Page 42 of 1202

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 110 of 1202
- PREPARATIONSTEERING
PP-63
11 0 Author: Date:
1996 TERCEL (RM440U)
09631-20081Seal Ring ToolPS gear
09631-20090Cylinder End Stopper Nut WrenchPS gear
09631-22020Power Steering Hose Nut
14 x 17 mm Wrench SetPS gear
09633-00020Power Steering Hose Nut WrenchPS gear
09640-10010Power Steering Pressure Gauge
Set
(09641-01010)Gauge AssyPower steering fluid
(09641-01030)Attachment BPower steering fluid
(09641-01060)Attachment EPower steering fluid
09922-10010Variable Open WrenchManual steering gear
PS gear
09950-4001 1Puller B Set
(09951-04010)Hanger 150Manual steering gear
PS gear
(09952-04010)Slide ArmManual steering gear
PS gear
(09953-04020)Center Bolt 150Manual steering gear
PS gear
Page 115 of 1202
PP18H-04
PP-68
- PREPARATIONSTEERING
1996 TERCEL (RM440U)
LUBRICANT
ItemCapacityClassification
Power steering fluid Total0.8 liters (0.85 US qts, 0.70 Imp. qts)ATF DEXRON®II or III
Page 901 of 1202

SR05N-06
SR-2
- STEERINGTROUBLESHOOTING
922 Author: Date:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
SymptomSuspect AreaSee page
Hard steering
1. Tires (Improperly inflated)
2. Power steering fluid level (Low)
3. Drive belt (Loose)
4. Front wheel alignment (Incorrect)
5. Steering system joints (Worn)
6. Suspension arm ball joints (Worn)
7. Steering column (Binding)
8. Power steering gearSA-2
SR-6
SR-3
SA-4
-
SA-36
-
SR-46
Poor return
1. Tires (Improperly inflated)
2. Front wheel alignment (Incorrect)
3. Steering column (Binding)
4. Power steering gearSA-2
SA-4
-
SR-46
Excessive play
1. Steering system joints (Worn)
2. Suspension arm ball joints (Worn)
3. Intermediate shaft, Sliding yoke (Worn)
4. Front wheel bearing (Worn)
5. Power steering gear-
SA-36
-
SA-10
SR-46
Abnormal noise
1. Power steering fluid level (Low)
2. Steering system joints (Worn)
3. Power steering gearSR-6
-
SR-46
Page 904 of 1202
SR05P-15
R07281
Normal
Abnormal
- STEERINGPOWER STEERING FLUID
SR-5
925 Author: Date:
1996 TERCEL (RM440U)
POWER STEERING FLUID
BLEEDING
1. CHECK FLUID LEVEL (See page SR-6)
2. JACK UP FRONT OF VEHICLE AND SUPPORT IT
WITH STANDS
3. TURN STEERING WHEEL
With the engine stopped, turn the wheel slowly from lock to lock
several times.
4. LOWER VEHICLE
5. START ENGINE
Run the engine at idle for a few minutes.
6. TURN STEERING WHEEL
(a) With the engine idling, turn the wheel to left or right full
lock position and keep it there for 2-3 seconds, then turn
the wheel to the opposite full lock position and keep it
there for 2-3 seconds.
(b) Repeat (a) several times.
7. STOP ENGINE
8. CHECK FOR FOAMING OR EMULSIFICATION
If the system has to be bled twice specifically because of foam-
ing or emulsification, check for fluid leaks in the system.
9. CHECK FLUID LEVEL (See page SR-6)
Page 905 of 1202

SR05Q-17
R11229
NormalAbnormal
R11025Engine Idling Engine Stopped5 mm (0.20 in.)
or less SR-6
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5)
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5)
(i) Check the fluid level.
Page 906 of 1202
Q10145
Attachment
Attachment
IN
OUT
Pressure Feed TubeSST
PS Vane Pump
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed
- STEERINGPOWER STEERING FLUID
SR-7
1996 TERCEL (RM440U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube from the PS vane
pump. (See page SR-24)
(b) Connect SST, as shown in the illustration below.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:
Do not keep the valve closed for more than 10 se-
conds.
Do not let the fluid temperature become too high.
Page 907 of 1202
Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open
Z15500
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open Lock Position SR-8
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:
Do not maintain lock position for more than 10 se-
conds.
Do not let the fluid temperature become too high.
(j) Disconnect the SST.
(k) Connect the pressure feed tube (See page SR-33).
(l) Bleed the power steering system.