1996 TOYOTA TERCEL maintenance

MA001-24
- MAINTENANCEOUTSIDE VEHICLE
MA-1
39 Author
: Date
:
1996 TERCEL (RM440U)
OUTSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. TIRES
(a) Check the pressure with a gauge.
If necessary, adjust.
(b) Check for cuts, damage or excessive wear.
3. WHEEL NUTS
When checking the tires, check the nuts for looseness or for missing nuts.
If necessary, tighten them.
4. TIRE ROTATION
Check the owner's manual supplement in which the maintenance schedule is shown.
5. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they do not wipe clean.
If necessary, replace.
6. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.
7. DOORS AND ENGINE HOOD
(a) Check that all doors and includiing the trunk lid operate smoothly, and that all latches lock securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the primary latch
is released.

MA002-30
MA-2
- MAINTENANCEINSIDE VEHICLE
40 Author
: Date
:
1996 TERCEL (RM440U)
INSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that all front seat controls such as seat adjusters, seatback reliner, etc. operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the locks hold securely in any latched position.
(d) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latched position.
(e) For fold-down rear seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

- MAINTENANCEINSIDE VEHICLE
MA-3
41 Author
: Date
:
1996 TERCEL (RM440U)
13. ACCELERATOR PEDAL
Check the pedal for smooth operation and uneven pedal effort or catching.
14. CLUTCH PEDAL (See page CL-2)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper freeplay.
15. BRAKE PEDAL (See page BR-6)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and freeplay.
(c) Check the brake booster function.
16. BRAKES
At a safe place, check that the brakes do not pull to one side when applied.
17. PARKING BRAKE (See page BR-8)
(a) Check that the lever has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
18. AUTOMATIC TRANSMISSION ºPARKº MECHANISM
(a) Check the lock release button of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in the P position and
all brakes released.

MA003-28
MA-4
- MAINTENANCEUNDER HOOD
42 Author
: Date
:
1996 TERCEL (RM440U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE AND CLUTCH FLUID LEVELS
(a) Check that the brake fluid level is near the upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within ±5 mm (0.20 in.). of the reservoir hem.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick and check
that the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F).
If the If the level is at the low side, add fluid.
NOTICE:
Do not overfill.
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.

MA00R-19
MA0659
Upper Lower
- MAINTENANCEENGINE
MA-5
43 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. REPLACE TIMING BELT (See pages EM-12 and
EM-17)
2. INSPECT DRIVE BELTS (See pages CH-2, SR-3 and
AC-18)
3. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty,
damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
First blow from the upper side thoroughly, then blow off
the lower side of the air filter.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE SPARK PLUGS (See page IG-1)
6. REPLACE ENGINE OIL AND OIL FILTER (See page
LU-3)
7. REPLACE ENGINE COOLANT (See page CO-2)
8. INSPECT CHARCOAL CANISTER (See page EC-5)
9. REPLACE GASKET IN FUEL TANK CAP (See page
EC-5)
10. INSPECT FUEL LINES AND CONNECTIONS (See
page EC-5)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for severe
corrosion, leaks or damage.
12. ADJUST VALVE CLEARANCE (See page EM-4)

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)

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.

P21589
SA3501
Grease
RA0489
MA-8
- MAINTENANCECHASSIS
46 Author
: Date
:
1996 TERCEL (RM440U)
(b) Check the dust cover for damage.
6. CHECK TRANSAXLE OIL (FLUID)
Visually check the transaxle for oil (fluid) leakage.
If leakage is found, check for the cause and repair.
7. REPLACE TRANSAXLE OIL (FLUID)
(a) M/T:
Replace the transaxle oil (See page MX-6).
(b) A/T:
Replace the transaxle fluid.
(A132L: See page AX-2)
(A242L: See page AX-2)
8. REPACK REAR WHEEL BEARINGS
(a) Change rear wheel bearing grease.
(1) Remove the hub and inner and outer bearings.
Clean in solvent and inspect the bearings for dam-
age.
(2) Pack the bearings and axle hubs with multipurpose
grease.
Wheel bearing grease grade:
Lithium base multipurpose grease (NLGI No.2)
(b) Install inner bearing and new oil seal.
(c) Install the hub and adjust the wheel bearing preload (See
page SA-42).
Preload (while turning):
Add frictional force plus
0 - 11.8 N (0 - 1.2 kgf, 0 - 2.6 lbf)