1996 TOYOTA TERCEL relay

IN0253
WRONG CORRECT
IN0252
WRONG CORRECT IN-6
- INTRODUCTIONREPAIR INSTRUCTIONS
6 Author
: Date
:
1996 TERCEL (RM440U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN-8).
Cancel the parking brake on the level place and
shift the transmission in Neutral (or N position).
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission-related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.

V07268
VIBRATION METHOD: When vibration seems to be the major cause.
CONNECTORS
WIRE HARNESS
PARTS AND SENSOR1
Slightly shake the connector vertically and horizontally.
Slightly shake the wire harness vertically and horizontally.
The connector joint, fulcrum of the vibration, and body
through portion are the major areas to be checked thorough-
ly.
Apply slight vibration with a finger to the part of the sensor
considered to be the problem cause and check that the mal-
function occurs.Shake Slightly
Swing Slightly
Vibrate Slightly
HINT:
Applying strong vibration to relays may result in open relays. IN-20
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TERCEL (RM440U)
3. SYMPTOM SIMULATION
The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases,
a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and
environment in which the problem occurred in the customer's vehicle. No matter how much experience a
technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem
symptoms he will tend to overlook something important in the repair operation and make a wrong guess
somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the en-
gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob-
lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the
vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which
is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex-
ternal causes are applied to the vehicle in a stopped condition.
Important Points in the Symptom Simulation Test:
In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area
or parts must also be found out. To do this, narrow down the possible problem circuits according to the symp-
toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation
test, judging whether the circuit being tested is defective or normal and also confirming the problem symp-
toms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes of the symptom.

- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-23
1996 TERCEL (RM440U)
5. PROBLEM SYMPTOMS TABLE
The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to
troubleshoot the problem when a ºNormalº code is displayed in the diagnostic trouble code check but the
problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts
should be checked.
HINT:
When the problem is not detected by the diagnostic system even though the problem symptom is present,
it is considered that the problem is occurring outside the detection range of the diagnostic system, or that
the problem is occurring in a system other than the diagnostic system.
Symptom
Suspected AreaSee page
Engine does not crank (Does not start)
No initial combustion (Does not start)
No complete combustion (Does not start)1. Starter and starter relay
1. ECM power source circuit
2. Fuel pump control circuit
3. ECM
1. Starter signal circuit
2. Fuel pump control circuit1. Fuel pump control circuitDI-147
DI-151
IN-29
PROBLEM SYMPTOMS TABLE
1. Compression
2. Fuel pump control circuit 1. A/C signal circuit
2. Fuel pump control circuit 1. A/C signal circuit (Compressor circuit)
2. ECM power source circuit 1. Starter signal circuit
2. Fuel pump control circuit1. Starter signal circuit
2. Fuel pump control circuit
3. Compression
idling) High engine idle speed (Poor idling) Hot engine Cold engine (Difficult to start)Engine cranks normally (Difficult to start)
AC-88 DI-144
DI-151
EM-3 DI-151

Problem Symptom
Page
Indicates the page where the flow chart for each circuit
is located.

Circuit Inspection, Inspection Order
Indicates the circuit which needs to be checked for each problem
symptom. Check in the order indicated by the numbers.

Circuit or Part Name
Indicates the circuit or part which needs to be checked.
ST-2
ST-17
DI-144
DI-151
DI-144
DI-151

IN-34
- INTRODUCTIONTERMS
34 Author
: Date
:
1996 TERCEL (RM440U) NA
Natural Aspiration
No.Number
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take-Of f
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight-Hand
RHDRight-Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear-Engine Rear-Wheel Drive
RRSRigid Rear Suspension
RWDRear-Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SMTSequential Manual Transmission
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold-Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection

- INTRODUCTIONTERMS
IN-37
1996 TERCEL (RM440U) HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air Temperature
ICMIgnition Control Module-
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel-Shutoff-
ISCIdle Speed Control-
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake Vacuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Differential Pressure-
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface Temperature-
MVZManifold Vacuum Zone-
NVRAMNon-V olatile Random Access Memory-
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn-Board DiagnosticOn-Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module-
PNPPark/Neutral Position-
PROMProgrammable Read Only Memory-
PSPPower Steering Pressure-
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module-
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE-ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter-
SRIService Reminder Indicator-
SRTSystem Readiness Test-
STScan Tool-
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter

PP184-01
PP-74
- PREPARATIONBODY ELECTRICAL
1996 TERCEL (RM440U)
EQUIPMENT
Test lead
Bulb (3.4 W)Fuel sender gauge, Seat belt warning relay
Bulb (21 W)Turn signal flasher relay
Dry cell batteryFuel sender gauge
Torque wrench
Masking tapeRear window defogger wire
Tin foilRear window defogger wire

SS0ME-05
SS-40
- SERVICE SPECIFICATIONSBODY ELECTRICAL
170 Author
: Date
:
1996 TERCEL (RM440U)
BODY ELECTRICAL
SERVICE DATA
INTEGRATION RELAY
Key Unlock Warning System:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
3 - Ground (Constant)Battery positive voltage
9 - Ground (Ignition switch LOCK or ACC)No voltage
9 - Ground (Ignition switch ON)Battery positive voltage
12 - Ground (Constant)Battery positive voltage
DAYTIME RUNNING LIGHT MAIN RELAY
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
18 - Ground (Ignition switch LOCK or ACC)No voltage
18 - Ground (Ignition switch ON)Battery positive voltage
4 - Ground (Constant)Battery positive voltage
6 - Ground (Constant)Battery positive voltage
10 - Ground (Constant)Battery positive voltage
11 - Ground (Engine stop)No voltage
11 - Ground (Engine running)Battery positive voltage
15 - Ground (Constant)Battery positive voltage
TURN SIGNAL FLASHER
Flashes/Minute60 - 120
SPEEDOMETER (USING A SPEEDOMETER TESTER)
Standard indication (mph)Allowable range (mph)
2018 - 24
4038 - 45
6059 - 67
8079 - 88
100100 - 110
Standard indication (km/h)Allowable range (km/h)
2016 - 26
4038 - 48
6059 - 69
8076 - 90
10096 - 110
120114 - 131
140134 - 152
160152 - 174
TACHOMETER (ON-VEHICLE)DC 13.5 V 25°C (77°F)
Standard indication (rpm)Allowable range (rpm)
700610 - 750
3,0002,850 - 3,150
5,0004,850 - 5,150
7,0006,790 - 7,210

DI4LI-02
- DIAGNOSTICSENGINE
DI-19
1996 TERCEL (RM440U)
PROBLEM SYMPTOMS TABLE
SymptomSuspect AreaSee page
Does not start (Engine does not crank)1. Starter and starter relayST-13
ST-31
Does not start (No combustion)1. ECM power source circuit
2. Fuel pump control circuitDI-97
DI-100
Does not start (No complete combustion)1. Fuel pump control circuitDI-100
Difficult to start (Engine cranks normally)
1. Starter signal circuit
2. Fuel pump control circuit
3. CompressionDI-90
DI-100
EM-3
Difficult to start (Cold engine)1. Starter signal circuit
2. Fuel pump control circuitDI-90
DI-100
Difficult to start (Hot engine)1. Starter signal circuit
2. Fuel pump control circuitDI-90
DI-100
Poor idling (High engine idle speed)1. A/C signal circuit
2. ECM power source circuitAC-66
DI-97
Poor idling (Low engine idle speed)1. A/C signal circuit
2. Fuel pump control circuitAC-66
DI-100
Poor idling (Rough idling)1. Compression
2. Fuel pump control circuitEM-3
DI-100
Poor idling (Hunting)1. ECM power source circuit
2. Fuel pump control circuitDI-97
DI-100
Poor driveability (Hesitation/Poor acceleration)
1. Fuel pump control circuit
2. A/T faulty (A132L)
A/T faulty (A242L)
3. A/C cut control circuitDI-100
AX-10
AX-13
DI-106
Poor driveability (Surging)1. Fuel pump control circuitDI-100
Engine stall (Soon after starting)1. Fuel pump control circuitDI-100
Engine stall (During A/C operation)1. A/C signal circuit
2. Engine control module (ECM)AC-66
IN-26