1996 TOYOTA TERCEL length

- INTRODUCTIONTERMS
IN-33
33 Author
: Date
:
1996 TERCEL (RM440U) H/B
Hatchback
H-FUSEHigh Current Fuse
HIHigh
HIDHigh Intensity Discharge (Head Lamp)
HPUHydraulic Power Unit
HSGHousing
HTHard Top
HWSHeated Windshield System
IACIdle Air Control
ICIntegrated circuit
IDIIndirect Diesel Injection
IFSIndependent Front Suspension
IGIgnition
IIAIntegrated Ignition Assembly
INIntake (Manifold, Valve)
INTIntermittent
I/PInstrument Panel
IRSIndependent Rear Suspension
J/BJunction Block
J/CJunction Connector
KDKick-Down
LANLocal Area Network
LBLiftback
LCDLiquid Crystal Display
LEDLight Emitting Diode
LHLeft-Hand
LHDLeft-Hand Drive
L/H/WLength, Height, Width
LLCLong-Life Coolant
LNGLiquified Natural Gas
LOLow
LPGLiquified Petroleum Gas
LSDLimited Slip Differential
LSP & PVLoad Sensing Proportioning And Bypass Valve
LSPVLoad Sensing Proportioning Valve
MAX.Maximum
M-FUSEMedium Current Fuse
MICMicrophone
MILMalfunction Indicator Lamp
MIN.Minimum
MPMultipurpose
MPXMultiplex Communication System
M/TManual Transmission (Transaxle)
MTMount
MTGMounting
NNeutral

P19770
MA00S-13
MA-6
- MAINTENANCEBRAKE
44 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses.

Check for damage.

Check for wear.

Check for deformation.

Check for cracks.

Check for corrosion.

Check for leaks.

Check for bends.

Check for twists.
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS (See page
BR-26)
HINT:
If a squealing or scraping noise comes from the brake during
driving, check the pad wear indicator to see if it is contacting the
disc. If so, the disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS (See
page BR-32)

PP0MS-07
PP-72
- PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
1996 TERCEL (RM440U)
EQUIPMENT
Torque wrench
Bolt
Length: 35 mm (1.38 in.)
Pitch: 1.0 mm (0.039 in.)
Diam: 6.0 mm (0.236 in.)Airbag disposal
Tire
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Tire with disc wheel
Width: 185 mm (7.28 in.)
Inner diam: 360 mm (14.17 in.)Airbag disposal
Vinyl bagAirbag disposal

SS0N5-03
- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-5
135 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,275 kPa (13.0 kgf/cm2, 185 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) No. 02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
340.15 - 0.25 mm (0.006 - 0.010 in.)
0.31 - 0.41 mm (0.012 - 0.016 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC110° BTDC @ idle
Idle speed-750 ± 50 rpm
Idler pulley tension
springFree length
Installed load at 47.4 mm (1.866 in.)38.4 mm (1.512 in.)
32 N (3.3 kgf, 7.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve guide bore diameter STD
O/S 0.05
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
11.000 - 11.027 mm (0.4331 - 0.4342 in.)
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
30°, 45°, 60°, 75°
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 - 6.030 mm (0.2366 - 0.2374 in.)
11.048 - 11.059 mm (0.4350 - 0.4354 in.)
11.098 - 11.109 mm (0.4369 - 0.4374 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum93.45 mm (3.6791 in.)
93.89 mm (3.6965 in.)
92.95 mm (3.6594 in.)
93.39 mm (3.6768 in.)
44.5°
5.970 - 5.985 mm (0.2350 - 0.2356 in.)
5.965 - 5.980 mm (0.2348 - 0.2354 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 - 1.2 mm (0.031 - 0.047 in.)
0.5 mm (0.020 in.)

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.)

SS0NF-07
- SERVICE SPECIFICATIONSSTARTING
SS-19
149 Author
: Date
:
1996 TERCEL (RM440U)
STARTING
SERVICE DATA
Starter
(Planetary type)Rated voltage and output power
No-load characteristics Current
rpm
Center bearing oil clearance STD
Maximum
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum12 V 0.8 kW
At 11.5 V 90 A or less
3,000 rpm or more
0.03 mm (0.0012 in.)
0.1 mm (0.004 in.)
14.0 mm (0.551 in.)
9.0 mm (0.354 in.)
13.7 - 17.6 N (1.4 - 1.8 kgf, 3.1 - 4.0 lbf)
8.8 N (0.9 kgf, 2.0 lbf)
28.0 mm (1.102 in.)
27.0 mm (1.063 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
Starter
(Reduction type)Rated voltage and output power
No-load characteristics Current
rpm
Brush length STD
Minimum
Spring installed load STD
Minimum
Commutator
Diameter STD
Minimum
Undercut depth STD
Minimum
Circle runout Maximum
Magnetic switch
Contact plate for wear Maximum12 V 1.0 kW
At 11.5 V 90 A or less
3,000 rpm or more
13.5 mm (0.531 in.)
8.5 mm (0.334 in.)
17.6 - 23.5 N (1.79 - 2.39 kgf, 4.0 - 5.3 lbf)
11.8 N (1.2 kgf, 2.6 lbf)
30.0 mm (1.181 in.)
29.0 mm (1.412 in.)
0.6 mm (0.024 in.)
0.2 mm (0.008 in.)
0.05 mm (0.0020 in.)
0.9 mm (0.035 in.)

SS0NH-03
- SERVICE SPECIFICATIONSCHARGING
SS-21
151 Author
: Date
:
1996 TERCEL (RM440U)
CHARGING
SERVICE DATA
BatterySpecific gravity at 20°C (68°F)1.25 - 1.29
Drive beltTension New belt
Used belt160 ± 20 lbf
100 ± 20 lbf
GeneratorRated output
Rotor coil resistance
Type A at 20°C (68°F)
Type B at 20°C (68°F)
Slip ring diameter STD
Minimum
Brush exposed length STD
Minimum12 V 70 A, 60 A
2.2 - 2.4 W
2.8 - 3.0 W
14.2 - 14.4 mm (0.559 - 0.567 in.)
12.8 mm (0.504 in.)
10.5 mm (0.413 in.)
1.5 mm (0.059 in.)
Voltage regulatorRegulating voltage at 25°C (77°F)
at 115°C (239°F)13.9 - 15.1 V
13.5 - 14.3 V

SS0N1-03
SS-36
- SERVICE SPECIFICATIONSSTEERING
166 Author
: Date
:
1996 TERCEL (RM440U)
STEERING
SERVICE DATA
ON-VEHICLE INSPECTION
Steering wheel freeplayMaximum30 mm (1.18 in.)
Drive belt tension New belt140 - 180 lbf Drive belt tension New belt
Used belt
140 180 lbf
80 - 120 lbf
Maximum rise of oil level5 mm (0.20 in.)
Oil pressure at idle speed with valve closed Minimum6,374 kPa (65 kgf/cm2, 925 psi)
Steering effort at idle speedMaximum7.8 N´m (80 kgf´cm, 69 in.lbf)
PS VANE PUMP
Rotor shaft bushing oil clearance STD0.01 - 0.03 mm (0.0004 - 0.0012 in.) Rotor shaft bushing oil clearance STD
Maximum
0.01 0.03 mm (0.0004 0.0012 in.)
0.07 mm (0.0028 in.)
Vane plate heightMinimum8.0 mm (0.315 in.)
Vane plate thickness Minimum1.77 mm (0.0697 in.)
Vane plate lengthMinimum14.97 mm (0.5894 in.)
Vane plate to rotor groove clearanceMaximum0.03 mm (0.0012 in.)
Vane plate length Pump rotor and cam ring mark Vane late length Pum rotor and cam ring mark
None14.996 - 14.998 mm (0.59039 - 0.59047 in.)None
1
14.996 - 14.998 mm (0.59039 - 0.59047 in.)
14.994 - 14.996 mm (0.59032 - 0.59039 in.)1
2
14.994 14.996 mm (0.59032 0.59039 in.)
14.992 - 14.994 mm (0.59024 - 0.59032 in.)2
3
14.992 14.994 mm (0.59024 0.59032 in.)
14.990 - 14.992 mm (0.59016 - 0.59024 in.)3
4
14.990 14.992 mm (0.59016 0.59024 in.)
14.988 - 14.990 mm (0.59008 - 0.59016 in.)
Spring free length36 - 38 mm (1.42 - 1.49 in.)
Vane pump rotating torqueMaximum0.3 N´m (2.8 kgf´cm, 2.4 in.´lbf) or less
MANUAL STEERING GEAR
Steering rack runout Maximum0.30 mm (0.0118 in.)
Pinion preload Turning0.23 - 0.32 N´m (2.3 - 3.3 kgf´cm, 2.0 - 2.9 in.lbf)
Total preload Turning0.6 - 1.2 N´m (6 - 12 kgf´cm, 5.2 - 10.4 in.´lbf)
PS GEAR
Steering rack runout Maximum0.30 mm (0.0118 in.)
Measure oil clearance STD0.050 - 0.083 mm (0.00197 - 0.00327 in.) Measure oil clearance STD
Maximum
0.050 0.083 mm (0.00197 0.00327 in.)
0.125 mm (0.00492 in.)
Total preload Turning0.8 - 1.4 N´m (8 - 14 kgf´cm, 6.9 - 12.2 in.´lbf)