1996 TOYOTA TERCEL seats

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.

MA02M-05
- MAINTENANCEBODY
MA-9
47 Author
: Date
:
1996 TERCEL (RM440U)
BODY
INSPECTION
1. TIGHTEN BOLTS AND NUTS ON CHASSIS AND BODY
(a) Tighten the front seat-to-body mounting bolts.
Torque: 37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Under Severe Conditions:
In addition to the above maintenance items, check for
loose or missing nuts and bolts on the steering system,
drive train, suspension system, fuel tank mounts, engine
mounts, etc.
2. FINAL INSPECTION
(a) Check the operation of the body parts:

Hood:
Auxiliary catch operates properly
Hood locks securely when closed

Front and rear doors:
Door lock operates properly
Doors close properly

Luggage compartment door:
Door lock operates properly

Seats:
Seat adjusts easily and locks securely in any posi-
tion
Front seat back locks securely in any position
Folding-down rear seat backs lock securely
(b) Road test:

Check the engine and chassis for abnormal noises.

Check that the vehicle does not wander or pull to
one side.

Check that the brakes work properly and do not
drag.
(b) Be sure to deliver a clean car.
Especially check the steering wheel, shift lever knob, all
switch knobs, door handles and seats.

EM9937
EM0JZ-03
P20416
SST
EM9939
EM-30
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE NO.2 ENGINE HANGER
2. REMOVE STUD BOLT FOR CYLINDER HEAD COVER
3. REMOVE VALVE LIFTERS AND SHIMS
HINT:
Arrange the valve lifters and shims in correct order.
4. REMOVE VALVES
(a) Using SST, compress the valve spring and remove the 2
keepers.
SST 09202-70010
(b) Remove the spring retainer, valve spring, valve and
spring seat.
HINT:
Arrange the valves, valve springs, spring seats and spring re-
tainers in correct order.
(c) Using needle-nose pliers, remove the oil seal.

P03849
Overall Length
EM0255
P20367
45° Carbide Cutter
Z07819
Width
Z08336
45°
1.0 - 1.4 mm30° EM-34
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
(d) Check the valve overall length.
Standard overall length:
Intake93.45 mm (3.6791 in.)
Exhaust93.89 mm (3.6768 in.)
Minimum overall length:
Intake92.95 mm (3.6594 in.)
Exhaust93.39 mm (3.6768 in.)
If the overall length is less than minimum, replace the valve.
(e) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, resurface the tip with a grinder or
replace the valve.
NOTICE:
Do not grind off more than minimum.
7. INSPECT AND CLEAN VALVE SEATS
(a) Using a 45° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) Check the valve seating position.
(c) Apply a light coat of prussian blue (or white lead) to the
valve face. Lightly press the valve against the seat. Do not
rotate valve.
(d) Check the valve face and seat for the following:
(1) If blue appears 360° around the face, the valve is
concentric. If not, replace the valve.
(2) If blue appears 360° around the valve seat, the
guide and face are concentric. If not, resurface the
seat.
(3) Check that the seat contact is in the middle of the
valve face with the following width:
1.0 - 1.4 mm (0.039 - 0.055 in.)
If not, correct the valve seats as follows:
(1) If the seating is too high on the valve face, use 30°
and 45° cutters to correct the seat.

MT0057
Q06516
C141 Only
Q06524
Z00668
- MANUAL TRANSAXLEMANUAL TRANSAXLE ASSEMBLY
MX-13
1996 TERCEL (RM440U)
16. REMOVE REVERSE IDLER GEAR SHAFT LOCK BOLT
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
17. REMOVE SNAP RING FROM NO.2 SHIFT FORK
SHAFT
Using 2 screwdrivers and a hammer, remove the snap ring.
18. REMOVE STRAIGHT SCREW PLUG, SEAT, SPRING
AND BALL
(a) Using a hexagon wrench, remove the 4 plugs.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
C141 Plug, As Shown:
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(b) Using a magnetic finger, remove the 3 seats, springs and
balls.
19. REMOVE STRAIGHT SCREW PLUG (C141) OR LOCK
BALL ASSEMBLY (C151)
Using a hexagon wrench, remove the straight screw plug
(C141) or lock ball assembly (C151).
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE
242 or equivalent
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
20. REMOVE TRANSMISSION CASE
(a) Remove the 16 bolts.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
(b) Carefully tap the transmission case with a plastic hammer
and remove it.

SR17W-02
R11026
SST
R11027
SST
R13122
R11029
SST SR-50
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
DISASSEMBLY
NOTICE:
When using a vise, do not overtighten it.
1. SECURE PS GEAR ASSEMBLY IN VISE
Using SST, secure the gear assembly in a vise.
SST 09612-00012
2. REMOVE 2 TURN PRESSURE TUBES
(a) Using SST, remove the tube.
SST 09633-00020
(b) Remove the 2 union seats from the rack housing.
3. REMOVE AIR CONTROL VALVE
4. REMOVE RH AND LH TIE ROD ENDS AND LOCK
NUTS (See page SR-37)
5. REMOVE RH AND LH CLIPS, RACK BOOTS AND
CLAMPS
Using a screwdriver, loosen the clamp.
NOTICE:

Be careful not to damage the boot.

Mark the RH and LH boots.
6. REMOVE RH AND LH RACK ENDS AND CLAW WASH-
ERS (See page SR-37)
7. REMOVE RACK GUIDE SPRING CAP LOCK NUT
Using SST, remove the nut.
SST 09922-10010
NOTICE:
Use SST 09922-10010 in the direction shown in the illustra-
tion.
8. REMOVE RACK GUIDE SPRING CAP
Using a hexagon wrench (21 mm), remove the cap.
9. REMOVE RACK GUIDE SPRING, RACK GUIDE AND
RACK GUIDE SEAT
Remove the seat from the guide.
10. REMOVE RACK HOUSING CAP

Z03128
Vinyl Tape
R11057
SST
SR4264
SST
- STEERINGPOWER STEERING GEAR
SR-57
1996 TERCEL (RM440U)
4. INSTALL OIL SEAL
(a) Coat a new oil seal lip with power steering fluid.
(b) To prevent oil seal lip damage, wind vinyl tape on the
steering rack end, and apply power steering fluid.
(c) Install the oil seal by pushing it into the rack housing, with-
out tilting.
NOTICE:
Make sure to install the oil seal facing the correct direction.
5. INSTALL BUSHING AND CYLINDER END STOPPER
(a) Install a new bushing to the stopper.
(b) Using SST, torque the stopper.
SST 09631-20090
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(c) Using a punch and a hammer, stake the stopper and rack
housing.
6. AIR TIGHTNESS TEST
(a) Install SST to the rack housing.
SST 09631-12071
NOTICE:
Do not install union seats.
(b) Apply 53 kPa (400 mmHg, 15.75 in.Hg) of vacuum for
about 30 seconds.
(c) Check that there is no change in the vacuum.
If there is change in the vacuum, check the installation of the oil
seals.
7. INSTALL CONTROL VALVE ASSEMBLY
(a) Coat the teflon rings with power steering fluid.
(b) Push the valve assembly into the rack housing.

R13123
R11032
SST
Fulcrum
Length
- STEERINGPOWER STEERING GEAR
SR-61
1996 TERCEL (RM440U)
(d) Install the clip.
HINT:
Face the open ends of the clip outward/upward, as shown.
17. INSTALL RH AND LH TIE ROD ENDS AND LOCK NUTS
(a) Screw the lock nut and tie rod end onto the rack end until
the matchmarks are aligned.
(b) After adjusting toe-in, torque the nut
(See page SA-4).
Torque: 47 N´m (480 kgf´cm, 35 ft´lbf)
18. INSTALL AIR CONTROL VALVE
Torque the valve.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
19. INSTALL 2 TURN PRESSURE TUBES
(a) Install 2 new union seats.
(b) Using SST, install the tube.
SST 09633-00020
Torque: 20 N´m (203 kgf´cm, 15 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.