1996 TOYOTA TERCEL clutch

A15740
DI-106
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
A/C Cut Control Circuit
CIRCUIT DESCRIPTION
This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration per-
formance. During acceleration with the vehicle speed at 25 km/h (16 mph) or less, engine speed at 1,200
rpm or less and throttle valve opening angle at 50° or more, the A/C magnet switch is turned OFF for several
seconds.
WIRING DIAGRAM
INSPECTION PROCEDURE
TOYOTA hand-held tester:
1 Connect TOYOTA hand-held tester and check operation of air conditioning cut
control.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn ignition switch ON and TOYOTA hand-held tester main switch ON.
(d) Start the engine and air conditioning switch ON.
HINT:
A/C magnet clutch is turned ON.
(e) Select the ACTIVE TEST mode on the TOYOTA hand-held tester.
CHECK:
Check operation of A/C magnet clutch cut when air conditioning cut control is operated by the TOYOTA
hand-held tester.
OK:
A/C magnet clutch is turned OFF
OK Proceed to next circuit inspection shown on
matrix chart (See page DI-19).
DI1EK-09

DI4N1-01
N12446N12538I10188
Engine Hood Courtesy Switch
Engine Room R/B
Starter Relay
Horn Relay
Headlight Control Relay
HAZ-HORN Fuse
HEAD LH Fuse
HEAD RH Fuse
Theft Deterrent Horn HORN
Door Lock Control Relay or
Theft Deterrent ECU
Combination Meter
Theft Deterrent Indicator
Ignition Switch
Light Control Switch Clutch Start Switch
I/P J/B
Taillight COntrol Relay
TAIL Fuse
CIG & RAD Fuse
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-219
1996 TERCEL (RM440U)
PARTS LOCATION

N20818
Battery MAIN FL B
EA21Engine Room Relay BlockMAIN AM2 22
Starter Relay
2
2B
EA17
S21
Starter B-R2
IC1B-R25
T4
SRLY
B-R
IC1
12 B-RIgnition Switch
78
IG2
7B
23
EA1
14A AJUNCTION
CONNECTOR
B-W
(A/T) Park/Neutral
Position Switch Clutch Start Switch
1
2
B-W3
IG2B-W
(M/T)Theft Deterrent ECU
C6
I10
P1J1
B-W
B-W
DI-226
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
Starter Relay Circuit
CIRCUIT DESCRIPTION
When the theft deterrent system is activated, contact (a) in the ECU becomes open, creating an open circuit
in terminal SRLY circuit and making the starter inoperative (starter cut).
In this condition, if one of the following operations is done, the contact (a) in the ECU is grounded, thus can-
celing the starter cut:
(1) Unlock the front LH or RH door with key.
(2) Unlock the doors with the wireless door lock control system.
WIRING DIAGRAM
DI4N5-02

P20565
M/T EM-58
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)

Engine coolant temperature sender gauge connec-
tor

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
15. M/T only:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
(a) Remove the 3 bolts, release cylinder and tube from the
transaxle.
(b) Disconnect the ground strap.
16. M/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.

Z14321
A242L A/T
P20255
Lift
P20167
P20161
P20245
A/T only
- ENGINE MECHANICALENGINE UNIT
EM-61
1996 TERCEL (RM440U)
(j) A242L A/T:
Remove the bolt and disconnect the ground strap.
(k) Remove the 5 bolts and LH engine mounting bracket.
(l) Lift the engine out of the vehicle slowly and carefully.
HINT:
Clear the battery carrier support while lowering the transaxle.
(m) Place the engine with the transaxle onto the stand.
23. w/PS:
REMOVE PS PUMP ADJUSTING STRUT
Remove the 2 bolts and PS pump adjusting strut.
24. w/A/C:
REMOVE A/C COMPRESSOR MOUNTING BRACKET
Remove the 4 bolts and compressor mounting bracket.
25. A/T only:
REMOVE TORQUE CONVERTER CLUTCH MOUNT-
ING BOLTS
(a) Remove the engine rear end plate hole cover.
(b) Turn the crankshaft to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench.
(d) Remove the 6 bolts.
26. REMOVE STARTER (See page ST-3 and ST-16)
27. SEPARATE ENGINE AND TRANSAXLE

EM1OI-01
P20245
A/T only
P20161
P20167
P20256
Lower EM-62
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
M/T: (See page MX-4)
A132L A/T: (See page AX-26)
A242L A/T: (See page AX-30)
2. INSTALL STARTER
(See page ST-14 and ST-30)
3. A/T only:
INSTALL TORQUE CONVERTER CLUTCH MOUNTING
BOLTS
(a) First, install the gray bolt and then 5 bolts.
(b) Tighten the bolts evenly.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
(c) Install the engine rear end plate hole cover.
4. w/A/C:
INSTALL A/C COMPRESSOR MOUNTING BRACKET
Install the compressor mounting bracket with the 4 bolts.
Torque: 27 N´m (280 kgf´cm, 20 ft´lbf)
5. w/PS:
INSTALL PS PUMP ADJUSTING STRUT
Install the PS pump adjusting strut with the 2 bolts.
Torque: 21 N´m (210 kgf´cm, 15 ft´lbf)
6. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN
VEHICLE
(a) Attach the engine sling device to the engine hangers.
(b) Lower the engine into the engine compartment.
(c) Tilt the transaxle downward, lower the engine and clear
the LH engine mounting.
NOTICE:
Be careful not to hit the PS gear housing, park/neutral posi-
tion switch and throttle position switch.

P20577
P20565
M/T
P21044
A132L A/T
P21045
A242L A/T
S06150
M/T only
- ENGINE MECHANICALENGINE UNIT
EM-65
1996 TERCEL (RM440U)
10. w/ PS:
INSTALL PS PUMP
(a) Install the PS pump and drive belt with the 2 bolts.
(b) Adjust the drive belt tension (See page SR-3).
11. M/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the retainer to the cable.
(b) Connect the linkage with the plate washer and clip.
12. A132L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
13. A242L A/T:
CONNECT CONTROL CABLE(S) TO TRANSAXLE
(a) Install the support bracket to the LH engine mounting
bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.
14. M/T only:
INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder, tube and ground strap with the 3
bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)

EM0JQ-06
EM9411
EM9412
P20480
SST
P20478
SST
P20477
12 mm
Hexagon
Wrench EM-70
- ENGINE MECHANICALCYLINDER BLOCK
1996 TERCEL (RM440U)
DISASSEMBLY
1. M/T:
REMOVE CLUTCH COVER AND DISC
2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)
3. REMOVE REAR END PLATE
4. INSTALL ENGINE TO ENGINE STAND FOR DIS-
ASSEMBLY
5. REMOVE TIMING BELT AND PULLEYS
6. REMOVE CYLINDER HEAD
7. REMOVE OIL DIPSTICK GUIDE AND GENERATOR
ADJUSTING BAR
8. REMOVE WATER PUMP WITH WATER INLET PIPE
9. REMOVE GENERATOR BRACKET
10. REMOVE KNOCK SENSOR
Using SST, remove the knock sensor.
SST 09816-30010
11. REMOVE RH ENGINE MOUNTING BRACKET
12. REMOVE OIL FILTER
13. REMOVE OIL PRESSURE SWITCH
Using SST, remove the oil pressure switch.
SST 09816-30010
14. REMOVE OIL PUMP AND PRESSURE REGULATOR
VA LV E
15. REMOVE OIL FILTER UNION
Using a 12 mm hexagon wrench, remove the oil filter union.