Page 9 of 1202
IN07J-05
BO4111
Negative Cable
- INTRODUCTIONFOR ALL OF VEHICLES
IN-9
9 Author: Date:
1996 TERCEL (RM440U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The TERCEL is equipped with an SRS (Supplemental
Restraint System), such as the driver airbag and front
passenger airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the negative (-) terminal cable from
the battery (See page DI-148).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back-up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (-) terminal cable from the battery, the SRS
may deploy.)
When the negative (-) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back-up power supply from anoth-
er battery.
Page 10 of 1202
R09725Match Marks
IN-10
- INTRODUCTIONFOR ALL OF VEHICLES
10 Author: Date:
1996 TERCEL (RM440U)
(3) Even in cases of a minor collision where the SRS
does not deploy, the steering wheel pad (See page
RS-9) and front passenger airbag assembly (See
page RS-22) should be inspected.
(4) Never use SRS parts from another vehicle. When
replacing parts, replace them with new parts.
(5) Before repairs, remove the airbag sensor if shocks
are likely to be attached to the sensor during re-
pairs.
(6) Never disassemble and repair the airbag sensor as-
sembly, steering wheel pad or front passenger air-
bag.
(7) If the airbag sensor assembly, steering wheel pad
or front passenger airbag have been dropped, or if
there are cracks, dents or other defects in the case,
bracket or connector, replace them with new ones.
(8) Do not directly expose the airbag sensor assembly,
steering wheel pad or front passenger airbag to hot
air or flames.
(9) Use a volt/ohmmeter with high impedance (10 kW/V
minimum) for troubleshooting of the electrical cir-
cuit.
(10) Information labels are attached to the periphery of
the SRS components. Follow the instructions on the
notices.
(11) After work is completed, check the SRS warning
light for the supplemental restraint system (See
page DI-148).
(c) SPIRAL CABLE (in Combination Switch)
The steering wheel must be fitted correctly to the steering
column with the spiral cable at the neutral position, other-
wise cable disconnection and other troubles may result.
Refer to RS-19 of this manual concerning correct steer-
ing wheel installation.
Page 11 of 1202
Z13953
Example:CORRECT WRONG
Z13950
Example:
- INTRODUCTIONFOR ALL OF VEHICLES
IN-1 1
11 Author: Date:
1996 TERCEL (RM440U)
(d) STEERING WHEEL PAD (with Airbag)
(1) When removing the steering wheel pad or handling
a new steering wheel pad, it should be placed with
the pad top surface facing up.
Storing the pad with its metallic surface facing up-
ward may lead to a serious accident if the airbag de-
ploys for some reason. In addition do not store a
steering wheel pad on top of another one.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be attached to the steering
wheel pad and the pad should not be cleaned with
detergents of any kind.
(4) Store the steering wheel pad where the ambient
temperature remains below 93°C (200°F), without
high humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) under the
steering column near the combination switch con-
nector before starting work.
(6) When disposing of a vehicle or the steering wheel
pad alone, the airbag should be deployed using an
SST before disposal (See page RS-1 1).
Perform the operation in a safe place away from
electrical noise.
Page 12 of 1202
Z13952
Example:CORRECT WRONG
Z13951
Example:
IN-12
- INTRODUCTIONFOR ALL OF VEHICLES
12 Author: Date:
1996 TERCEL (RM440U)
(e) FRONT PASSENGER AIRBAG ASSEMBLY
(1) Always store a removed or new front passenger air-
bag assembly with the airbag deployment direction
facing up.
Storing the airbag assembly with the airbag deploy-
ment direction facing down could cause a serious
accident if the airbag deploys.
(2) Never measure the resistance of the airbag squib.
(This may cause the airbag to deploy, which is very
dangerous.)
(3) Grease should not be attached to the front passen-
ger airbag assembly and the airbag door should not
be cleaned with detergents of any kind.
(4) Store the airbag assembly where the ambient tem-
perature remains below 93°C (200°F), without high
humidity and away from electrical noise.
(5) When using electric welding, first disconnect the air-
bag connector (yellow color and 2 pins) installed on
the assembly before starting work.
(6) When disposing of a vehicle or the airbag assembly
alone, the airbag should be deployed using an SST
before disposal (See page RS-24).
Perform the operation in a safe place away from
electrical noise.
Page 13 of 1202
- INTRODUCTIONFOR ALL OF VEHICLES
IN-13
13 Author: Date:
1996 TERCEL (RM440U)
(f) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired deployment of the supplemental re-
straint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(g) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly and floor wire harness as-
sembly. The wires for the SRS wire harness are encased
in a yellow corrugated tube. All the connectors for the sys-
tem are also a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it as
shown on page RS-37.
Page 45 of 1202
MA03P-02
P19780BootBoot
P19895
- MAINTENANCECHASSIS
MA-7
45 Author: Date:
1996 TERCEL (RM440U)
CHASSIS
INSPECTION
1. INSPECT STEERING LINKAGE
(a) Check the steering wheel freeplay (See page SR-10).
(b) Check the steering linkage for looseness or damage.
Check that the tie rod ends do not have excessive
play.
Check that the dust seals and boots are not dam-
aged.
Check that the boot clamps are not loose.
2. INSPECT SRS AIRBAG (See page RS-2)
3. INSPECT STEERING GEAR HOUSING OIL
Check the steering gear housing for oil leakage.
4. INSPECT DRIVE SHAFT BOOTS
Check the drive shaft boots for clamp looseness, leakage or
damage.
5. INSPECT BALL JOINT AND DUST COVERS
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place wooden
blocks with a height of 180 - 200 mm (7.09 - 7.87
in.) under the front tires.
(2) Lower the jack until there is about half a load on the
front coil spring. Place stands under the vehicle for
safety.
(3) Make sure the front wheels are in a straightforward
position and block the wheel with chocks.
(4) Move the lower arm up and down, and check that
the ball joint has no excessive play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is play, replace the ball joint.
Page 117 of 1202
PP312-01
PP-70
- PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
11 7 Author: Date:
1996 TERCEL (RM440U)
SUPPLEMENTAL RESTRAINT SYSTEM
SST (Special Service Tools)
09082-00700SRS Airbag Deployment Tool
09843-18020Diagnosis Check Wire
Page 118 of 1202
PP313-01
- PREPARATIONSUPPLEMENTAL RESTRAINT SYSTEM
PP-71
1996 TERCEL (RM440U)
RECOMMENDED TOOLS
09042-00020Torx Socket T40 .Airbag sensor assembly
09082-00040TOYOTA Electrical Tester.
