1996 TOYOTA TERCEL wheel

MA002-30
MA-2
- MAINTENANCEINSIDE VEHICLE
40 Author
: Date
:
1996 TERCEL (RM440U)
INSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
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. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that all front seat controls such as seat adjusters, seatback reliner, etc. operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the locks hold securely in any latched position.
(d) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latched position.
(e) For fold-down rear seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

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)

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.

P21589
SA3501
Grease
RA0489
MA-8
- MAINTENANCECHASSIS
46 Author
: Date
:
1996 TERCEL (RM440U)
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
(a) M/T:
Replace the transaxle oil (See page MX-6).
(b) A/T:
Replace the transaxle fluid.
(A132L: See page AX-2)
(A242L: See page AX-2)
8. REPACK REAR WHEEL BEARINGS
(a) Change rear wheel bearing grease.
(1) Remove the hub and inner and outer bearings.
Clean in solvent and inspect the bearings for dam-
age.
(2) Pack the bearings and axle hubs with multipurpose
grease.
Wheel bearing grease grade:
Lithium base multipurpose grease (NLGI No.2)
(b) Install inner bearing and new oil seal.
(c) Install the hub and adjust the wheel bearing preload (See
page SA-42).
Preload (while turning):
Add frictional force plus
0 - 11.8 N (0 - 1.2 kgf, 0 - 2.6 lbf)

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.

PP18T-03
- PREPARATIONENGINE MECHANICAL
PP-7
1996 TERCEL (RM440U)
SSM (Special Service Materials)
08826-00080Seal Packing Black or equivalent
(FIPG)Camshaft bearing cap (No. 1 and
No. 2)
Cylinder head cover
Rear oil seal retainer
08826-00100Seal Packing 1282B,
THREE BOND 1282B or equivalent
(FIPG)Water outlet housing
08833-00070Adhesive 1324,
THREE BOND 1324 or equivalentSpark plug tube
Flywheel or drive plate bolt
08833-00080Adhesive 1344
THREE BOND 1344
LOCTITE 242 or equivalentOil pressure switch

PP0MS-07
PP-72
- PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
1996 TERCEL (RM440U)
EQUIPMENT
Torque wrench
Bolt
Length: 35 mm (1.38 in.)
Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Tire
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Vinyl bagAirbag disposal

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015