1996 TOYOTA TERCEL engine

N20820
BatteryMAIN FL
B1
EA2 HAZ-HORN
2 W2Engine Room Relay Block
Horn Relay
11
2
2IC1G-Y24
T4
G-R
1
HORNTheft Deterrent ECU
HORN
H4 G-Y
B
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-231
1996 TERCEL (RM440U)
Horn Relay Circuit
CIRCUIT DESCRIPTION
When the theft deterrent system is activated, it causes the Tr in the ECU to switch on and off in approximately
0.4 sec. cycles. This switches the horn relay on and off, thus the horns blow (See the wiring diagram below).
In this condition, if any of the following operations is done, the Tr in the ECU goes off and the horn relay
switches off, thus stopping the horns from blowing:
(1) Unlock the front LH or RH door with key.
(2) Turn the ignition switch to ACC or ON position.
(3) Unlock the doors with the wireless door lock control system.
(4) Wait for approximately 60 seconds.
WIRING DIAGRAM
DI4N7-01

N20821
BatteryHeadlight
LHHeadlight
RH MAIN FL B 1
EA2
R
R-L2
2HEAD LH
HEAD RH2 B-R Engine Room Relay Block
Headlight Control Relay
2
2R-L
IC1
16
Light Control
Switch
(Combination
Switch)
13R-L R-L10
T4 Theft Deterrent ECU
HEAD
C12
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-233
1996 TERCEL (RM440U)
Headlight Control Relay Circuit
CIRCUIT DESCRIPTION
When the theft deterrent system is activated, it causes the Tr in the ECU for switch on and off at approximate-
ly 0.4 sec. cycles. This switches the headlight control relay on and off, thus flashing the headlights (See the
wiring diagram below).
In this condition, if any of the following operations is done, the Tr in the ECU goes off and the headlight control
relay switches off, thus stopping the headlights flashing:
(1) Unlock the front LH or RH door with key.
(2) Turn the ignition switch to ACC or ON position.
(3) Unlock the doors with the wireless door lock control system.
(4) Wait for approximately 60 seconds.
WIRING DIAGRAM
DI4N8-02

N12897
EB W-BEngine Room
Relay Block
(JUNCTION CONNECTOR)A
A
2 2Engine Hood
Courtesy Switch
12
LG-B12
IC2
LG-B14
T4 Theft Deterrent ECU
DSWH
E5
W-B DI-246
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
Engine Hood Courtesy Switch Circuit
CIRCUIT DESCRIPTION
The engine hood courtesy switch is built into the engine hood lock assembly and goes on when the engine
hood is opened and goes off when the engine hood is closed.
WIRING DIAGRAM
DI4NE-02

BE4061I00298I09784
1
2 Disconnect
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-247
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check engine hood courtesy switch.
PREPARATION:
(a) Remove engine hood lock assembly.
(b) Disconnect engine hood courtesy switch connector.
CHECK:
Check continuity between terminals 1 and 2 when engine hood
lock is locked and unlocked.
OK:
Engine hood lockTester connectionSpecified condition
LOCK-No continuity
UNLOCK1 - 2Continuity
NG Replace engine hood courtesy switch.
OK
2 Check harness and connector between theft deterrent ECU and switch, switch
and body ground (See page IN-26).
NG Repair or replace harness or connector.
OK
Check and replace theft deterrent ECU
(See
page
IN-26).

EM18U-02
P19776
CO/HC Meter
- ENGINE MECHANICALCO/HC
EM-1
422 Author
: Date
:
1996 TERCEL (RM440U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
(i) CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.

EM-2
- ENGINE MECHANICALCO/HC
423 Author
: Date
:
1996 TERCEL (RM440U)
If the CO/HC concentration does not comply with regulations,
troubleshoot according to the table below. Check and correct
the cause if necessary.

EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.

If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.

If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS

EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author
: Date
:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)