Page 45 of 1202
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.
Page 82 of 1202
PP3IW-01
- PREPARATIONMANUAL TRANSAXLE
PP-35
82 Author: Date:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerOutput shaft front bearing
09309-120205th Driven Gear Replacer
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32090)Oil Seal Remover & ReplacerDifferential side bearing
(09351-321 11)Side Bearing Race ReplacerDifferential side bearing oil seal
(Transmission case side)
(09351-32120)Overdrive Bearing ReplacerDifferential side bearing
(09351-32130)Handle
(09351-32150)Oil Seal ReplacerDifferential side bearing oil seal
(Transaxle case side)
09564-3201 1Differential Preload Adaptor
09608-00071Drive Pinion Rear Bearing Cone
ReplacerInput shaft rear ball bearing
4th driven gear and rear ball bearing
Page 83 of 1202
PP-36
- PREPARATIONMANUAL TRANSAXLE
83 Author: Date:
1996 TERCEL (RM440U)
09612-2201 1Tilt Handle Bearing ReplacerNo. 3 hub sleeve assembly
09612-65014Steering Worm Bearing PullerInput shaft front bearing and oil seal
Differential taper roller bearing outer
race
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09950-00020Bearing Remover
09950-00030Bearing Remover Attachment
09950-4001 1Puller B Set
09950-60010Replacer Set
(09951-00360)Replacer 36Input shaft front oil seal
Differential case side bearing
(09951-00460)Replacer 46Input shaft front bearing
(09951-00620)Replacer 62Output shaft front bearing
09950-60020Replacer Set No.2
(09951-00680)Replacer 68Differential taper roller bearing outer
race (Transaxle case side)
(09951-00710)Replacer 71Differential taper roller bearing outer
race (Transmission case side)
Page 89 of 1202
PP3IX-01
PP-42
- PREPARATIONAUTOMATIC TRANSAXLE (A132L)
89 Author: Date:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A132L)
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerSide gear shaft oil seal
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32010)One-way Clutch Test Tool
(09351-32020)Stator Stopper
(09351-32130)Handle
(09351-32150)Oil Seal Replacer
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09992-00095Automatic Transmission Oil
Pressure Gauge SetLine pressure
Page 94 of 1202
PP3IY-01
- PREPARATIONAUTOMATIC TRANSAXLE (A242L)
PP-47
94 Author: Date:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SST (Special Service Tools)
09201-10000Valve Guide Bushing Remover &
Replacer SetSpeedometer driven gear oil seal
(09201-01080)Valve Guide Bushing Remover &
Replacer 8
09308-00010Oil Seal PullerSide gear shaft oil seal
09350-32014TOYOTA Automatic Transmission
Tool Set
(09351-32010)One-way Clutch Test Tool
(09351-32020)Stator Stopper
(09351-32130)Handle
(09351-32150)Oil Seal Replacer
09921-00010Spring Tension ToolSpeedometer driven gear oil seal
09992-00095Automatic Transmission Oil
Pressure Gauge SetLine pressure
Page 109 of 1202
PP3IO-01
PP-62
- PREPARATIONSTEERING
109 Author: Date:
1996 TERCEL (RM440U)
STEERING
SST (Special Service Tools)
09612-00012Rack & Pinion Steering Rack
Housing StandManual steering gear
PS gear
09612-2201 1Tilt Handle Bearing ReplacerPS gear
09612-24014Steering Gear Housing Overhaul
Tool Set
(09612-10061)Steering Pinion Bearing ReplacerManual steering gear
PS gear
(09616-10010)Steering Pinion Bearing
Adjusting SocketManual steering gear
(09616-10020)Steering Pinion Bearing
Adjusting Screw WrenchManual steering gear
09612-65014Steering Worm Bearing Puller
(09612-01030)Claw ºCºPS gear
09613-12010Power Steering Control Valve
PullerPS gear
09616-0001 1Steering Worm Bearing Adjusting
SocketPS gear
09631-10041Steering Rack Cover ºDºPS gear
09631-12071Steering Rack Oil Seal Test ToolPS gear
Page 136 of 1202
SS-6
- SERVICE SPECIFICATIONSENGINE MECHANICAL
136 Author: Date:
1996 TERCEL (RM440U) Valve spring
Deviation Maximum
Free length
Installed tension at 31.8 mm (1.252 in.)2.0 mm (0.079 in.)
53.58 mm (2.1094 in.)
148 - 164 N (15.1 - 16.7 kgf, 33.3 - 36.8 lbf)
CamshaftThrust clearance STD
Maximum
Cam lobe height STD Intake
Exhaust
Maximum Intake
Exhaust
Journal diameter Exhaust No. 1
Others
Journal oil clearance STD
Maximum
Circle runout
Camshaft gear backlash STD
Maximum
Camshaft gear spring end free distance0.045 - 0.100 mm (0.0018 - 0.0039 in.)
0.12 mm (0.0047 in.)
41.514 - 41.614 mm (1.6344 - 1.6383 in.)
41.011 - 41.111 mm (1.6146 - 1.6185 in.)
41.35 mm (1.6279 in.)
40.85 mm (1.6083 in.)
24.949 - 24.965 mm (0.9822 - 0.9829 in.)
22.949 - 22.965 mm (0.9035 - 0.9041 in.)
0.035 - 0.072 mm (0.0014 - 0.0028 in.)
0.10 mm (0.0039 in.)
0.04 mm (0.0016 in.)
0.020 - 0.200 mm (0.0008 - 0.0079 in.)
0.30 mm (0.0118 in.)
22.5 - 22.9 mm (0.886 - 0.902 in.)
Valve lifterLifter diameter
Lifter bore diameter
Oil clearance STD
Maximum27.975 - 27.985 mm (1.1014 - 1.1018 in.)
28.000 - 28.021 mm (1.1024 - 1.1032 in.)
0.015 - 0.046 mm (0.0006 - 0.0018 in.)
0.10 mm (0.0039 in.)
ManifoldWarpageMaximum Intake
Exhaust0.1 mm (0.004 in.)
0.5 mm (0.020 in.)
Spark tubeProtrusion47.5 - 48.5 mm (1.870 - 1.909 in.)
Cylinder blockCylinder head surface warpage Maximum
Cylinder bore diameter Mark 1
2
3
Maximum
Main journal bore diameter (Reference) Mark 1
2
30.05 mm (0.0020 in.)
74.000 - 74.010 mm (2.9134 - 2.9138 in.)
74.011 - 74.020 mm (2.9138 - 2.9142 in.)
74.021 - 74.030 mm (2.9142 - 2.9146 in.)
74.23 mm (2.9244 in.)
54.018 - 54.024 mm (2.1267 - 2.1269 in.)
54.025 - 54.030 mm (2.1270 - 2.1272 in.)
54.031 - 54.036 mm (2.1272 - 2.1274 in.)
Piston and piston
ringPiston diameter Mark 1
2
3
Piston oil clearance STD
Maximum
Piston ring groove clearance No. 1
No. 2
Piston ring end gap STD No. 1
No. 2
Oil
Maximum No. 1
No. 2
Oil73.900 - 73.910 mm (2.9094 - 2.9098 in.)
73.910 - 73.920 mm (2.9098 - 2.9102 in.)
73.920 - 73.930 mm (2.9102 - 2.9106 in.)
0.09 - 0.11 mm (0.0035 - 0.0043 in.)
0.13 mm (0.0051 in.)
0.04 - 0.08 mm (0.0016 - 0.0031 in.)
0.03 - 0.07 mm (0.0012 - 0.0028 in.)
0.26 - 0.48 mm (0.0102 - 0.0189 in.)
0.30 - 0.57 mm (0.0118 - 0.0224 in.)
0.13 - 0.50 mm (0.0059 - 0.0197 in.)
1.07 mm (0.0421 in.)
1.02 mm (0.0354 in.)
1.10 mm (0.0433 in.)
Page 155 of 1202
SS0KP-02
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-25
155 Author: Date:
1996 TERCEL (RM440U)
MANUAL TRANSAXLE
SERVICE DATA
Input shaft roller bearing journal diameterMin.24.970 mm (0.9831 in.)
Input shaft 3rd gear journal diameterMin.30.970 mm (1.2193 in.)
Input shaft 4th gear journal diameterMin.28.970 mm (1.1405 in.)
Input shaft 5th gear journal diameter (for C151)Min.24.870 mm (0.9791 in.)
Input shaft runoutMax.0.05 mm (0.0020 in.)
Output shaft roller bearing journal diameterMin.32.970 mm (1.2980 in.)
Output shaft 1st gear journal diameterMin.37.970 mm (1.4949 in.)
Output shaft 2nd gear journal diameterMin.31.970 mm (1.2587 in.)
Output shaft runoutMax.0.05 mm (0.0020 in.)
Gear thrust clearance 1st STD
Max.0.10 - 0.40 mm (0.0039 - 0.0157 in.)
0.45 mm (0.0177 in.)
Gear thrust clearance 2nd STD
Max.0.10 - 0.45 mm (0.0039 - 0.0177 in.)
0.50 mm (0.0197 in.)
Gear thrust clearance 3rd STD
Max.0.10 - 0.35 mm (0.0039 - 0.0138 in.)
0.40 mm (0.0157 in.)
Gear thrust clearance 4th STD
Max.0.10 - 0.55 mm (0.0039 - 0.0217 in.)
0.60 mm (0.0236 in.)
Gear thrust clearance 5th (for C151) STD
Max.0.10 - 0.57 mm (0.0039 - 0.0224 in.)
0.65 mm (0.0256 in.)
1st, 2nd, 3rd, 4th and 5th (for C151) gear radial clearance STD
Max.0.015 - 0.058 mm (0.0006 - 0.0023 in.)
0.070 mm (0.0028 in.)
Shift fork to hub sleeve clearance Max.1.0 mm (0.039 in.)
Synchronizer ring to gear clearance Min.0.6 mm (0.024 in.)
Drive in depth
Input shaft front oil seal
Speedometer driven gear oil seal
Control shaft cover oil seal
Select inner lever slotted spring pin
No. 1 shift inner lever slotted spring pin
No. 2 shift inner lever slotted spring pin
Transmission case oil seal
Transaxle case oil seal
15.8 ± 0.2 mm (0.622 ± 0.008 in.)
25 mm (0.98 in.)
1.0 - 2.0 mm (0.039 - 0.079 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
0 ± 0.5 mm (0 ± 0.020 in.)
2.4 ± 0.3 mm (0.094 ± 0.012 in.)
1.9 ± 0.3 mm (0.075 ± 0.012 in.)
Differential side gear backlash0.05 - 0.20 mm (0.0020 - 0.0079 in.)
Differential side gear thrust washer thickness1.50 mm (0.0591 in.)
1.55 mm (0.0610 in.)
1.60 mm (0.0630 in.)
1.65 mm (0.0650 in.)
1.70 mm (0.0669 in.)
1.75 mm (0.0689 in.)
Differential side bearing preload (at starting) (for use with SST)
New bearing
Reused bearing
0.8 - 1.6 N´m (8 - 16 kgf´cm, 6.9 - 13.9 in.´lbf)
0.5 - 1.0 N´m (5 - 10 kgf´cm, 4.3 - 8.7 in.´lbf)
