1996 TOYOTA TERCEL warning

Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350-30020 (09350-06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40
1.70 mm (0.0551
0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392
785 kPa, 4
8 kgf/cm
2 or 57
114 psi) as shown
in the illustration. IN-2
- INTRODUCTIONHOW TO USE THIS MANUAL
2 Author
: Date
:
1996 TERCEL (RM440U)
The procedures are presented in a step-by-step format:

The illustration shows what to do and where to do it.

The task heading tells what to do.

The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.

NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.

HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)

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.

MA002-30
MA-2
- MAINTENANCEINSIDE VEHICLE
40 Author
: Date
:
1996 TERCEL (RM440U)
INSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
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. LIGHTS
(a) Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working.
(b) Check the headlight aim.
3. WARNING LIGHTS AND BUZZERS
Check that all warning lights and buzzers function properly.
4. HORN
Check that it is working.
5. WINDSHIELD
Check for scratches, pits or abrasions.
6. WINDSHIELD WIPER AND WASHER
(a) Check operation of the wipers and washer.
(b) Check that the wipers do not streak.
7. WINDSHIELD DEFROSTER
Check that air comes out from the defroster outlet when operating the heater or air conditioner.
8. REAR VIEW MIRROR
Check that it is mounted securely.
9. SUN VISORS
Check that they move freely and are mounted securely.
10. STEERING WHEEL
Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering,
excessive freeplay or strange noises.
11. SEATS
(a) Check that all front seat controls such as seat adjusters, seatback reliner, etc. operate smoothly.
(b) Check that all latches lock securely in any position.
(c) Check that the locks hold securely in any latched position.
(d) Check that the head restraints move up and down smoothly and that the locks hold securely in any
latched position.
(e) For fold-down rear seat backs, check that the latches lock securely.
12. SEAT BELTS
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and
smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.

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

DI4LO-01
ABS Check SheetInspector 's
Name:
Customer 's Name
Date Vehicle
Brought InRegistration Year Registration No.
Frame No.
Odometer Reading/ /
/ /
Date Problem First Occurred
Frequency Problem Occurs/ /
ContinuousIntermittent ( times a day)
Remains ONDoes not Light Up
DTC Check1st Time
2nd TimeNormal Code
Malfunction Code (Code )
Normal CodeMalfunction Code (Code )
Symptomskm
miles
ABS does not operate.
ABS Warning Light
AbnormalABS does not operate intermittently. DI-1 10
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
1996 TERCEL (RM440U)
CUSTOMER PROBLEM ANALYSIS CHECK

R12149
DI4LP-02
FI6443
Short Pin
DLC1
R13006
DLC1
E
1
Tc
R01346
Normal Code
0.25 sec.
0.25 sec.
ON
OFF
ON
OFF0.5 sec.
Code 11 and 21
4 sec.1.5
sec.2.5 sec.
Code 11Code 21
2 sec.
0.5 sec.
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
DI-1 11
1996 TERCEL (RM440U)
PRE-CHECK
1. DIAGNOSIS SYSTEM
(a) Check the indicator.
When the ignition switch is turned ON, check that the ABS
warning light goes on for 3 seconds.
HINT:
If the indicator check result is not normal, proceed to trouble-
shooting for the ABS warning light circuit (See page DI-138).
(b) Check the DTC.
(1) Turn the ignition switch ON.
(2) Disconnect the short pin from the DLC1.
(3) Using SST, connect terminals Tc and E
1 of the
DLC1.
SST 09843-18020
(4) Read the DTC from the ABS warning light on the
combination meter.
HINT:

If no code appears, inspect the diagnostic circuit or ABS
warning light circuit (See page DI-141 or DI-138).

As an example, the blinking patterns for normal code and
codes 11 and 21 are shown in the illustration.
(5) Code are explained in the code table on page
DI-1 15.
(6) After completing the check, disconnect terminals Tc
and E
1, and turn off the display.
If 2 or more malfunctions are indicated at the same time, the
lowest numbered DTC will be displayed 1st.

BR3890
FI6443
Short Pin
DLC1
N09348
Interface Box
Harness VehicleTOYOTA
Tester Hand-held
TOYOTA Break-out-box DI-1 12
- DIAGNOSTICSANTI-LOCK BRAKE SYSTEM
1996 TERCEL (RM440U)
(c) Clear the DTC.
(1) Using SST, connect terminals Tc and E
1 of the
DLC1 and remove the short pin from the DLC1.
SST 09843-18020
(2) IG switch ON.
(3) Clear the DTC stored in ECU by depressing the
brake pedal 8 or more times within 3 seconds.
(4) Check that the warning light shows the normal
code.
(5) Remove the SST from the terminals of the DLC1.
SST 09843-18020
(6) Connect the short pin to the DLC1.
HINT:
Cancellation can also be done by removing the DOME fuse , but
in this case, other memory systems will also be cancelled out.
(d) Using TOYOTA break-out-box and TOYOTA hand-held
tester, measure the ECU terminal values.
(1) Hook up the TOYOTA hand-held tester and TOYO-
TA break-out-box to the vehicle.
(2) Read the ECU input/output values by following the
prompts on the tester screen.
HINT:
TOYOTA hand-held tester has a ºSnapshot º function. This re-
cords the measured values and is effective in the diagnosis of
intermittent problems.
Please refer to the TOYOTA hand-held tester/TOYOTA break
out-box operators manual for further details.