1996 TOYOTA TERCEL width

- 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

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.)

SS0KR-04
- SERVICE SPECIFICATIONSCLUTCH
SS-23
153 Author
: Date
:
1996 TERCEL (RM440U)
CLUTCH
SERVICE DATA
Pedal height from ashalt sheet143.0 - 151.0 mm (5.944 - 5.945 in.)
Push rod play at pedal top1.0 - 5.0 mm (0.039 - 0.197 in.)
Pedal freeplay5.0 - 15.0 mm (0.197 - 0.591 in.)
Clutch release point from pedal full stroke end position25 mm (0.98 in.) or more
Clutch start switch ON-OFF stroke5.0 ± 0.5 mm (0.197 ± 0.020 in.)
Slotted spring pin protrusion1.5 - 3.5 mm (0.059 - 0.138 in.)
Disc rivet head depth Min.0.3 mm (0.012 in.)
Disc runout Max.0.8 mm (0.031 in.)
Flywheel runoutMax.0.1 mm (0.004 in.)
Diaphragm spring finger wear Max. depth0.6 mm (0.024 in.)Dia hragm s ring finger wear Max. de th
Max. width
0.6 mm (0.024 in.)
5.0 mm (0.197 in.)
Diaphragm spring tip non-alignment Max.0.5 mm (0.020 in.)

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.

ST084-06
Z07247
York Side
Terminal
Served PartCut
York Side
Terminal
Served Part
Z07248
Width Thickness
Z07249
Weld Side
Z07250
3.3 mm
7 mm
Z03208
SST
- STARTINGSTARTER (Planetary Type)
ST-23
1996 TERCEL (RM440U)
REPLACEMENT
1. REPLACE BRUSHES
HINT:
Only the 2 brushes of the positive (+) side (york side) are ex-
changeable, negative (-) side brush must be changed in the
body with the brush holder.
(a) Cut the brush lead wire at the terminal side.
(b) Shave welded mark of the brush lead wire with sandpaper
etc., and correct the terminal to the specified.
NOTICE:
Part to be shaved is so narrow that you should take care not
to harm the field coil.
Specified width: 5.0 mm (0.197 in.)
Specified thickness: 1.5 - 1.7 mm (0.059 - 0.067 in.)
(c) Press the plate of the supply brush on the welded side of
the terminal lead wire.
(d) Solder the pressed part, and shave to the specified mea-
sures with the sandpaper etc.
Specified width: 7.0 mm (0.276 in.)
Specified thickness: 3.3 mm (0.130 in.)

Heat the soldered part well, and fiow the solder in-
side the plate, take care not to flow it into flow it into
the inside lead wire.

Take care not to flow the solder into field.
2. REPLACE CENTER BEARING
(a) Using SST and press, press out the center bearing.
SST 09221-25026 (09221-00090)

CL062-01
CL0239
CL0373
CL0290
Z08001
AB
N00414
CL-16
- CLUTCHCLUTCH UNIT
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT CLUTCH DISC FOR WEAR OR DAMAGE
Using calipers, measure the rivet head depth.
Minimum rivet depth: 0.3 mm (0.012 in.)
If necessary, replace the clutch disc.
2. INSPECT CLUTCH DISC RUNOUT
Using a dial indicator, check the disc runout.
Maximum runout: 0.8 mm (0.031 in.)
If necessary, replace the clutch disc.
3. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 in.)
If necessary, replace the flywheel.
4. INSPECT DIAPHRAGM SPRING FOR WEAR
Using calipers, measure the diaphragm spring for depth and
width of wear.
Maximum depth:
A: 0.6 mm (0.024 in.)
Maximum width:
B: 5.0 mm (0.197 in.)
If necessary, replace the clutch cover.
5. INSPECT RELEASE BEARING
Turn the bearing by hand while applying force in the axial direc-
tion.
HINT:
The bearing is permanently lubricated and requires no cleaning
or lubrication.
If necessary, replace the release bearing.

R05752
SST
AB0164
R04211
Tires
(3 or more)Inner Diam.
Width RS-16
- SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TERCEL (RM440U)
(d) Install the SST.
CAUTION:
Place the disc wheel on level ground.
Connect the SST connector to the steering wheel pad
connector.
SST 09082-00700
NOTICE:
To avoid damaging the SST connector and wire harness,
do not lock the secondary lock of the twin lock. Also, pro-
vide some slack for the SST wire harness inside the disc
wheel.
(e) Cover the steering wheel pad with cardboard box or tires.

Covering method using cardboard box:
Cover the steering wheel pad with the cardboard
box and weight the cardboard box down in 4 places
with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
x= 460 mm (18.11 in.)
When dimension y of the cardboard box exceeds the
diameter of the disc wheel with tire to which the steer-
ing wheel pad is tied -
x= 460 mm (18.11 in.) + width of tire
y= 650 mm (25.59 in.)
NOTICE:
If a cardboard box smaller than the specified size is used,
the cardboard box will be broken by the shock of the airbag
deployment.

Covering method using tires:
Place at least 3 tires without disc wheel on top of the
disc wheel with tire to which the steering wheel pad
is tied.
Tire size: Must exceed the following dimensions-
Width: 185 mm (7.28 in.)
Inner diameter: 360 mm (14.17 in.)
CAUTION:
Do not use tires with disc wheels.