1996 TOYOTA TERCEL Service Repair Manual

SS061-41
- SERVICE SPECIFICATIONSSUPPLEMENTAL RESTRAINT SYSTEM
SS-39
169 Author
: Date
:
1996 TERCEL (RM440U)
SUPPLEMENTAL RESTRAINT SYSTEM
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Steering wheel3435025
Steering wheel pad8.89078 in.´lbf
Front passenger airbag assembly1919514
Airbag sensor assembly2020014

SS0ME-05
SS-40
- SERVICE SPECIFICATIONSBODY ELECTRICAL
170 Author
: Date
:
1996 TERCEL (RM440U)
BODY ELECTRICAL
SERVICE DATA
INTEGRATION RELAY
Key Unlock Warning System:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
3 - Ground (Constant)Battery positive voltage
9 - Ground (Ignition switch LOCK or ACC)No voltage
9 - Ground (Ignition switch ON)Battery positive voltage
12 - Ground (Constant)Battery positive voltage
DAYTIME RUNNING LIGHT MAIN RELAY
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
18 - Ground (Ignition switch LOCK or ACC)No voltage
18 - Ground (Ignition switch ON)Battery positive voltage
4 - Ground (Constant)Battery positive voltage
6 - Ground (Constant)Battery positive voltage
10 - Ground (Constant)Battery positive voltage
11 - Ground (Engine stop)No voltage
11 - Ground (Engine running)Battery positive voltage
15 - Ground (Constant)Battery positive voltage
TURN SIGNAL FLASHER
Flashes/Minute60 - 120
SPEEDOMETER (USING A SPEEDOMETER TESTER)
Standard indication (mph)Allowable range (mph)
2018 - 24
4038 - 45
6059 - 67
8079 - 88
100100 - 110
Standard indication (km/h)Allowable range (km/h)
2016 - 26
4038 - 48
6059 - 69
8076 - 90
10096 - 110
120114 - 131
140134 - 152
160152 - 174
TACHOMETER (ON-VEHICLE)DC 13.5 V 25°C (77°F)
Standard indication (rpm)Allowable range (rpm)
700610 - 750
3,0002,850 - 3,150
5,0004,850 - 5,150
7,0006,790 - 7,210

- SERVICE SPECIFICATIONSBODY ELECTRICAL
SS-41
171 Author
: Date
:
1996 TERCEL (RM440U) FUEL RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 115.8
A - CApprox. 177.2
B - CApprox. 61.4
w/o Tachometer:Resistance (W)
A - BApprox. 171.2
A - CApprox. 272.8
B - CApprox. 101.6
FUEL SENDER GAUGE
Float position: mm (in.)Resistance (W)
F: Approx. 13.0 ± 3 (0.512 ± 0.118)Approx. 3 ± 1.0
1/2: Approx. 61.0 (2.402)Approx. 29 ± 4.8
E: Approx. 124.0 ± 3 (4.882 ± 0.118)Approx. 110 ± 7.7
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 51.0
A - CApprox. 148.6
B - CApprox. 199.6
w/o Tachometer:Resistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
DEFOGGER SWITCH
Timer Circuit:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
6 - Ground (Ignition switch LOCK or ACC)No voltage
6 - Ground (Ignition switch ON)Battery positive voltage

SS0NJ-06
SS-42
- SERVICE SPECIFICATIONSBODY
172 Author
: Date
:
1996 TERCEL (RM440U)
BODY
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT SEAT
Seat track x Body3737527
REAR SEAT
Seat back x Body1818513
Seat x Seat center hinge1818513
Seat center hinge x Body7.88069 in.´lbf
Seat x Seat hinge1818513
Seat hinge x Body7.88069 in.´lbf
FRONT SEAT BELT
Shoulder anchor x Adjustable anchor4344032
Outer belt anchor x Body4344032
ELR x Body4344032
Adjustable anchor x Body4344032
Inner belt x Seat4344032
REAR SEAT BELT
Outer belt anchor x Body4344032
ELR x Body4344032
Center belt x Body4344032
CANADA:
CRS, tether anchor x Body
2121015

SS0M9-03
- SERVICE SPECIFICATIONSAIR CONDITIONING
SS-43
173 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING
SERVICE DATA
Refrigerant charge volume650 ± 50 g (22.93 ± 1.76 oz.)
Drive belt tension New belt
Used belt160 ± 25 lbf
100 ± 20 lbf
Idle-up speed850 ± 50 rpm
Magnetic clutch clearance0.5 ± 0.15 mm (0.02 ± 0.0059 in.)

SS0MA-05
SS-44
- SERVICE SPECIFICATIONSAIR CONDITIONING
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Compressor x Suction hose101007
Compressor x Discharge hose101007
Compressor x Compressor bracket2525018
Receiver x Liquid tube5.45548 in.´lbf
Condenser x Liquid tube5.45548 in.´lbf
Cooling unit x Liquid tube1414010
Cooling unit x Suction tube3233024
Expansion valve x Evaporator5.45548 in.´lbf
Revolution detecting sensor x Compressor1111 08
Pressure plate x Compressor1414010

DI4LC-02
Vehicle Brought to Workshop
Customer Problem Analysis
Problem Symptom Confirmation
If the engine does not start, perform steps 10 and 12 firstConnect the OBD II scan tool or TOYOTA hand-held tester to DLC3 P. DI-3
If the display indicates a communication fault in the tool, inspect DLC3 P. DI-3
Check DTC and Freeze Frame Data (Pre-check)
Record or Print DTC and Freeze Frame Data P. DI-3
Clear DTC and Freeze Frame Data P. DI-3
Visual Inspection
Setting the Check Mode Diagnosis P. DI-3
Symptom Simulation P. IN-16
Basic Inspection P. DI-3DTC Chart P. DI-13
Matrix Chart of Problem Symptom P. DI-19
Circuit Inspection P. DI-20
Adjustment, Repair
DTC Check P. DI-3
Titles insideare titles of pages in
in the bottom portion. See the indicated
pages for detailed explanations. this manual, with the page number indicated
Malfunction
occurs.Malfunction does not occur.
Parts Inspection
Check for Intermittent Problems P. DI-3
Identification of Problem
Confirmation Test
End 1
2
3
4
5
6
7
108
9
11
12
13
15 14
16
Normal Malfunction code.
17
P. DI-2
- DIAGNOSTICSENGINE
DI-1
175 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following pages.

DI4LD-02
ENGINE CONTROL SYSTEM Check Sheet
Customer's Name
Driver's Name
Date Vehicle
Brought in
License No.
Model and Model
Year
Frame No.
Engine Model
Odometer Reading
km
miles
Problem Symptoms
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Driveaability
Engine Stall
Others
Engine does not crankNo initial combustionNo complete combustion
Engine cranks slowly
Other
Incorrect first idleIdling rpm is abnormalHigh ( rpm)Low ( rpm)
Rough idling
Other
HesitationBack fireMuffler explosion (after-fire)Surging
Knocking
Other
Soon after startingAfter accelerator pedal depressed
After accelerator pedal released
During A/C operation
Shifting from N to D
Other
Datas Problem
Occurred
Problem Frequency
Condition When
Problem Occurs
Weather
Engine Operation
Engine Temp. Place Outdoor
TemperatureConstant
Sometimes ( times per day/month)Once only
Other
Fine
CloudyRainySnowyVarious/Other
Hot
Warm CoolCold (approx. °F/ °C)
Highway
SuburbsInner CityUphillDownhill
Rough road
Other
Cold
Warming upAfter Warming upAny temp.Other
Starting
Just after starting ( min.)IdlingRacing
Driving
Constant speedAccelerationDeceleration
A/C switch ON/OFF
Other
Condition of MILRemains on Sometimes light up Does not light up
NormalMalfunction code(s) (code )
Freeze frame data ( )
NormalMalfunction code(s) (code )
Freeze frame data ( )
Normal mode
(Pre-check)
Check Mode DTC InspectionInspector's
Name
DI-2
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
CUSTOMER PROBLEM ANALYSIS CHECK