbf
Rectifier end frame x Drive end frame Type A, B4.54640 in.´lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame Type A, B1.962017 in.´lbf
Rear end cover x Rectifier holder Type A, B4.44540 in.´lbf
Terminal insulator x Rectifier holder4.14236 in.´lbf