1996 TOYOTA TERCEL manual transmission

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Page 31 of 1202

TOYOTA TERCEL 1996 Service Repair Manual IN04Q-07
- INTRODUCTIONTERMS
IN-31
31 Author: Date:
1996 TERCEL (RM440U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory

Page 33 of 1202

TOYOTA TERCEL 1996 Service Repair Manual - 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
H

Page 34 of 1202

TOYOTA TERCEL 1996 Service Repair Manual IN-34
- INTRODUCTIONTERMS
34 Author: Date:
1996 TERCEL (RM440U) NA
Natural Aspiration
No.Number
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/

Page 42 of 1202

TOYOTA TERCEL 1996 Service Repair Manual 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 owners

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.

Page 82 of 1202

TOYOTA TERCEL 1996 Service Repair Manual 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 dri

Page 83 of 1202

TOYOTA TERCEL 1996 Service Repair Manual 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

Page 88 of 1202

TOYOTA TERCEL 1996 Service Repair Manual PP14U-01
- PREPARATIONMANUAL TRANSAXLE
PP-41
1996 TERCEL (RM440U)
SSM (Special Service Materials)
08826-00090Seal Packing 1281,
THREE BOND 1281 or equivalent
(FIPG)Transmission case x Transaxle cas

Page 155 of 1202

TOYOTA TERCEL 1996 Service Repair Manual 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.)
I

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)

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