Page 45 of 1202
MA03P-02
P19780BootBoot
P19895
- MAINTENANCECHASSIS
MA-7
45 Author: Date:
1996 TERCEL (RM440U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay (See page SR-10).
(b) Check the steering linkage for looseness or damage.
Check that the tie rod ends do not have excessive
play.
Check that the dust seals and boots are not dam-
aged.
Check that the boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS-2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINT AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place wooden
blocks with a height of 180 - 200 mm (7.09 - 7.87
in.) under the front tires.
(2) Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.
(3) Make sure the front wheels are in a straightforward
position and block the wheel with chocks.
(4) Move the lower arm up and down, and check that
the ball joint has no excessive play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
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 58 of 1202
PP3IT-01
- PREPARATIONMFI
PP-1 1
58 Author: Date:
1996 TERCEL (RM440U)
MFI
SST (Special Service Tools)
09268-41046Injection Measuring Tool Set
(09268-41091)NO.7 Union
(90405-09015)No.1 Union
09268-45012EFI Fuel Pressure Gauge
09631-22020Power Steering Hose Nut
14 x 17 mm Wrench SetFuel line flare nut
09816-30010Oil Pressure Switch SocketKnock sensor
09842-30070Wiring ºFº EFI Inspection
09843-18020Diagnosis Check Wire
Page 83 of 1202
PP-36
- PREPARATIONMANUAL TRANSAXLE
83 Author: Date:
1996 TERCEL (RM440U)
09612-2201 1Tilt Handle Bearing ReplacerNo. 3 hub sleeve assembly
09612-65014Steering Worm Bearing PullerInput shaft front bearing and oil seal
Differential taper roller bearing outer
race
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09950-00020Bearing Remover
09950-00030Bearing Remover Attachment
09950-4001 1Puller B Set
09950-60010Replacer Set
(09951-00360)Replacer 36Input shaft front oil seal
Differential case side bearing
(09951-00460)Replacer 46Input shaft front bearing
(09951-00620)Replacer 62Output shaft front bearing
09950-60020Replacer Set No.2
(09951-00680)Replacer 68Differential taper roller bearing outer
race (Transaxle case side)
(09951-00710)Replacer 71Differential taper roller bearing outer
race (Transmission case side)
Page 99 of 1202
PP3IZ-01
PP-52
- PREPARATIONSUSPENSION AND AXLE
99 Author: Date:
1996 TERCEL (RM440U)
SUSPENSION AND AXLE
SST (Special Service Tools)
09223-00010Cover & Seal ReplacerRear suspension
09223-15020Oil Seal & Bearing ReplacerFront axle
09308-00010Oil Seal PullerFront axle
Rear axle
09309-36010Transmission Rear Bearing
ReplacerFront drive shaft
09316-2001 1Transfer Bearing ReplacerFront drive shaft
09520-00031Rear Axle Shaft PullerFront axle
09550-10013Replacer Set ºBºRear axle
(09553-10010)Differential Side Bearing
Replacer
(09557-1001 1)Differential Drive Pinion
Front Bearing Replacer
09608-10010Steering Knuckle Oil Seal
ReplacerFront axle
09608-16042Front Hub Bearing Adjusting ToolFront drive shaft
(09608-02021)Bolt & Nut
Page 109 of 1202
PP3IO-01
PP-62
- PREPARATIONSTEERING
109 Author: Date:
1996 TERCEL (RM440U)
STEERING
SST (Special Service Tools)
09612-00012Rack & Pinion Steering Rack
Housing StandManual steering gear
PS gear
09612-2201 1Tilt Handle Bearing ReplacerPS gear
09612-24014Steering Gear Housing Overhaul
Tool Set
(09612-10061)Steering Pinion Bearing ReplacerManual steering gear
PS gear
(09616-10010)Steering Pinion Bearing
Adjusting SocketManual steering gear
(09616-10020)Steering Pinion Bearing
Adjusting Screw WrenchManual steering gear
09612-65014Steering Worm Bearing Puller
(09612-01030)Claw ºCºPS gear
09613-12010Power Steering Control Valve
PullerPS gear
09616-0001 1Steering Worm Bearing Adjusting
SocketPS gear
09631-10041Steering Rack Cover ºDºPS gear
09631-12071Steering Rack Oil Seal Test ToolPS gear
Page 110 of 1202
- PREPARATIONSTEERING
PP-63
11 0 Author: Date:
1996 TERCEL (RM440U)
09631-20081Seal Ring ToolPS gear
09631-20090Cylinder End Stopper Nut WrenchPS gear
09631-22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS gear
09633-00020Power Steering Hose Nut WrenchPS gear
09640-10010Power Steering Pressure Gauge
Set
(09641-01010)Gauge AssyPower steering fluid
(09641-01030)Attachment BPower steering fluid
(09641-01060)Attachment EPower steering fluid
09922-10010Variable Open WrenchManual steering gear
PS gear
09950-4001 1Puller B Set
(09951-04010)Hanger 150Manual steering gear
PS gear
(09952-04010)Slide ArmManual steering gear
PS gear
(09953-04020)Center Bolt 150Manual steering gear
PS gear
Page 111 of 1202
PP-64
- PREPARATIONSTEERING
111 Author: Date:
1996 TERCEL (RM440U)
(09954-04010)Arm 25Manual steering gear
PS gear
(09955-04051)Claw No.5Manual steering gear
PS gear
(09957-04010)AttachmentManual steering gear
PS gear
(09958-0401 1)HolderManual steering gear
PS gear
09950-50012Puller C Set
(09951-05010)Hanger 150Non-tilt steering column
(09952-05010)Slide ArmNon-tilt steering column
(09953-05020)Center Bolt 150Non-tilt steering column
(09954-05020)Claw No.2Non-tilt steering column
09950-60010Replacer Set
(09951-00220)Replacer 22PS gear
(09951-00240)Replacer 24Manual steering gear
(09951-00340)Replacer 34Manual steering gear
