1996 TOYOTA TERCEL light

BE1485
432
1
5
6 7
8 9
Q06563
ON
OFF
O/D Main
SwitchIndicator
Light
Q01167
Q01168
- AUTOMATIC TRANSAXLE (A242L)AUTOMATIC TRANSAXLE SYSTEM (A242L)
AX-1 1
1996 TERCEL (RM440U)
(a) Inspect the Park/Neutral position switch.
(1) Remove the park/neutral position switch
(See page AX-19).
(2) Using an ohmmeter, check continuity between each
terminal shown below when the shift lever is put in
each position.
If the continuity is not as specified, replace the switch.
(b) Inspect the O/D OFF indicator light.
(1) Turn the ignition switch ON.
(2) The O/D OFF indicator light will come on when the
O/D main switch is in OFF position.
(3) The O/D OFF indicator light will go on when the O/D
main switch is placed at ON.
(c) Inspect the O/D solenoid valve.
(1) Disconnect the solenoid connector.
(2) Using an ohmmeter, measure the resistance be-
tween terminals 1 and 3.
Resistance: 11 - 15 W
If the resistance is not as specified, replace the solenoid.
(3) Apply battery positive voltage between terminals 1
and 3. At this time, confirm that a solenoid operation
sound is heard.
If the operation is not as specified, replace the solenoid.
(4) Connect the solenoid connector.

AX0RZ-01
Q06565
N00513
N00515
0.8 - 1.5 mm
200 mm
- AUTOMATIC TRANSAXLE (A242L)THROTTLE CABLE
AX-19
801 Author
: Date
:
1996 TERCEL (RM440U)
THROTTLE CABLE
ON-VEHICLE REPAIR
1. DISCONNECT THROTTLE CABLE FROM ENGINE
Disconnect the cable from the throttle linkage.
2. REMOVE PARK/NEUTRAL POSITION SWITCH
(a) Disconnect the transaxle control cable from the transaxle
control shaft lever.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(b) Remove the nut and transaxle control shaft lever.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
(c) Using a screwdriver, pry off the nut stopper.
(d) Remove the nut and nut stopper.
Torque: 6.9 N´m (70 kgf´cm, 61 in.´lbf)
(e) Remove the 2 bolts and park/neutral position switch.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
3. REMOVE VALVE BODY (See page AX-16)
4. REMOVE THROTTLE CABLE
(a) Remove the retaining bolt and plate.
(b) Pull out the cable from the transaxle case.
HINT:
New cable does not have a staked cable stopper
(c) Bend the cable so that there is a radius of about 200 mm
(7.87 in.).
(d) Pull the inner cable lightly until a slight resistance is felt,
and hold it there.
(e) Stake the stopper so that the distance from the end of out-
er cable to the stopper is 0.8 - 1.5 mm (0.031 - 0.059 in.).

AX084-01
D01645
Key Interlock Solenoid
Stop Light SwitchShift Lock
Override Button
Shift Lock Control
Unit Assembly
BatteryMAIN
FLALTStopIgnition Switch
ACC
IGCIG
ECU-IG
IG
Shift Lock
Control ECUACC
Key Interlock Solenoid
KLS
+
E Stop Light
Switch
Stop
LightSTP WIRING DIAGRAM
- AUTOMATIC TRANSAXLE (A242L)SHIFT LOCK SYSTEM
AX-27
809 Author
: Date
:
1996 TERCEL (RM440U)
SHIFT LOCK SYSTEM
LOCATION

R12354
Stop Light Switch
Push Rod
Pedal Height
BR4980
A
BR1DT-01
BR-6
- BRAKEBRAKE PEDAL
880 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE PEDAL
ON-VEHICLE INSPECTION
1. CHECK PEDAL HEIGHT
Pedal height from asphalt sheet:
EZ Grade:
143.0 - 153.0 mm (5.630 - 6.024 in.)
Except EZ Grade:
140.0 - 150.0 mm (5.512 - 5.906 in.)
If the pedal height is incorrect, adjust it.
2. IF NECESSARY, ADJUST PEDAL HEIGHT
(a) Disconnect the connector from the stop light switch.
(b) Loosen the stop light switch lock nut and remove the stop
light switch.
(c) Loosen the push rod lock nut.
(d) Adjust the pedal height by turning the pedal push rod.
(e) Tighten the push rod lock nut.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(f) Install the stop light switch and turn it until it lightly con-
tacts the pedal stopper.
(g) Turn the stop light switch back one turn.
(h) Check the clearance (A) between stop light switch and
pedal.
Clearance: 0.5 - 2.4 mm (0.020 - 0.094 in.)
(i) Tighten the stop light switch lock nut.
(j) Connect the connector to the stop light switch.
(k) Check the stop lights come on when the brake pedal is de-
pressed, and go off when the brake pedal is released.
(l) After adjusting the pedal height, check the pedal freeplay.
HINT:
If clearance (A) between the stop light switch and the brack ped-
al stopper has been adjusted correctly, the pedal freeplay will
meet the specifications.

R12355
Pedal Freeplay
BR4228
Pedal Reserve Distance
- BRAKEBRAKE PEDAL
BR-7
881 Author
: Date
:
1996 TERCEL (RM440U)
3. CHECK PEDAL FREEPLAY
(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the booster.
(b) Push in the pedal by hand until the resistance begins to
be felt, then measure the distance, as shown.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 in.)
If incorrect, check the stop light switch clearance. If the clear-
ance is OK, then troubleshoot the brake system.
4. CHECK PEDAL RESERVE DISTANCE
(a) Release the parking brake.
(b) With the engine running, depress the pedal and measure
the pedal reserve distance.
Pedal reserve distance from asphalt sheet at 490 N
(50 kgf, 110.2 lbf):
w/o ABS: More than 60 mm (2.36 in.)
w/ ABS: More than 55 mm (2.17 in.)
If the reserve distance is incorrect, troubleshoot the brake sys-
tem.

BR0RF-06
BR5036
Soft Jaws
BR5037
Soft Jaws
R12236
A
- BRAKEBRAKE MASTER CYLINDER
BR-1 1
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE RESERVOIR
(a) Remove the set screw and pull out the reservoir.
Torque: 1.7 N´m (17.5 kgf´cm, 15.2 in.´lbf)
(b) Remove the cap and strainer from the reservoir.
2. REMOVE 2 GROMMETS
3. PLACE CYLINDER IN VISE
4. REMOVE PISTON STOPPER BOLT
Using a screwdriver, push the pistons in all the way and remove
the piston stopper bolt and gasket.
HINT:
Tape the screwdriver tip before use.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
5. REMOVE PISTONS
(a) Push in the piston with a screwdriver and remove the
snap ring with snap ring pliers.
(b) Remove the No.1 piston and spring by hand, pulling
straight out, not at an angle.
NOTICE:

If pulled out and installed at an angle, there is a possi-
bility that the cylinder bore could be damaged.

Be careful not to damage the rubber lips on the pis-
tons.
(c) Place a rag and 2 wooden blocks on the work table and
lightly tap the cylinder flange against the block edges until
the No.2 piston drops out of the cylinder.
HINT:
Make sure the distance (A) from the rag to the top of the blocks
is at least 100 mm (3.94 in.).

BR2237
BR0RJ-01
BR2238
GOOD NO GOOD
1st2nd3rd
- BRAKEBRAKE BOOSTER ASSEMBLY
BR-15
889 Author
: Date
:
1996 TERCEL (RM440U)
BRAKE BOOSTER ASSEMBLY
ON-VEHICLE INSPECTION
1. OPERATING CHECK
(a) Depress the brake pedal several times with the engine off
and check that there is no change in the pedal reserve
distance.
(b) Depress the brake pedal and start the engine. If the pedal
goes down slightly, operation is normal.
2. AIR TIGHTNESS CHECK
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
If the pedal goes down farthest the 1st time, but gradually rises
after the 2nd or 3rd time, the booster is air tight.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed. If there is no
change in the pedal reserve travel after holding the pedal
for 30 seconds, the booster is air tight.

BR0RM-04
F03521
SST
Gasket
N00744
SST
BR1728 BR0021
BR-18
- BRAKEBRAKE BOOSTER ASSEMBLY
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL BRAKE BOOSTER
(a) Install the booster and a new gasket.
(b) Install the clevis to the operating rod.
(c) Install and torque the booster installation nuts.
Torque: 14 N´m (145 kgf´cm, 10 ft´lbf)
(d) Insert the clevis pin into the clevis and brake pedal, and
install the clip to the clevis pin.
(e) Install the pedal return spring.
(f) Install the No.1 brake line clamp to the body.
(g) Install the No.2 brake line clamp to the body.
2. ADJUST LENGTH OF BOOSTER PUSH ROD
(a) Install the gasket on the master cylinder.
(b) Set SST on the gasket, and lower the pin until its tip slight-
ly touches the piston.
SST 09737-00010
(c) Turn SST upside down, and set it on the booster.
SST 09737-00010
(d) Measure the clearance between the booster push rod
and pin head (SST).
Clearance: 0 mm (0 in.)
(e) Adjust the booster push rod length until the push rod
slightly touches the pin head.
HINT:
When loosening the push rod nut, depress the brake pedal
enough so that the push rod sticks out.
3. INSTALL MASTER CYLINDER
4. CONNECT VACUUM HOSE TO BRAKE BOOSTER
5. FILL BRAKE RESERVOIR WITH BRAKE FLUID AND
BLEED BRAKE SYSTEM (See page BR-4)
6. CHECK FOR LEAKS