Page 42 of 1202

MA003-28
MA-4
- MAINTENANCEUNDER HOOD
42 Author: Date:
1996 TERCEL (RM440U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE AND CLUTCH FLUID LEVELS
(a) Check that the brake fluid level is near the upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within ±5 mm (0.20 in.). of the reservoir hem.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick and check
that the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F).
If the If the level is at the low side, add fluid.
NOTICE:
Do not overfill.
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.
Page 44 of 1202

P19770
MA00S-13
MA-6
- MAINTENANCEBRAKE
44 Author: Date:
1996 TERCEL (RM440U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses.
Check for damage.
Check for wear.
Check for deformation.
Check for cracks.
Check for corrosion.
Check for leaks.
Check for bends.
Check for twists.
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS (See page
BR-26)
HINT:
If a squealing or scraping noise comes from the brake during
driving, check the pad wear indicator to see if it is contacting the
disc. If so, the disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS (See
page BR-32)
Page 47 of 1202

MA02M-05
- MAINTENANCEBODY
MA-9
47 Author: Date:
1996 TERCEL (RM440U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten the front seat-to-body mounting bolts.
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing nuts and bolts on the steering system,
drive train, suspension system, fuel tank mounts, engine
mounts, etc.
2. FINAL INSPECTION
(a) Check the operation of the body parts:
Hood:
Auxiliary catch operates properly
Hood locks securely when closed
Front and rear doors:
Door lock operates properly
Doors close properly
Luggage compartment door:
Door lock operates properly
Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding-down rear seat backs lock securely
(b) Road test:
Check the engine and chassis for abnormal noises.
Check that the vehicle does not wander or pull to
one side.
Check that the brakes work properly and do not
drag.
(b) Be sure to deliver a clean car.
Especially check the steering wheel, shift lever knob, all
switch knobs, door handles and seats.
Page 48 of 1202
PP18P-01
- PREPARATIONMAINTENANCE
PP-1
48 Author: Date:
1996 TERCEL (RM440U)
MAINTENANCE
EQUIPMENT
MirrorBrake hose
Torque wrench
Page 100 of 1202
- PREPARATIONSUSPENSION AND AXLE
PP-53
100 Author: Date:
1996 TERCEL (RM440U)
(09608-02041)Retainer
09628-1001 1Ball Joint PullerFront axle
09628-6201 1Ball Joint PullerFront axle
Front drive shaft
Front suspension
09631-12040Oil Seal ºAº ReplacerFront axle
09727-30021Coil Spring CompressorFront suspension
Rear suspension
09729-22031Front Spring Upper Seat HolderFront suspension
09751-3601 1Brake Line Union Nut 10 x 12 mm
WrenchBrake Line
09950-00020Bearing RemoverFront axle
Front drive shaft
09950-60010Replacer SetFront axle
Rear axle
(09951-00460)Replacer 46
(09951-00610)Replacer 61
(09951-00650)Replacer 65
09950-70010Handle SetFront axle
Rear axle
Page 105 of 1202
PP310-01
PP-58
- PREPARATIONBRAKE
105 Author: Date:
1996 TERCEL (RM440U)
BRAKE
SST (Special Service Tools)
09023-00100Union Nut Wrench 10 mm
09709-29018LSPV Gauge Set
09718-00010Shoe Hold Down Spring Driver
09737-00010Brake Booster Push Rod Gauge
09751-3601 1Brake Line Union Nut 10 x 12 mm
Wrench
09843-18020Diagnosis Check Wire
09990-00150ABS Actuator Checker and
Sub-harness
09990-00163ABS Actuator Checker Sheet ºAº
09990-00200ABS Actuator Checker Sub-harness
ºCº
09990-00300ABS Actuator Checker Sub-harness
ºIº
Page 106 of 1202
PP17T-01
- PREPARATIONBRAKE
PP-59
1996 TERCEL (RM440U)
RECOMMENDED TOOLS
09082-00040TOYOTA Electrical Tester.
09905-00013Snap Ring Pliers .
Page 107 of 1202
PP17U-01
PP-60
- PREPARATIONBRAKE
1996 TERCEL (RM440U)
EQUIPMENT
Dial indicatorBrake disc
MicrometerBrake disc
Torque wrench
Vernier calipersBrake drum