Page 522 of 1202
EC0JP-01
EC-8
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the stmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using 3 - way connector, connect a vacuum gauge to the EGR
valve vacuum hose as shown in the illustration.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. INSPECT OPERATION VSV WITH COLD ENGINE
(a) The engine coolant temperature shold be below 45°C
(113°F).
(b) Check that the vacuum gauge indicates zero at 2,500
rpm.
5. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 60°C (140°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,500 rpm.
(c) Check that the vacuum gauge indicates zero at idle.
(d) Disconnect the vacuum hose from port R of the EGR vac-
uum modulator and connect port R directley to the intake
manifold with another hose.
(e) Check that the vacuum gauge indicates high vacuum at
2,500 rpm.
HINT:
As a large amount of exhaust gas enters, the will misfire slghtly.
6. REMOVE VACUUM GAUGE
Remove the vacuum gauge and reconnect the vacuum hoses
to the proper locations.
Page 568 of 1202
SF0XP-05
- MFIENGINE COOLANT TEMPERATURE (ECT) SENSOR
MF-43
567 Author: Date:
1996 TERCEL (RM440U)
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
COMPONENTS
Page 569 of 1202
SF0XQ-05
Z02917
Ohmmeter
Resistance kW
Temperature °C (°F) Acceptable MF-44
- MFIENGINE COOLANT TEMPERATURE (ECT) SENSOR
1996 TERCEL (RM440U)
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SENSOR
3. INSPECT ECT SENSOR
Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
4. REINSTALL ECT SENSOR
5. REFILL WITH ENGINE COOLANT
Page 604 of 1202
CO0Y5-02
P20875
Above 94°C
P20883
Ammeter
Battery
- COOLINGELECTRIC COOLING FAN
CO-23
603 Author: Date:
1996 TERCEL (RM440U)
ELECTRIC COOLING FAN
ON-VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the engine main relay, cooling fan relay, cooling
fan, fuses, and check for short circuit between the cooling fan
relay and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 94°C (201°F))
(a) Start the engine, and raise coolant temperature to above
94°C (201°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
M/T5.7 - 7.7 A
A/T8.6 - 11.6 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 6.4 - 7.4 A
(d) Reconnect the cooling fan connector.
Page 613 of 1202
P21098
ECT SwitchCO0ID-04
P05962
Ohmmeter CO-32
- COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
612 Author: Date:
1996 TERCEL (RM440U)
ENGINE COOLANT
TEMPERATURE (ECT) SWITCH
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SWITCH
3. INSPECT ECT SWITCH
(a) Using an ohmmeter, check that there is no continuity be-
tween the terminals when the coolant temperature is
above 94°C (201°F).
If there is continuity, replace the switch.
(b) Using an ohmmeter, check that there is continuity be-
tween the terminals when the coolant temperature is be-
low 83°C (181°F).
If there is no continuity, replace the switch.
4. REINSTALL ECT SWITCH
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR COOLANT LEAKS
Page 1007 of 1202
BE-6
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U) Washer fluid does not operate.
1. Washer Hose and Nozzle-
At wiper switch HI position, the wiper blade is in contact with the
body.
When the wiper switch is OFF, the wiper blade does not retract
or the retract position is wrong.
1. *1 Wiper Switch
2. Wire harnessBE-30
-
*1: Inspect wiper arm and blade set position
COMBINATION METER (METER, GAUGES AND ILLUMINATION)
TroubleParts nameSee page
Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge
do not operate.3. GAUGE Fuse (Engine Room R/B)
4. Meter Circuit
5. Wire Harness-
BE-35
-
Speedometer does not operate.
1. Vehicle Speed Sensor
2. Meter Circuit
3. Wire HarnessBE-38
BE-35
-
Tachometer does not operate.
1. Igniter
2. ECM
3. Meter Circuit
4. Wire Harness-
-
BE-35
-
Fuel Gauge does not operate or operate abnormally.
1. Fuel Receiver Gauge
2. Fuel Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
Engine Coolant Temperature Gauge does not operate or operate
abnormally.
1. Engine Coolant Temperature Receiver Gauge
2. Engine Coolant Temperature Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
All illumination lights do not light up.
1. TAIL Fuse (I/P J/B)
2. Light Control Rheostat
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Only one illumination light does not light up.1. Bulb
2. Meter Circuit-
BE-35
COMBINATION METER (WARNING LIGHTS)
TroubleParts nameSee page
Warning lights do not light up.
(Except Discharge, SRS and Door Open)
1. Bulb
2. GAUGE Fuse (I/P J/B)
3. Ignition Switch
4. Meter Circuit
5. Wire Harness-
-
BE-1 1
BE-35
-
Brake Warning Light does not light up.
1. Bulb
2. Brake Fluid Level Warning Switch
3. Parking Brake Switch
4. Bulb Check Relay
5. Meter Circuit
6. Wire Harness-
BE-38
BE-38
-
BE-35
-
Seat Belt Warning Light does not light up.
1. Bulb
2. Seat Belt Retractor Switch
3. Integration Relay
4. Meter Circuit
5. Wire Harness-
BE-38
BE-38
BE-35
-
Page 1035 of 1202
I05919
Door Courtesy Switches Seat Belt
Retractor Switch
Fuel Sender Gauge
Fuel Level Warning Switch
Engine Coolant Temperature Gauge
Low Oil Pressure Warning Switch
Park/Neutral Position SwitchDoor Courtesy Switches
BE-34
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
Page 1037 of 1202
I16684
No.Wiring Connector Side
1
2
3
4
5
6
7GAUGE Fuse
10
11
12
13
1
2
3
4
5
7
8
1
2
3
4
5
6
7
8
9
10Generator
IGN Fuse
SRS Fuse
Airbag Sensor Assembly
Seat Belt Buckle Switch
Low Oil Pressure Warning Switch
Igniter
TAIL Fuse
Door Courtesy Switch
DOME Fuse
Fuel Level Warning Switch
Engine Coolant Temperature Sender Gauge
ABS ECU
ECM
O/D Off Switch
Light Control Rheostat
Ground
Headlight Dimmer Switch
Turn Signal Switch (Left) Ground
Fuel Sender Gauge
Theft Deterrent ECU
Speed Control Unit
Ground
Starter Relay
Brake Fluid Level Warning Switch
and Parking Brake Switch
Turn Signal Switch (Right) A
B
C
F
E
T: Fuel Receiver Gauge
: Engine Coolant Temperature Receiver Gauge
: Tachometer
Hi-Grade
SRS Warning Illumination Open Door Warning Hi-Beam Indicator Security Indicator Left Turn Indicator Right Turn Indicator Discharge Warning Seat Belt Warning O/D Off Indicator Brake WarningBulb Check Relay Malfunction Indicator Low Oil Pressure Warning ABS Warning Fuel Lever Warning Speed Sensor
A5 B7 A12 C2 A2
A6
B5 C9 B4 A7 B3 B1 A10 B8 B9 C7 C4
A4 A11 A13C1 C5C3 C10A3 C8C6 A1TE F BE-36
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
