1996 TOYOTA TERCEL cylinder

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

SS0KS-01
SS-24
- SERVICE SPECIFICATIONSCLUTCH
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Clutch line union1515511
Master cylinder installation nut121209
Bleeder plug8.38574 in.´lbf
Clutch cover x Flywheel1919514
Release cylinder installation bolt121209

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

SS0LP-06
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-33
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT:
Disc brake dust cover x Steering knuckle8.38574 in.´lbf
Lower ball joint x Steering knuckle981,00072
Steering knuckle x Shock absorber2452,500181
Lower ball joint x Lower suspension arm8082059
Tie rod end lock nut4748035
Tie rod end x Steering knuckle4950036
Disc brake caliper x Steering knuckle8890065
Drive shaft lock nut2162,200159
Piston rod x Suspension support4747534
Suspension support x Body3940029
Flexible hose x Shock absorber2930022
Lower suspension arm x BodyFront side1421,450105Lower sus ension arm x Body Front side
Rear side
142
74
1,450
750
105
55
Hub nut1031,05076
ABS speed sensor x Steering knuckle7.88069 in.´lbf
REAR:
Piston rod x Suspension support3435025
Suspension support x Body3940029
Shock absorber x Axle beam6869050
Backing plate x Axle beam7071051
Parking brake cable x Backing plate7.88069 in.´lbf
Brake line x Wheel cylinder1515511
Body x Axle beam1421,450105
Lateral control rod x Axle beam8385061
Lateral control rod x Body11 31,15083
ABS speed sensor x Axle beam7.88069 in.´lbf
ABS speed sensor wire x Axle beam5.45548 in.´lbf

SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf

SS0N2-05
- SERVICE SPECIFICATIONSSTEERING
SS-37
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
STEERING COLUMN
Steering support x Column tube5.45548 in.´lbf
Control valve shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Steering column assembly set nut2526019
Steering wheel set nut3435025
Steering wheel pad set screw8.89078 in.´lbf
PS VANE PUMP
Pressure port union x Front housing6970051
Suction port union x Front housing131309
Pressure feed tube x Pressure port union5455040
PS vane pump pulley set nut4344032
PS vane pump assembly set nut Bolt A4344032 PS vane um assembly set nut Bolt A
Bolt B
43
39
440
400
32
30
MANUAL STEERING GEAR
Pinion bearing adjusting screw lock nut for use with SST
for use without SST85
11 3871
1,15063
83
Rack guide spring cap lock nut for use with SST
for use without SST41
56419
57530
42
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Manual steering gear bracket x Body5859043
Pinion shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Column hole cover x Body4.95043 in.´lbf
PS GEAR
Cylinder end stopper5960043
Self-locking nut5960043
Rack housing cap5960043
Rack guide spring cap lock nut for use with SST
for use without SST31
44316
45023
33
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Turn pressure tube union nut for use with SST
for use without SST20
25203
25015
18
Air control valve2930022
PS gear bracket x Body5859043
Engine rear mount insulator Bolt A6465047 Engine rear mount insulator Bolt A
Bolt B
64
78
650
800
47
58
Engine rear mount bracket x Transaxle4849035
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe clamp1919014
Front exhaust pipe x Oxygen sensor4445032

- DIAGNOSTICSENGINE
DI-1 1
1996 TERCEL (RM440U)
Proceed to matrix chart of problem symp-
toms on page DI-19.
7. ENGINE OPERATING CONDITION
NOTICE:
The values given below for ºNormal Conditionº are representative values, so a vehicle may still be
normal even if its value from those listed here. So do not decide whether a part is faulty or not solely
according to the ºNormal Conditionº here.
CARB mandated signals:
TOYOTA hand-held tester displayMeasurement ItemNormal Condition*
FUEL SYS #1
Fuel System Bank 1
OPEN: Air-fuel ratio feedback stopped
CLOSED: Air-fuel ratio feedback operating
Idling after warming up: CLOSED
CALC LOAD
Calculator Load:
Current intake air volume as a proportion of max.
intake air volumeIdling: 19.7 - 47.4 %
Racing without load (2,500rpm): 18.8 - 46.4 %
COOLANT TEMP.Engine Coolant Temp. Sensor ValueAfter warming up: 80 - 95°C (176 - 203°F)
SHORT FT #1Short-term Fuel Trim Bank 10 ± 20%
LONG FT #1Long-term Fuel Trim Bank 10 ± 20%
ENGINE SPDEngine SpeedIdling: 700 - 800 rpm
VEHICLE SPDVehicle SpeedVehicle Stopped: 0 km/h (0 mph)
IGN ADVANCEIgnition Advance:
Ignition Timing of Cylinder No. 1Idling: BTDC 7 - 14°
INTAKE AIRIntake Air Temp. Sensor ValueEquivalent to Ambient Temp.
MAPAbsolute Pressure Inside Intake Manifold
Idling: 20 - 48 kPa
Racing without load (2,500 rpm):
19 - 47 kPa
THROTTLE POS
Voltage Output of Throttle Position Sensor
Calculated as a percentage:
0 V "0%, 5 V "100%Throttle Fully Closed: 6 - 16 %
Throttle Fully Open: 64 - 98 %
O2S B1, S1Voltage Output of Heated Oxygen Sensor
Bank 1, Sensor 1Idling: 0.1 - 0.9 V
O2FT B1, S1Oxygen Sensor Fuel Trim Bank 1, Sensor 1
(Same as SHORT FT #1)0 ± 20 %
O2S B1, S2Voltage Output of Oxygen Sensor
Bank 1, Sensor 2Driving at 50 km/h (31 mph): 0.1 - 0.9 V
*: If no conditions are specifically stated for ºldlingº, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.

DI-12
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
TOYOTA Enhanced Signals:
TOYOTA hand-held tester displayMeasurement ItemNormal Condition*
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 2.66 - 3.9 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 25.5 - 43 %
STARTER SIGStarter SignalCranking: ON
CTP SIGClosed Throttle Position SignalThrottle Fully Closed: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark/Neutral Position Switch SignalP or N position: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL#1, CYL#2, CYL#3, CYL#4Abnormal revolution variation for each cylinder0%
IGNITIONTotal number of ignition for every 1,000 revolu-
tions0 - 2,000 rpm
FUEL PUMPFuel Pump SignalIdling: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 - 1.2 V
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from lean to rich.
Idling after warmed up: 0 - 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from rich to lean.
Idling after warmed up: 0 - 1,000 msec.
*: If no conditions are specifically stated for ºldlingº, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.