1996 TOYOTA TERCEL engine

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)

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)

I16685
No.Wiring Connector Side
1
2
3
4
5
6
7GAUGE Fuse
10
11
12
13
1
3
4
5
7
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
ABS ECU
ECM
O/D Off Switch
Light Control Rheostat
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
8
9Ground
Engine Coolant Temperature Sender Gauge
A4 A11 A13C1 C5C3 C10A3 C8C6 A1
A5 B7 A12 C2 A2
A6
B5 C9 B4 A7 B3 B1 A10 A8 A9 C7 C4
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 TE F Lo-Grade
- BODY ELECTRICALCOMBINATION METER
BE-37
1996 TERCEL (RM440U)

N13603
1
4
Z08045
Engine Coolant Temperature Gauge
Ignition
Switch
BatterySender
Gauge
Z07424
Engine Coolant Temperature Gauge
BatteryTest Bulb
(3.4 W)
N12804
A
BC
DE F
N12806
A B
C BE-40
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
(b) Submerge the switch in fuel, and check that the bulb goes
out.
If operation is not as specified, replace the sender gauge.
7. INSPECT RECEIVER ENGINE COOLANT
TEMPERATURE GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON, and check that the receiver
gauge needle indicates COOL.
(c) Ground terminal on the wire harness side connecter
through a 3.4 W test bulb.
(d) Turn the ignition switch ON, check that the bulb lights up
and the receiver gauge needle moves to the hot side.
If operation is as specified, replace the sender gauge. Then, re-
check the system.
If operation is not as specified, measure the receiver gauge re-
sistance.
8. INSPECT ENGINE COOLANT TEMPERATURE
RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer:
Between terminalsResistance (W)
D - EApprox. 51.0
D - FApprox. 148.6
E - FApprox. 199.6
w/o Tachometer:
Between terminalsResistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
HINT:
Connect the test leads so that the current from the ohmmeter
can flow according to the above order. This circuit includes the
diode.

BE0044
Ignition
Switch
BatteryWarning Light
BE0146
BE1217
Ignition
Switch
BatteryWarning Light
BE1601
ON OFF
- BODY ELECTRICALCOMBINATION METER
BE-41
1996 TERCEL (RM440U)
If resistance value is not as specified, replace the receiver
gauge.
9. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Disconnect the connector from the warning switch and
ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
10. INSPECT LOW OIL PRESSURE SWITCH CONTINUITY
(a) Disconnect the connector from the switch.
(b) Check that there is continuity between terminal and
ground with the engine stopped.
(c) Check that there is no continuity between terminal and
ground with the engine running.
HINT:
Oil pressure should be over 49 kPa (0.5 kgf/cm
2, 7.1 psi).
If operation is not as specified, replace the switch.
11. INSPECT BRAKE SYSTEM WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
12. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
CONTINUITY
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.

BE26T-01
- BODY ELECTRICALAUDIO SYSTEM
BE-55
1996 TERCEL (RM440U)
TROUBLESHOOTING
NOTICE:
When replacing the internal mechanism (computer part) of the audio system, be careful that no part
of your body or clothing comes in contact with the terminals of the leads from the IC, etc. of the re-
placement part (spare part).
HINT:
This inspection procedure is a simple troubleshooting which should be carried out on the vehicle during sys-
tem operation and is prepared on the assumption of system component troubles (except for the wires and
connectors, etc.).
Always inspect the trouble taking the following items into consideration.

Open or short circuit of the wire harness

Connector or terminal connection fault
ProblemNo.
RadioNo power coming in.1
Power coming in, but radio not operating.2
Noise present, but AM - FM not operating.3
Either speaker does not work.4
Either AM or FM does not work.5
Reception poor (Volume faint).5
Few preset tuning bands.5
Sound quality poor.6
Cannot set station select button.7
Preset memory disappears.7
Tape PlayerCassette tape cannot be inserted.8
Cassette tape inserts, but no power.9
Power coming in, but tape player not operating.10
Either speaker does not work.11
Sound quality poor (Volume faint).12
Tape jammed, malfunction with tape speed or auto-reverse.13
APS, SKIP, RPT buttons not operating.14
Cassette tape will not eject.15
AntennaAntenna dose not fully extend or fully retract.16
Antenna - related.17
NoiseNoise produced by vibration or shock while driving.18
Noise produced when engine starts.19
The term ºAMº includes LW, MW and the term ºFMº includes UKW.

AC2810
AC1DR-02
AC2811
N11084
Wrong Okay
HI LO HILO
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-1
1153 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

AC2WA-02
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-3
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control set at ºMAX COOLº
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to item 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sigh glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect-
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.