1996 TOYOTA TERCEL length

R12040
SST
Fulcrum
Length
N00349
R15520
0 mm
6 mm
(0.24 in.)
R15519
SR-44
- STEERINGMANUAL STEERING GEAR
1996 TERCEL (RM440U)
10. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 43 N´m (434 kgf´cm, 31 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
11. INSTALL RH AND LH BOOTS, CLAMPS AND CLIPS
(a) Install the rack boot.
NOTICE:
Be careful not to damage or twist the boot.
(b) Install the clamp screw, as shown in the illustration.
(c) Install the clip.
HINT:
Face the open ends of the clips outward/upward as shown in
the illustration, to avoid damage to the boot.
12. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut.
(See page SA-4)
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)

W04432
Hexagon
Wrench
12°
W00840
SST
W00841
SST
Hexagon
Wrench
W01203SSTHexagon
Wrench Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-59
1996 TERCEL (RM440U)
13. ADJUST TOTAL PRELOAD
(a) To prevent the steering rack teeth from damaging the oil
seal lip, temporarily install the RH and LH rack ends.
(b) Using a hexagon wrench (21 mm), torque the rack guide
spring cap.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(c) Using a hexagon wrench (21 mm), return the cap 12°.
(d) Using SST, turn the control valve shaft right and left 1 or
2 times.
SST 09616-00010
(e) Using a hexagon wrench (21 mm), loosen the cap until the
rack guide spring is not functioning.
(f) Using SST, a torque wrench and hexagon wrench (21
mm), tighten the cap until the preload is within the specifi-
cation.
SST 09616-00010
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
14. INSTALL RACK GUIDE SPRING CAP LOCK NUT
(a) Apply sealant to 2 or 3 threads of the nut.
Sealant: Part No.08833-00080, THREE BOND 1344,
LOCTITE 242 or equivalent
(b) Using a hexagon wrench (21 mm), hold the rack guide
spring cap and using SST, torque the nut.
SST 09922-10010
Torque: 36 N´m (366 kgf´cm, 26 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 300 mm (11.81
in.).
(c) Recheck the total preload.
Preload (turning):
0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)
(d) Remove the RH and LH rack end.

R07337
Rack Groove
R11031
SST
Fulcrum
Length
R10934
Brass
Bar
F05319
SR4273
0 - 3 mm
(0 - 0.12 in.) SR-60
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
15. INSTALL RH AND LH CLAW WASHERS AND RACK
ENDS
(a) Install a new washer, and temporarily tighten the rack
end.
HINT:
Align the claws of the washer with the steering rack grooves.
(b) Using a spanner, hold the steering rack steadily and using
SST, torque the rack end.
SST 09922-10010
Torque: 51 N´m (520 kgf´cm, 18 ft´lbf)
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
HINT:
Use a torque wrench with a fulcrum length of 345 mm (13.58
in.).
(c) Using a brass bar and a hammer, stake the washer.
NOTICE:
Avoid any impact on the rack.
16. INSTALL RH AND LH RACK BOOTS, CLAMPS AND
CLIPS
(a) Ensure that the steering rack hole is not clogged with
grease.
HINT:
If the hole is clogged, the pressure inside the boot will change
after it is assembled and the steering wheel is turned.
(b) Install the boot.
NOTICE:
Be careful not to damage or twist the boots.
(c) Tighten a new clamp, as shown in the illustration.

R13123
R11032
SST
Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-61
1996 TERCEL (RM440U)
(d) Install the clip.
HINT:
Face the open ends of the clip outward/upward, as shown.
17. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut
(See page SA-4).
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
18. INSTALL AIR CONTROL VALVE
Torque the valve.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Install 2 new union seats.
(b) Using SST, install the tube.
SST 09633-00020
Torque: 20 N´m (203 kgf´cm, 15 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.

SR0L2-03
R11193
R13112
Fulcrum
Length
SST
Z14367
B AB
B
BB
SR-62
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the tube.
SST 09631-22020
Torque: 36 N´m (366 kgf´cm, 27 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT TUBE CLAMP
Torque the bolt.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
5. M/T:
CONNECT CONTROL CABLES
(a) Connect the 2 cables to the control lever housing.
(b) Install the 2 clips to the cables.
(c) Install the 2 clips and washers.
6. CONNECT 2 VACUUM HOSES
7. INSTALL ENGINE REAR MOUNT BRACKET
Torque the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
8. INSTALL ENGINE REAR MOUNT INSULATOR
Torque the 6 bolts.
Torque:
Bolt A: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt B: 78 N´m (800 kgf´cm, 58 ft´lbf)

BO34E-01
BO0632
BO0633
15°
45°
- BODYSEAT BELT
BO-57
1996 TERCEL (RM440U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts
or nuts and sill-bar) if it has been used in a severe impact.
The entire assembly should be replaced even if damage is
not obvious.
Emergency Locking Retractor (ELR) and Automatic Lock-
ing Retractor (ALR) type
1. All seat belt:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard
stop.
(c) Check that the belt is locked and cannot be extended at
this time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt. Then retract the belt slightly and pull it out
again.
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.

N10070
Fall Length minus
200 mm (7.87 in.)
BO0635
BO-58
- BODYSEAT BELT
1996 TERCEL (RM440U)
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees of tilt.
If a problem is found, replace the assembly.
4. Manual Type:
TESTING
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.