Page 148 of 1202
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
Page 157 of 1202
SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513
Page 391 of 1202
DI4MZ-01
THEFT DETERRENT SYSTEM Check Sheet
Inspector 's name:
Customer 's Name
Date of VehicleRegistration No.
Registration Year
Frame No.
Odometer Reading / /km
Mile
Weather Conditions
When Problem
Occurred Frequency Problem OccursWeather
Outdoor temperature
/ /
Constant Sometimes ( Times per day, month)
Once only Brought in
Theft deterrent system cannot be set.
Indicator light does not flash when the theft deterrent system is set.
(It stays on or does not light at all.)
Theft deterrent system
does not operate. When unlocked using the
door lock knob.
When the engine hood is
opened.
System cannot be
canceled once set. When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON
position.
(However, only when the system has never operated)
When the luggage compartment door is opened with the key.
System cannot be
canceled during warning
operation. When door is unlocked using key or wireless door lock control system.
When the key is inserted in the ignition key cylinder and turned to ACC or ON
position.
Warning operation starts when the system is set and the door or luggage compartment door is opened with
the key.
Others.
Date Problem First Occurred
Fine Cloudy Rainy Snowy
Various/Others
Hot Warm Cool
Cold (Approx. 5F ( 5C))
Problem Symptom
Malfunction
Horns only
Theft deterrent horn only
Headlights only
Taillights only
Starter cut only
Door lock operation only
DI-216
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
CUSTOMER PROBLEM ANALYSIS CHECK
Page 392 of 1202
DI4N0-02
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-217
1996 TERCEL (RM440U)
PRE-CHECK
1. SETTING OF THE THEFT DETERRENT SYSTEM
Setting Conditions
(a) Close all the doors.
(b) Close the engine hood and luggage compartment door.
(c) Remove the ignition key from the ignition key cylinder.
Setting Operation
When any of the following operations (a), (b) or (c) is performed, the theft deterrent indicator light will light
up as described.
(1) Lock the left or right front door using the key
(All doors are locked by key-interlinked lock operation).
(2) Lock all the doors using the wireless door lock control system.
(3) With the rear doors locked and with one of the front doors locked, lock the other front door without
using the key (keyless door lock).
Elapsed time after operationIndicator light
Within about 30 secondsLight up
After about 30 secondsBlinks *1
*1: 1 sec. or, 1 sec. off
HINT:
When the theft deterrent system is set, doors cannot be locked or unlocked with the door lock control switch
and the luggage compartment door cannot be unlocked with the luggage compartment door opener switch.
2. CANCELING OF THE THEFT DETERRENT SYSTEM IN THE SET CONDITION
Check if the theft deterrent indicator light is blinking.
Canceling Operation
When any of the following operations (a), (b), (c) or (d) is performed, the theft deterrent system is canceled
and indicator light will go off.
Condition
(1) Unlock the left or right front door using the key.
(2) Unlock all the doors using the wireless door lock control system.
(3) Insert the ignition key in the ignition key cylinder and turn it to the ACC or ON position
(This is operative only when the theft deterrent system has never operated).
(4) Unlock the luggage compartment door with the key. *1
*1: The theft deterrent system is temporarily canceled only while the luggage compartment door is open.
Approximately 2 seconds after the luggage compartment door is closed, the theft deterrent system is reset.
3. CHECK OF THE THEFT DETERRENT SYSTEM OPERATION
Check if the theft deterrent indicator light is blinking.
When any of the following operations (a) or (b) is performed, the system sounds the horns and theft deterrent
horn and flashes the headlights and taillights for about one minute to alert. At the same time, the system
disconnects the starter motor circuit and locks all doors (if all doors are not locked, the system repeats door
locking operation every 2 seconds during the one minute alert time).
(1) Open the engine hood using the engine hood opener lever.
(2) Unlock any of the front or rear doors without key operation.
Page 426 of 1202
EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author: Date:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)
Page 428 of 1202
EM0494
P20156
SST(A)
SST(B)
EM-6
- ENGINE MECHANICALVALVE CLEARANCE
427 Author: Date:
1996 TERCEL (RM440U)
(b) Determine the replacement adjusting shim size by the fol-
lowing Formula or Charts on the next 2 pages:
(1) Using a micrometer, measure the thickness of the
removed shim.
(2) Calculate the thickness of a new shim so that the
valve clearance comes within specified value.
T ....... Thickness of removed shim
A ....... Measured valve clearance
N ....... Thickness of new shim
Intake:
N = T + (A - 0.20 mm (0.008 in.))
Exhaust:
N = T + (A - 0.36 mm (0.014 in.))
Select a new shim with a thickness as close as possible
to the calculated value.
HINT:
Shims are available in 17 increments of 0.05 mm (0.0020 in.),
from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
(c) Install a new adjusting shim.
(1) Place a new adjusting shim on the valve lifter.
(2) Using SST (A), press down the valve lifter and re-
move SST (B).
SST 09248-55040 (09248-05410, 09248-05020)
(d) Recheck the valve clearance.
7. REINSTALL CYLINDER HEAD COVER
(a) Apply seal packing to the cylinder head as shown in the
illustration.
Seal packing:
Part No. 08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the 5 seal washers and
cap nuts.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
(d) Install oil filler cap.
8. REINSTALL IGNITION COILS AND HIGH-TENSION
CORDS
9. RECONNECT EGR VACUUM MODULATOR
10. RECONNECT PCV HOSES TO CYLINDER HEAD COV-
ER
Page 443 of 1202
EM0JX-05
- ENGINE MECHANICALCYLINDER HEAD
EM-21
442 Author: Date:
1996 TERCEL (RM440U)
CYLINDER HEAD
COMPONENTS
Page 444 of 1202
EM-22
- ENGINE MECHANICALCYLINDER HEAD
443 Author: Date:
1996 TERCEL (RM440U)
