1996 TOYOTA TERCEL engine

F04746
R00326
R00324
R00325
BR1813
BR-36
- BRAKEABS ACTUATOR
910 Author
: Date
:
1996 TERCEL (RM440U)
4. INSPECT BRAKE ACTUATOR OPERATION
(a) Start the engine, and run it at idle.
(b) Turn the selector switch of the actuator checker to
ºFRONT RHº position.
(c) Push and hold in the MOTOR switch for a few seconds.
Make sure that you can hear the motor running.
(d) Depress the brake pedal and hold it for about 15 seconds,
and check that the brake pedal dose not go down.
(e) With your foot still applied onto the brake pedal, push the
MOTOR switch and check the brake pedal does not pul-
sate.
(f) Depress the brake pedal and hold it. As you hold the ped-
al down, push and hold in the POWER SWITCH for a few
seconds. Check the pedal does not go down.
(g) With your foot still applied onto the brake pedal, release
the POWER SWITCH and check that the pedal goes
down.
(h) With your foot still applied on the brake pedal, push the
MOTOR switch and check the brake pedal returns.
(i) Release the brake pedal.
5. INSPECT FOR OHTER WHEELS
(a) Turn the selector switch to ºFRONT LHº position.
(b) Repeat (c) to (i) of step 4, check the actuator operation as
before.
(c) Similarly, inspect ºREAR RHº and ºREAR LHº position.
HINT:
When inspecting ºREAR LHº position, push the REAR LH
switch instead of the POWER SWITCH, and you can inspect in
any selector switch position.

- BRAKEABS ACTUATOR
BR-37
911 Author
: Date
:
1996 TERCEL (RM440U)
6. PUSH MOTOR SWITCH
(a) Push and hold in the MOTOR switch for a few seconds.
(b) Stop the engine.
7. DISCONNECT ACTUATOR CHECKER (SST)
Remove the ºSHEET Aº (SST) and disconnect the actuator
checker (SST) and sub-wire harness (SST) from the actuator,
control relay and body side wire harness.
8. CONNECT CONNECTORS
(a) Connect the connector to the actuator.
(b) Connect the 2 connectors to the control relay.
9. CLEAR DTC (See page DI-1 11)

Z00038
DENSO BorroughsSR1F5-01
CH0087
CORRECT
WRONG
WRONG
R11541
PS Vane
Pump
CORRECTWRONG C
D
E
F
- STEERINGDRIVE BELT
SR-3
923 Author
: Date
:
1996 TERCEL (RM440U)
DRIVE BELT
INSPECTION
1. CHECK DRIVE BELT TENSION
Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020) or
Borroughs No. BT-33-73F
Drive belt tension:
New belt: 140 - 180 lbf
Used belt: 80 - 120 lbf
NOTICE:
After installing the belt, check that it fits properly in the
ribbed grooves.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
2. VEHICLES WITH BELT TENSION ADJUSTING BOLT:
ADJUST DRIVE BELT TENSION
(a) Loosen the bolts A and B.
(b) Loosen the lock nuts D and E.
(c) Adjust adjusting bolt F so that its protrusion above nut C
is ± 0 mm (0 in.).
(d) Fix nut C using lock nut D.
(e) Push up the PS pump body so that there is no free play
in the belt. Turn adjusting bolt F to obtain the play in the
correct belt tension as specified above.
NOTICE:
Ensure that the pump body and nut C are positioned cor-
rectly, as shown before turning bolt F to adjust the bet ten-
sion.
(f) Torque the bolt A.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

SR05P-15
R07281
Normal
Abnormal
- STEERINGPOWER STEERING FLUID
SR-5
925 Author
: Date
:
1996 TERCEL (RM440U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-6)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock position and keep it there for 2-3 seconds, then turn
the wheel to the opposite full lock position and keep it
there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-6)

SR05Q-17
R11229
NormalAbnormal
R11025Engine Idling Engine Stopped5 mm (0.20 in.)
or less SR-6
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5)
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5)
(i) Check the fluid level.

Q10145
Attachment
Attachment
IN
OUT
Pressure Feed TubeSST
PS Vane Pump
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed
- STEERINGPOWER STEERING FLUID
SR-7
1996 TERCEL (RM440U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube from the PS vane
pump. (See page SR-24)
(b) Connect SST, as shown in the illustration below.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.

Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open
Z15500
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open Lock Position SR-8
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(j) Disconnect the SST.
(k) Connect the pressure feed tube (See page SR-33).
(l) Bleed the power steering system.

SR0KE-01
R14423
Vacuum Hose
- STEERINGAIR CONTROL VALVE
SR-9
929 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONTROL VALVE
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
(a) Start the engine and run it at idle.
(b) Fully turn the steering wheel.
(c) Check that the engine rpm decreases when the vacuum
hose is pinched.
(d) Check that the engine rpm increases when the hose is re-
leased.