1996 TOYOTA TERCEL coolant temperature

IN0CI-02
IN-36
- INTRODUCTIONTERMS
1996 TERCEL (RM440U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE-J1930 terms and abbreviations used in this manual in compliance with SAE rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOTA TERMS
( )--ABBREVIATIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal-
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection-
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position-
CTOXContinuous Trap Oxidizer-
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition-
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode-
ECLEngine Control Level-
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant TemperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control-
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory-
FEPROMFlash Erasable Programmable Read Only Memory-
FFFlexible Fuel-
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)

MA003-28
MA-4
- MAINTENANCEUNDER HOOD
42 Author
: Date
:
1996 TERCEL (RM440U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE AND CLUTCH FLUID LEVELS
(a) Check that the brake fluid level is near the upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within ±5 mm (0.20 in.). of the reservoir hem.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick and check
that the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F).
If the If the level is at the low side, add fluid.
NOTICE:
Do not overfill.
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.

- SERVICE SPECIFICATIONSBODY ELECTRICAL
SS-41
171 Author
: Date
:
1996 TERCEL (RM440U) FUEL RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 115.8
A - CApprox. 177.2
B - CApprox. 61.4
w/o Tachometer:Resistance (W)
A - BApprox. 171.2
A - CApprox. 272.8
B - CApprox. 101.6
FUEL SENDER GAUGE
Float position: mm (in.)Resistance (W)
F: Approx. 13.0 ± 3 (0.512 ± 0.118)Approx. 3 ± 1.0
1/2: Approx. 61.0 (2.402)Approx. 29 ± 4.8
E: Approx. 124.0 ± 3 (4.882 ± 0.118)Approx. 110 ± 7.7
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 51.0
A - CApprox. 148.6
B - CApprox. 199.6
w/o Tachometer:Resistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
DEFOGGER SWITCH
Timer Circuit:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
6 - Ground (Ignition switch LOCK or ACC)No voltage
6 - Ground (Ignition switch ON)Battery positive voltage

N09214
DTC3 DI-4
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)

The diagnosis system operates in normal mode
during normal vehicle use. It also has a check mode
for technicians to simulate malfunction symptoms
and troubleshoot. Most DTC use 2 trip detection
logic* to prevent erroneous detection, and ensure
thorough malfunction detection. By switching the
ECM to check mode when troubleshooting, the
technician can cause the MIL to light up for a mal-
function that is only detected once or momentarily
(TOYOTA hand-held tester only) (See page
DI-3).

*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the
second drive test, this second detection causes the
MIL to light up.

The 2 trip repeats the same mode a 2nd time (How-
ever, the IG switch must be turned OFF between the
1st trip and 2nd trip.).

Freeze frame data:
Freeze frame data records the engine condition
when a misfire (DTC P0300 - P0304) or fuel trim
malfunction (DTC P0171, P0172) or other malfunc-
tion (first malfunction only), is detected, as freeze
frame data records the engine conditions (fuel sys-
tem, calculator load, engine coolant temperature,
fuel trim,engine speed, vehicle speed, etc.) when
the malfunction is detected, when troubleshooting
it is useful for determining whether the vehicle was
running or stopped, the engine warmed up or not,
the air-fuel ratio lean or rich, etc. at the time of the
malfunction.
Priorities for troubleshooting:
If troubleshooting priorities for multiple DTC are given in the ap-
plicable DTC chart, these should be followed.
If no instructions are given troubleshoot DTC according to the
following priorities.
(1) DTC other than fuel trim malfunction (DTC P0171,
P0172) and misfire (DTC P0300 - P0304).
(2) Fuel trim malfunction (DTC P0171, P0172).
(3) Misfire (DTC P0300 - P0304).
(b) Check the DLC3.
The vehicle's ECM uses ISO 9141-2 for communication.
The terminal arrangement of DLC3 complies with SAE
J1962 and matches the ISO 9141-2 format.

A10940
ECM
E7
E7 G-B
BR5V
E1 E2 THW
2
1 Engine Coolant Temp. Sensor
3
16 DI-28
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0115 Engine Coolant Temp. Circuit Malfunction
CIRCUIT DESCRIPTION
A thermistor built into the engine coolant temperature sensor changes the resistance value according to the
engine coolant temperature. The structure of the sensor and connection to the ECM is the same as in the
intake air temp. circuit malfunction shown on page DI-24.
If the ECM detects the DTC P0115, it operates the fail-safe function in which the engine coolant temp. is
assumed to be 80°C (176°F).
DTC No.DTC Detection ConditionTrouble Area
P0115Open or short in engine coolant temp. sensor circuit

Open or short in engine coolant temp. sensor circuit

Engine coolant temp. sensor

ECM
HINT:
After confirming DTC P0115, use the OBD II scan tool or TOYOTA hand-held tester to confirm the engine
coolant temperature from the CURRENT DATA.
Temperature DisplayedMalfunction
-40°C (-40°F)Open circuit
140°C (284°F) or moreShort circuit
WIRING DIAGRAM
DI1E6-08

A15685
- DIAGNOSTICSENGINE
DI-29
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
HINT:
If DTC P0105, P0106, P0110, P0115, P0120 are output simultaneously, E2 (sensor ground) may be open.
1 Connect OBD II scan tool or TOYOTA hand-held tester, and read value of engine
coolant temperature.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3.
(c) Turn the ignition switch ON and OBD II scan tool or TOYOTA hand-held tester main switch ON.
CHECK:
Read temperature value on the OBD II scan tool or TOYOTA hand-held tester.
OK:
Same value as the actual engine coolant temperature
HINT:

If there is open circuit, OBD II scan tool or TOYOTA hand-held tester indicates -40°C (-40°F).

If there is short circuit, OBD II scan tool or TOYOTA hand-held tester indicates 140°C (284°F) or more.
NG -40°C (-40°F) ... Go to step 2.
140°C (284°F) or more ... Go to step 4.
OK
Check for intermittent problems (See page
DI-3).
2 Check for open in harness or ECM.
PREPARATION:
(a) Disconnect the engine coolant temp. sensor connector.
(b) Connect sensor wire harness terminals together.
(c) Turn the ignition switch ON.
CHECK:
Read the temperature value on the OBD II scan tool or TOYO-
TA hand-held tester.
OK:
Temperature value: 140°C (284°F) or more
OK Confirm good connection at sensor. If OK, re-
place engine coolant temp. sensor
NG

A15686
A15687
DI-30
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
3 Check for open in harness or ECM.
PREPARATION:
(a) Remove the lower finish panel.
(b) Connect terminals THW and E2 of ECM connector to-
gether.
HINT:
Engine coolant temperature sensor connector is disconnected.
Before checking, do a visual and contact pressure check for the
ECM connector (See page IN-26).
(c) Turn the ignition switch ON.
CHECK:
Read the temperature value on the OBD II scan tool or TOYO-
TA hand-held tester.
OK:
Temperature value: 140°C (284°F) or more
OK Open in harness between terminal E2 or termi-
nal THW, repair or replace harness.
NG
Confirm good connection at ECM.
If OK, replace ECM.
4 Check for short in harness and ECM.
PREPARATION:
(a) Disconnect the engine coolant temperature sensor con-
nector.
(b) Turn the ignition switch ON.
CHECK:
Read the temperature value on the OBD II scan tool or TOYO-
TA hand-held tester.
OK:
Temperature value: -40°C (-40°F)
OK Replace engine coolant temperature sensor.
NG

A15688
- DIAGNOSTICSENGINE
DI-31
1996 TERCEL (RM440U)
5 Check for short in harness or ECM.
PREPARATION:
(a) Remove the lower finish panel.
(b) Disconnect the E7 connector of ECM.
HINT:
The engine coolant temperature sensor connector is discon-
nected.
(c) Turn the ignition switch ON.
CHECK:
Read the temperature value on the OBD II scan tool or TOYO-
TA hand-held tester.
OK:
Temperature value: -40°C (-40°F)
OK Repair or replace harness or connector.
NG
Check and replace ECM (See page IN-26).