1996 TOYOTA TERCEL low beam

SS0LP-06
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-33
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT:
Disc brake dust cover x Steering knuckle8.38574 in.´lbf
Lower ball joint x Steering knuckle981,00072
Steering knuckle x Shock absorber2452,500181
Lower ball joint x Lower suspension arm8082059
Tie rod end lock nut4748035
Tie rod end x Steering knuckle4950036
Disc brake caliper x Steering knuckle8890065
Drive shaft lock nut2162,200159
Piston rod x Suspension support4747534
Suspension support x Body3940029
Flexible hose x Shock absorber2930022
Lower suspension arm x BodyFront side1421,450105Lower sus ension arm x Body Front side
Rear side
142
74
1,450
750
105
55
Hub nut1031,05076
ABS speed sensor x Steering knuckle7.88069 in.´lbf
REAR:
Piston rod x Suspension support3435025
Suspension support x Body3940029
Shock absorber x Axle beam6869050
Backing plate x Axle beam7071051
Parking brake cable x Backing plate7.88069 in.´lbf
Brake line x Wheel cylinder1515511
Body x Axle beam1421,450105
Lateral control rod x Axle beam8385061
Lateral control rod x Body11 31,15083
ABS speed sensor x Axle beam7.88069 in.´lbf
ABS speed sensor wire x Axle beam5.45548 in.´lbf

P13734
Terminal F CH-4
- CHARGINGCHARGING SYSTEM
1996 TERCEL (RM440U)

Connect the positive (+) tester probe of the amme-
ter to terminal B of the generator.

Connect the positive (+) tester probe of the voltme-
ter to terminal B of the generator.

Ground the negative (-) tester probe of the voltme-
ter.
(b) Check the charging circuit as follows:
With the engine running from idling to 2,000 rpm, check
the reading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage:
at 25°C (77°F)13.9 - 15.1 V
at 115°C (239°F)13.5 - 14.3 V
If the voltmeter reading is greater than standard voltage, re-
place the voltage regulator.
If the voltmeter reading is less than standard voltage, check the
voltage regulator and generator as follows:

With terminal F grounded, start the engine and
check the voltmeter reading of terminal B.

If the voltmeter reading is greater than standard
voltage, replace the voltage regulator.

If the voltmeter reading is less than standard volt-
age, check the generator.
7. INSPECT CHARGING CIRCUIT WITH LOAD
(a) With the engine running at 2,000 rpm, turn on the high
beam headlights and place the heater blower switch at
ºHIº.
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less than the standard amperage, re-
pair the generator.
HINT:
If the battery is fully charged, the indication will sometimes be
less than standard amperage.

R11681R11753F02280
Front
RearSA23E-01
Z03382
SA3213
AB
C D
Front SA-4
- SUSPENSION AND AXLEFRONT WHEEL ALIGNMENT
820 Author
: Date
:
1996 TERCEL (RM440U)
FRONT WHEEL ALIGNMENT
INSPECTION
1. MEASURE VEHICLE HEIGHT
Tire sizeFrontRear
155SR13187.9 mm (7.40 in.)253.2 mm (9.97 in.)
Front measuring point:
Measure from the ground to the center of the lower suspension
arm front mounting bolt.
Rear measuring point:
Measure from the ground to the center of the axle beam mount-
ing bolt.
NOTICE:
Before inspecting the wheel alignment, adjust the vehicle
height to the specification.
If the vehicle height is not the specification, try to adjust it by
pushing down on or lifting the body.
2. INSTALL CAMBER-CASTER-KINGPIN GAUGE OR
ONTO WHEEL ALIGNMENT TESTER
Follow the specific instruction of the equipment manufacturer.
3. INSPECT CAMBER, CASTER AND STEERING AXIS
INCLINATION
Camber
Left-right error-0°20' ± 45'
45' (0.75°) or less
Caster
Left-right error1°20' ± 45
45' (0.75°) or less
Steering axis inclination
Left-right error12°10' ± 45'
45' (0.75°) or less
HINT:
If the caster and steering axis inclination are not within the spec-
ification, after the camber has been correctly adjusted, recheck
the suspension parts for damaged and/or worn out parts.
4. INSPECT TOE-IN
Toe-in
(total)A + B: 0.1° ± 0.2°
C - D: 1 ± 2 mm (0.04 ± 0.08 in.)
If the toe-in is not within the specification, adjust by the tie rod
end.

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-7
1996 TERCEL (RM440U) Fuel Level Warning Light does not light up.
1. Bulb
2. Fuel Level Warning Switch
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Low Oil Pressure Warning Light does not light up.
1. Bulb
2. Low Oil Pressure Warning Switch
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Door Open Warning Light does not light up.
1. Bulb
2. DOME Fuse (Engine Room R/B)
3. Door Courtesy Switch
4. Meter Circuit
5. Wire Harness-
-
BE-38
BE-35
-
Discharge Warning Light does not light up.
1. Bulb
2. IGN Fuse (I/P J/B)
3. Generator
4. Meter Circuit
5. Wire Harness-
-
-
BE-35
-
COMBINATION METER (INDICATOR LIGHTS)
TroubleParts nameSee page
SRS Indicator Light does not light up.
1. Bulb
2. Wire Harness
3. Airbag Sensor Assembly-
-
DI-146
ABS Indicator Light does not light up.
1. Bulb
2. Wire Harness
3. ABS ECU-
-
DI-109
Malfunction Indicator Light does not light up.
1. Bulb
2. ECM
3. Wire Harness-
-
-
O/D OFF Indicator Light does not light up.
1. Bulb
2. O/D Main Switch
3. ECM
4. Meter Circuit
5. Wire Harness-
-
-
BE-35
-
Turn Indicator Light does not light up.
1. Bulb
2. Turn Signal and Hazard Warning System
3. Meter Circuit
4. Wire Harness-
BE-21
BE-35
-
High Beam Indicator Light does not light up.
1. Bulb
2. Headlight System
3. Meter Circuit
4. Wire Harness-
BE-13
BE-35
-
Security Indicator Light does not light up.
1. Bulb
2. Theft Deterrent System
3. Meter Circuit
4. Wire Harness-
DI-215
BE-35
-

BE0QX-03
Z11156
Z08444
Z05657
1
2 3
553 21
Z08446
BE-16
- BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT LIGHT CONTROL SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
OFF-No continuity
TAIL14 - 15Continuity
HEAD13 - 14 - 15Continuity
If continuity is not as specified, replace the switch.
2. INSPECT DIMMER SWITCH CONTINUITY
Switch positionTester connectionSpecified condition
Flash8 - 9 - 16Continuity
Low beam16 - 17Continuity
High beam8 - 16Continuity
If continuity is not as specified, replace the switch.
3. INSPECT HEADLIGHT CONTROL RELAY
CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2Continuity
Apply B+ between
terminals 1 and 2.3 - 4Continuity
If continuity is not as specified, replace the relay.
4. INSPECT TAILLIGHT CONTROL RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2Continuity
Apply B+ between
terminals 1 and 2.3 - 5Continuity
If continuity is not as specified, replace the relay.
5. INSPECT HEADLIGHT DIMMER RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 4, 2 - 4Continuity
Apply B+ between
terminals 2 and 4.2 - 3 - 4Continuity
If continuity is not as specified, replace the relay.

Z08448
Wire Harness Side
- BODY ELECTRICALHEADLIGHT AND TAILLIGHT SYSTEM
BE-17
1996 TERCEL (RM440U)
6. INSPECT D.R.L. MAIN RELAY CIRCUIT
(a) Disconnect the connector from relay and inspect the con-
nector on wire harness side, as shown.
Tester connectionConditionSpecified condition
7 - GroundHeadlight dimmer switch Low beam or High
beam No continuity
7 - GroundHeadlight dimmer switch Flash Continuity
8 - GroundParking brake switch OFF
(Switch pin pushed in)No continuity
8 - GroundParking brake switch ON
(Switch pin released)Continuity
12 - GroundConstantContinuity
13 - GroundConstantContinuity
16 - GroundHeadlight dimmer switch Low beam No continuity
16 - GroundHeadlight dimmer switch High beam or Flash Continuity
2 - Ground
18 - GroundIgnition switch LOCK or ACCNo voltage
2 - Ground
18 - GroundIgnition switch ONBattery positive voltage
4 - GroundConstantBattery positive voltage
6 - GroundConstantBattery positive voltage
10 - GroundConstantBattery positive voltage
11 - GroundEngine StopNo voltage
11 - GroundEngine RunningBattery positive voltage
15 - GroundConstantBattery positive voltage
If circuit is as specified, try replacing the relay with a new one.
If the circuit is not as specified, inspect the circuit connected to
other parts.

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)