1996 TOYOTA TERCEL engine

SR4208
Maximum
Freeplay
30 mm (1.18 in.)SR05R-1 1
R12030
SR-10
- STEERINGSTEERING WHEEL
930 Author
: Date
:
1996 TERCEL (RM440U)
STEERING WHEEL
INSPECTION
1. CHECK STEERING WHEEL FREEPLAY
With the vehicle stopped and tires pointed straight ahead, rock
the steering wheel gently back and forth with light finger pres-
sure.
Freeplay should not exceed the maximum.
Maximum freeplay: 30 mm (1.18 in.)
2. CHECK STEERING EFFORT
(a) Center the steering wheel.
(b) Remove the steering wheel pad (See page SR-13).
(c) Start the engine and run it at idle.
(d) Measure the steering effort in both directions.
Reference: 7.8 N´m (80 kgf´cm, 69 in.´lbf)
HINT:
Be sure to consider the tire type, pressure and contact surface
before making your diagnosis.
(e) Torque the steering wheel set nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(f) Install the steering wheel pad (See page SR-20).

SR0KY-02
R11074
SST
SR4244
- STEERINGPOWER STEERING GEAR
SR-49
1996 TERCEL (RM440U)
REMOVAL
1. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
2. w/ Airbag:
REMOVE STEERING WHEEL PAD (See page SR-13)
3. w/ Airbag:
REMOVE STEERING WHEEL (See page SR-13)
4. DISCONNECT RH AND LH TIE ROD ENDS (See page
SA-10)
5. REMOVE COLUMN HOLE COVER
Remove the 2 bolts and nut.
6. DISCONNECT SLIDING YOKE (See page SR-13)
7. REMOVE OXYGEN SENSOR
8. REMOVE FRONT EXHAUST PIPE
(a) Remove the 2 bolts, compression springs and gasket.
(b) Remove the bolt, clamp and gasket.
(c) Disconnect the 2 rings.
9. REMOVE ENGINE REAR MOUNT INSULATOR
Remove the 6 bolts.
10. REMOVE ENGINE REAR MOUNT BRACKET
Remove the 2 bolts.
11. DISCONNECT 2 VACUUM HOSES
12. M/T:
DISCONNECT CONTROL CABLES
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
(c) Disconnect the 2 cables from the control lever housing
support bracket.
13. DISCONNECT PRESSURE FEED AND RETURN
TUBES
Using SST, disconnect the tube.
SST 09631-22020
14. DISCONNECT TUBE CLAMP
Remove the bolt.
15. REMOVE 2 BRACKETS AND GROMMETS
Remove the 2 bolts and nuts.
16. REMOVE PS GEAR ASSEMBLY
(a) Slide the gear assembly to the RH side of the vehicle.
(b) Slide the gear assembly to the LH side and pull it out.

SR0L2-03
R11193
R13112
Fulcrum
Length
SST
Z14367
B AB
B
BB
SR-62
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the tube.
SST 09631-22020
Torque: 36 N´m (366 kgf´cm, 27 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT TUBE CLAMP
Torque the bolt.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
5. M/T:
CONNECT CONTROL CABLES
(a) Connect the 2 cables to the control lever housing.
(b) Install the 2 clips to the cables.
(c) Install the 2 clips and washers.
6. CONNECT 2 VACUUM HOSES
7. INSTALL ENGINE REAR MOUNT BRACKET
Torque the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
8. INSTALL ENGINE REAR MOUNT INSULATOR
Torque the 6 bolts.
Torque:
Bolt A: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt B: 78 N´m (800 kgf´cm, 58 ft´lbf)

BE0QQ-05
BE-2
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U)
PROBLEM SYMPTOMS TABLE
The table below will be useful for you in troubleshooting these electrical problems. The most likely causes
of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and re-
place the part when it is found to be faulty.
USA:
HEADLIGHT AND TAILLIGHT SYSTEM
TroubleParts nameSee page
ºLight-on warning systemº does not operate.
3. Integration Relay (I/P J/B)
4. DOME Fuse (Engine Room R/B)
5. GAUGE Fuse (I/P J/B)
6. TAIL Fuse (I/P J/B)
7. CIG/RAD Fuse (I/P J/B)
8. Wire Harness
9. Door Courtesy SwitchBE-16
-
-
-
-
-
BE-38
Only one side headlight does not light up.
1. HEAD Fuse (LH, RH) (Engine Room R/B)
2. Headlight Bulb
3. Wire Harness-
-
-
ºLo-Beamº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
ºHi-Beamº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
ºFlashº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
Headlight does not light up. (Taillight is normal)
1. Headlight Control Relay (Engine Room R/B)
2. Headlight Dimmer Switch
3. Light Control Switch
4. Headlight Bulb
5. Wire HarnessBE-16
BE-16
BE-16
-
-
Headlight does not light up. (Taillight does not light up)
1. Light Control Switch
2. Wire Harness
3. Headlight BulbBE-16
-
-
Only one side taillight does not light up.1. Taillight Bulb
2. Wire Harness-
-
Taillight does not light up. (Headlight is normal)
1. TAIL Fuse (I/P J/B)
2. Taillight Control Relay (I/P J/B)
3. Light Control Switch
4. Headlight Bulb
5. Wire Harness-
BE-16
BE-16
-
-
Taillight does not light up. (Headlight does not light up)
1. Light Control Switch
2. Headlight Bulb
3. Wire HarnessBE-16
-
-

- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-3
1996 TERCEL (RM440U)
CANADA:
HEADLIGHT AND TAILLIGHT SYSTEM
TroubleParts nameSee page
ºLight-on warning systemº does not operate.
1. Integration Relay (I/P J/B)
2. DOME Fuse (Engine Room R/B)
3. GAUGE Fuse (I/P J/B)
4. TAIL Fuse (I/P J/B)
5. CIG/RAD Fuse (I/P J/B)
6. Wire Harness
7. Door Courtesy SwitchBE-16
-
-
-
-
-
BE-38
Only one side headlight does not light up.1. Headlight Bulb
2. Wire Harness-
-
ºLo-Beamº does not light up. (ALL)1. Headlight Control Relay (Engine Room R/B)
2. Wire HarnessBE-16
-
ºLo-Beamº does not light up. (ONE SIDE)
1. HEAD LH-LWR Fuse (R/B No.5)
2. HEAD RH-LWR Fuse (R/B No.5)
3. Headlight Bulb
4. Wire Harness-
-
-
-
ºHi-Beamº does not light up. (ALL)
1. DRL Fuse (Engine Room R/B)
2. Headlight Dimmer Switch
3. D.R.L. Main Relay
4. D.R.L. No.4 Relay (R/B No.5)
5. Daytime Resistor
6. Wire Harness-
BE-16
BE-16
BE-16
BE-16
-
ºHi-Beamº does not light up. (ONE SIDE)
1. HEAD LH-UPR Fuse (R/B No.5)
2. HEAD RH-UPR Fuse (R/B No.5)
3. Headlight Bulb
4. Wire Harness-
-
-
-
ºFlashº does not light up.
1. DRL Fuse (Engine Room R/B)
2. Headlight Dimmer Switch
3. D.R.L. Main Relay
4. D.R.L. No.4 Relay (R/B No.5)
5. Daytime Resistor
6. Wire Harness-
BE-16
BE-16
BE-16
BE-16
-
Headlight does not light up. (Taillight is normal)
1. Headlight Control Relay (Engine Room R/B)
2. D.R.L. Main Relay
3. D.R.L. No.4 Relay (R/B No.5)
4. Daytime Resistor
5. Headlight Dimmer Switch
6. Light Control Switch
7. Headlight Bulb
8. Wire HarnessBE-16
BE-16
BE-16
BE-16
BE-16
BE-16
-
-
Headlight does not light up. (Taillight does not light up)
1. D.R.L. Main Relay
2. D.R.L. No.4 Relay (R/B No.5)
3. Daytime Resistor
4. Light Control Switch
5. Headlight Bulb
6. Wire HarnessBE-16
BE-16
BE-16
BE-16
-
-
Only one side taillight does not light up.1. Taillight Bulb
2. Wire Harness-
-
Taillight does not light up.
(Headlight is normal)
1. TAIL Fuse (I/P J/B)
2. Taillight Control Relay (I/P J/B)
3. Light Control Switch
4. Headlight Bulb
5. Wire Harness-
BE-16
BE-16
-
-

BE-4
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U) Taillight does not light up. (Headlight does not light up)
1. Light Control Switch
2. Headlight Bulb
3. Wire HarnessBE-16
-
-
Headlight does not light up with light control SW in HEAD.
1. Light Control Switch
2. D.R.L. Main Relay
3. D.R.L. No.4 Relay (R/B No.5)
4. Daytime Resistor
5. Wire HarnessBE-16
BE-16
BE-16
BE-16
-
Headlight does not go out with light control SW in OFF.1. Headlight Control Relay (Engine Room R/B)
2. Wire HarnessBE-16
-
Taillight does not light up with light control SW in TAIL.
1. Taillight Control Relay (I/P J/B)
2. Light Control Switch
3. Wire HarnessBE-16
BE-16
-
Taillight does not go out with light control SW in OFF.
1. Taillight Control Relay (I/P J/B)
2. Light Control Switch
3. Wire HarnessBE-16
BE-16
-
Headlight do not light up with engine running and light control SW
in OFF.
1. DOME Fuse (Engine Room R/B)
2. ECU-IG Fuse (I/P J/B)
3. DRL Fuse (Engine Room R/B)
4. D.R.L. Main Relay
5. D.R.L. No.4 Relay (R/B No.5)
6. Daytime Resistor
7. Wire Harness
8. Generator L Terminal
9. Parking Brake Switch
10.Brake Fluid Level Warning Switch-
-
-
BE-16
BE-16
BE-16
-
-
BE-38
BE-38
TURN SIGNAL AND HAZARD WARNING SYSTEM
TroubleParts nameSee page
ºHazardº and ºTurnº do not light up.
1. Hazard Warning Switch
2. Turn Signal Flasher
3. Wire HarnessBE-22
BE-22
-
No of blinks for Hazard.
(Turn is abnormal)1. Bulb
2. Turn Signal Flasher
3. Wire Harness-
BE-22
-
Hazard warning light does not light up.
(Turn signal is normal)1. HAZ-HORN Fuse (Engine Room R/B)
2. Wire Harness-
-
Hazard waning light does not light up in one direction.1. Hazard Warning Switch
2. Wire HarnessBE-22
-
Turn signal does not light up.
(Combination meter, wiper and washer do not operate.)
1. Ignition Switch
2. TURN Fuse (Engine Room R/B)
3. Turn Signal Switch
4. Wire HarnessBE-1 1
-
BE-22
-
Turn signal does not light up.
(Combination meter, wiper and washer are normal.)1. TURN Fuse (Engine Room R/B)
2. Turn Signal Switch
3. Wire Harness-
BE-22
-

- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-5
1996 TERCEL (RM440U)
INTERIOR LIGHT SYSTEM
TroubleParts nameSee page
Room light does not light up.
1. DOME Fuse (Engine Room R/B)
2. Room Light Switch
3. Door Courtesy Switch
4. Wire Harness
5. Bulb-
BE-24
BE-38
-
-
Room light always remains on.
1. Room Light Switch
2. Door Courtesy Switch
3. Wire HarnessBE-24
BE-38
-
BACK-UP LIGHT SYSTEM
TroubleParts nameSee page
Back-up Light does not light up.
1. GAUGE Fuse (I/P J/B)
2. Ignition Switch
3. Park/Neutral Position Switch (A/X)
4. Back-up Light Switch (M/X)
5. Wire Harness
6. Bulb-
BE-1 1
AX-2
AX-2
BE-26
-
-
Back-up light always remains on.1. Wire Harness-
Only one light does not light up.1. Bulb
2. Wire Harness-
-
STOP LIGHT SYSTEM
TroubleParts nameSee page
Stop light does not light up.
1. STOP Fuse (I/P J/B)
2. Stop Light Switch
3. Bulb
4. Wire Harness-
BE-28
-
-
Stop light always remains on.1. Stop Light Switch
2. Wire HarnessBE-28
-
Only one light does not light up.1. Bulb
2. Wire Harness-
-
WIPER AND WASHER SYSTEM
TroubleParts nameSee page
Wiper and washers do not operate.
1. WIPER Fuse (I/P J/B)
2. Wiper Switch
3. Wiper Motor
4. Wire Harness-
BE-30
BE-30
-
Wipers do not operate in LO, HI or MIST.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE-30
BE-30
-
Wipers do not operate in INT.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE-30
BE-30
-
Washer motor does not operate.
1. Washer Switch
2. Washer Motor
3. Wire HarnessBE-30
BE-30
-
Wipers do not operate when washer switch in ON.1. Washer Motor
2. Wire HarnessBE-30
-

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
-