1996 TOYOTA TERCEL Transmission

SS0KQ-04
- SERVICE SPECIFICATIONSMANUAL TRANSAXLE
SS-27
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Transaxle x Engine 17 mm head
14 mm head
10 mm head64
46
7.4650
470
7547
34
65 in.´lbf
Engine left mounting bracket x Insulator4849036
Engine rear mounting insulator x Body7880058
Engine rear mounting insulator x Bracket B bolt
C bolt64
90650
92047
67
Front exhaust pipe clamp set bolt1919014
Front exhaust pipe x Exhaust manifold6263046
Starter x Transaxle3940029
Clutch release cylinder x Transaxle121209
Shift lever assembly x Body121209
Grommet retainer x Body4.95043 in.´lbf
Retainer x Body4.95043 in.´lbf
Output shaft front bearing lock plate set bolt1111 58
Transmission case x Transaxle case2930022
Reverse shift arm bracket1717513
Straight screw plug (Reverse restrict pin) (C151)
Straight screw plug13
13130
1309
9
Straight screw plug (Shift fork shaft)2525018
Straight screw plug (Lock ball assembly) (C151)
Straight screw plug (C141)39
39400
40029
29
Reverse idler gear shaft lock bolt2930022
Rear bearing retainer2728020
Output shaft lock nut11 81,20087
Shift fork and shift head x Shift fork shaft1616012
Shift and select lever assembly2020014
Transmission case x Transmission case cover1818513
Back-up light switch4041030
Filler and drain plugs3940029
Ring gear x Differential case1241,26091
Speedometer driven gear1111 58
Control lever housing support bracket x Transmission case1111 58
Selecting bellcrank assembly x Transmission case2525018
Shift and select lever shaft assembly lock bolt2930022
Transaxle case receiver x Transaxle case1111 58
No. 1 and No. 2 oil receiver pipe1717513

S00840
- DIAGNOSTICSENGINE
DI-5
1996 TERCEL (RM440U)Terminal No.
Connection / Voltage or ResistanceCondition
7Bus + Line / Pulse generationDuring transmission
4Chassis Ground - Body Ground / 1 W or lessAlways
5Signal Ground - Body Ground / 1 W or lessAlways
16Battery Positive - Body Ground / 9 - 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the OBD II scan tool or
TOYOTA hand-held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool its self, so consult the Service Department listed in
the tool's instruction manual.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter.
(2) When the engine started, the MIL should go off. If
the lamp remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system
(b) Check the DTC.
NOTICE:
TOYOTA hand-held tester only: When the diagnosis sys-
tem is switched from the normal mode to the check mode,
it erases all DTC and freeze frame data recorded in the nor-
mal mode. So before switching modes, always check the
DTC and freeze frame data, and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J 1978) or TOYOTA hand-held tester.
(2) Connect the OBD II scan tool or TOYOTA hand-
held tester to DLC3 in the fuse box at the lower left
of the instrument panel.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand-held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand-held
tester to check the DTC and freezed frame data;
note them down (For operating instructions, see the
OBD II scan tool's instruction book.).
(5) See page DI-13 to confirm the details of the
DTC.

FI3605
Flashing
ON
OFF
0.13 Seconds
DI-6
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand-held tester) to check the DTC, use
the normal mode. For code on the DTC chart subject to º2
trip detection logicº, turn the ignition switch OFF after the
symptom is simulated the first time. Then repeat the simu-
lation process again. When the problem has been simu-
lated twice, the MIL lights up and the DTC are recorded in
the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand-held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.

Battery positive voltage 11V or more.

Throttle valve fully closed.

Transmission in ºPº or ºNº position.

Air conditioning switched OFF.
(2) Turn the ignition switch OFF.
(3) Prepare the TOYOTA hand-held tester.
(4) Connect the TOYOTA hand-held tester to DLC3 in
the fuse box at the lower left of the instrument panel.
(5) Turn the ignition switch ON and switch the TOYOTA
hand-held tester ON.
(6) Switch the TOYOTA hand-held tester normal mode
to check mode. (Check that the MIL flashes.)
(7) Switch the engine. (The MIL goes out after the en-
gine start.)
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTC, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand-held tester diagnosis selector to
check the DTC and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch OFF switches the diagnosis system from check mode to
normal mode, so all DTC, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.

MA0659
Outside
Inside
DI-8
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
YES
2 Is engine cranked ?
NO Proceed to ST-13, ST-28, ST-31 and continue
to troubleshoot.
YES
3 Does engine start ?
NO Go to step 7.
YES
4 Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visual check that the air cleaner element is not excessively dirty
or oily.
HINT:
If necessary, clean the filter with compressed air. First blow from
inside thoroughly, then blow from outside of filter.
NG Repair or replace.
OK
5 Check engine idle speed.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all accessories.
(c) Switch off air conditioning.
(d) Shift transmission into ºNº position.

P25914P25915A07081
TE1
E1 SST
DLC1
- DIAGNOSTICSENGINE
DI-9
1996 TERCEL (RM440U)
(e) Remove the fuse cover on the instrument panel.
(f) Connect the OBD II scan tool or TOYOTA hand-held tester to DLC3 on the vehicle.
CHECK:
Use CURRENT DATA to check the engine idle speed.
OK:
Idle speed: 700 - 800 rpm
NG Proceed to matrix chart of problem symptoms
on page DI-19.
OK
6 Check ignition timing.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Shift transmission into ºNº position.
(c) Keep the engine speed at idle.
(d) Using SST, connect terminals TE1 and E1 of DLC1.
SST 09843-18020
(e) Using a timing light, connect the tester to No.1 high-ten-
sion cord.
CHECK:
Check ignition timing.
OK:
Ignition timing: 10° BTDC at idle
NG Proceed to page IG-1 and continue to trouble-
shoot.
OK
Proceed to matrix chart of problem symp-
toms on page DI-19.

BE3841N14680I09775
SRLY
(+)(-) Disconnect START
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-227
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
HINT:
This troubleshooting is based on the premise that engine cranking occurs.
If the engine does not crank, proceed to the engine troubleshooting on DI-1.
1 Check voltage between terminal SRLY of theft deterrent ECU connector and
body ground.
PREPARATION:
(a) Disconnect the theft deterrent ECU connector.
(b) Transmission in neutral position.
CHECK:
Measure voltage between terminal SRLY of theft deterrent ECU
connector and body ground, when ignition switch is turned to
ST position.
OK:
Voltage: 10 - 14V
OK Check and repair theft deterrent ECU.
NG
Check and repair harness and connector between starter and 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.

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL