Page 152 of 1202
SS0NI-03
SS-22
- SERVICE SPECIFICATIONSCHARGING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Generator x Generator bracket4142030
Generator x Adjusting lever121209
Bearing retainer x Drive end frame2.62723 in.´lbf
Rectifier end frame x Drive end frame Type A, B4.54640 in.´lbf
Generator pulley x Rotor11 01,12581
Rectifier holder x Coil lead on rectifier end frame Type A, B1.962017 in.´lbf
Rear end cover x Rectifier holder Type A, B4.44540 in.´lbf
Terminal insulator x Rectifier holder4.14236 in.´lbf
Page 154 of 1202
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
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 158 of 1202
SS0LK-02
SS-28
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
158 Author: Date:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
186 - 265 kPa (1.9 - 2.7 kgf/cm2, 27 - 38 psi)
353 - 431 kPa (3.6 - 4.4 kgf/cm2, 51 - 63 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
363 - 422 kPa (3.7 - 4.3 kgf/cm2, 53 - 61 psi)
530 - 706 kPa (5.4 - 7.2 kgf/cm2, 77 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,412 - 1,647 kPa (14.4 - 16.8 kgf/cm2, 205 - 239 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth0 ± 0.5 mm (0 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth19 mm (0.75 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
L position
Throttle valve fully closed 2 " 1
47 - 62 km/h (29 - 39 mph)
91 - 107 km/h (57 - 66 mph)
85 - 104 km/h (53 - 65 mph)
36 - 46 km/h (22 - 29 mph)
39 - 49 km/h (24 - 30 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
63 - 72 km/h (39 - 45 mph)
59 - 68 km/h (37 - 42 mph)
Page 159 of 1202
SS0LL-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A132L)
SS-29
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug4950036
Oil pan4.95043 in.´lbf
Detent spring101007
Valve body x Oil pipe clamp101007
Valve body x Oil strainer101007
Valve body x Apply pipe bracket101007
Valve body x Transaxle101007
Park/neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/neutral position switch (nut)6.97061 in.´lbf
Transaxle control shaft lever x Park/neutral position switch131309
Transaxle control shaft lever x Transaxle control cable121209
Drive plate x Crankshaft8890065
Torque converter clutch x Drive plate2728020
Starter3940029
Transaxle housing x Engine (upper side)6465047
Transaxle housing x Engine (lower side) Bolt A
Bolt B
Bolt C
Bolt D7.4
25
46
6475
250
470
65065 in.´lbf
18
34
47
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Oxygen sensor4445032
Exhaust pipe clamp1919014
LH engine mounting x Body4949036
Engine rear mounting bracket x Engine rear mounting insulator6565048
Engine rear mounting insulator x Body Bolt A
Bolt B80
92800
92059
69
Page 160 of 1202
SS0LI-04
SS-30
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
160 Author: Date:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth LH side
RH side5.3 ± 0.5 mm (0.209 ± 0.020 in.)
3.1 ± 0.5 mm (0.122 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth25.0 mm (0.98 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
Throttle valve fully closed 3 O/D
L position
Throttle valve fully closed 2 " 1
45 - 61 km/h (28 - 38 mph)
89 - 106 km/h (55 - 66 mph)
83 - 102 km/h (52 - 63 mph)
83 - 43 km/h (19 - 27 mph)
19 - 33 km/h (12 - 21 mph)
44 - 56 km/h (27 - 35 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
65 - 76 km/h (40 - 47 mph)
61 - 72 km/h (38 - 45 mph)
Page 161 of 1202
SS0LJ-04
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
SS-31
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Oil pan drain plug1717513
Oil pan4.95043 in.´lbf
Detent spring101007
Valve body x Oil pipe clamp101007
Valve body x Oil strainer101007
Valve body x Apply pipe bracket101007
Valve body x Transaxle101007
Park/neutral position switch x Transaxle case (bolt)5.45548 in.´lbf
Park/neutral position switch (nut)6.97061 in.´lbf
Transaxle control shaft lever x Park/neutral position switch131309
Transaxle control shaft lever x Transaxle control cable121209
Drive plate x Crankshaft8890065
Torque converter clutch x Drive plate2728020
Starter3940029
Transaxle housing x Engine (upper side)6465047
Transaxle housing x Engine (lower side) Bolt A
Bolt B
Bolt C7.4
64
4675
650
47065 in.´lbf
47
34
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe x Oxygen sensor4445032
Exhaust pipe clamp1919014
LH engine mounting x Body4949036
Engine rear mounting bracket x Engine rear mounting insulator6565048
Engine rear mounting insulator x Body Bolt A
Bolt B80
92800
92059
69
Page 162 of 1202
SS0LO-07
SS-32
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
162 Author: Date:
1996 TERCEL (RM440U)
SUSPENSION AND AXLE
SERVICE DATA
Cold tire inflationTire sizeCold tire inflation
pressure
Tire size
155SR13 ASFront240 kPa (2.4 kgf/cm2, 34 psi)ressure 155SR13 AS Front
Rear
240 kPa (2.4 kgf/cm, 34 si)
225 kPa (2.25 kgf/cm2, 32 psi)
Vehicle heightTire size
155SR13 ASFront
Rear
187.9 mm (7.40 in.)
253.2 mm (9.97 in.)
Front wheel align-
mentToe-in (Total)
Tie rod end left-right error0.1° ± 0.2° (1 ± 2 mm, 0.04 ± 0.08 in.)
1.5 mm (0.059 in.) or less
ment
Camber
Left-right error-0°20' ± 45'
45' or less
Caster
Left-right error1°20' ± 45'
45' or less
Steering axis inclination
Left-right error12°10' ± 45'
45' or less
Wheel angle Inside wheel
Outside wheel35°55' ± 2°
32°10' (Reference)
Rear wheel align-Toe-in (Total)0.3° ± 0.3° (3 ± 3 mm, 0.12 ± 0.12 in.)Rear wheel align-
ment
Camber
Left-right error-0°30' ± 45'
45' or less
Front axleAxle bearing backlash0.05 mm (0.0020 in.) or lessFront axle
Axle hub deviation0.05 mm (0.0020 in.) or less
Front suspensionLower ball joint turning torque0.8 - 2.5 N´m (8 - 25 kgf´cm, 7 - 22 in.´lbf)
Rear axleBearing preload (turning)Add frictional force plus 0 - 11.8 N (0 - 1.2 kgf, 0 - 2.6 lbf)Rear axle
Axle hub axial play0.05 mm (0.0020 in.) or less
