ABS TOYOTA TERCEL 1996 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1996, Model line: TERCEL, Model: TOYOTA TERCEL 1996Pages: 1202, PDF Size: 17.43 MB
Page 6 of 1202
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.
Page 14 of 1202
IN-14
- INTRODUCTIONFOR ALL OF VEHICLES
14 Author: Date:
1996 TERCEL (RM440U)
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER
CAUTION:
Observe the following items for safety reasons:
Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool's instruc-
tion book or TOYOTA hand-held tester's operator manual should be read thoroughly.
Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand-
held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)
Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held
tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand-held tester.
Page 31 of 1202
IN04Q-07
- INTRODUCTIONTERMS
IN-31
31 Author: Date:
1996 TERCEL (RM440U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
Page 37 of 1202
- 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
Page 105 of 1202
PP310-01
PP-58
- PREPARATIONBRAKE
105 Author: Date:
1996 TERCEL (RM440U)
BRAKE
SST (Special Service Tools)
09023-00100Union Nut Wrench 10 mm
09709-29018LSPV Gauge Set
09718-00010Shoe Hold Down Spring Driver
09737-00010Brake Booster Push Rod Gauge
09751-3601 1Brake Line Union Nut 10 x 12 mm
Wrench
09843-18020Diagnosis Check Wire
09990-00150ABS Actuator Checker and
Sub-harness
09990-00163ABS Actuator Checker Sheet ºAº
09990-00200ABS Actuator Checker Sub-harness
ºCº
09990-00300ABS Actuator Checker Sub-harness
ºIº
Page 163 of 1202
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
Page 164 of 1202
SS0M2-1 1
SS-34
- SERVICE SPECIFICATIONSBRAKE
164 Author: Date:
1996 TERCEL (RM440U)
BRAKE
SERVICE DATA
Brake pedal height (from asphalt sheet) EZ grade143.0 - 153.0 mm (5.63 - 6.02 in.)Brake edal height (from as halt sheet) EZ grade
Except EZ grade
143.0 153.0 mm (5.63 6.02 in.)
140.0 - 150.0 mm (5.51 - 5.91 in.)
Brake pedal freeplay1 - 6 mm (0.04 - 0.24 in.)
Brake pedal reserve distance at 490 N (50 kgf, 110.2 lbf) w/o ABSMore than 60 mm (2.36 in.)Brake edal reserve distance at 490 N (50 kgf, 11 0.2 lbf) w/o ABS
w/ ABS
More than 60 mm (2.36 in.)
More than 55 mm (2.17 in.)
Brake booster push rod to piston clearance (w/ SST)0 mm (0 in.)
Front brake pad thickness STD10.0 mm (0.394 in.)Front brake ad thickness STD
Minimum
10.0 mm (0.394 in.)
1.0 mm (0.039 in.)
Front brake disc thickness STD18.0 mm (0.709 in.)Front brake disc thickness STD
Minimum
18.0 mm (0.709 in.)
17.0 mm (0.669 in.)
Front brake disc runout Maximum0.07 mm (0.0028 in.)
Rear brake drum inside diameter STD180 mm (7.087 in.)Rear brake drum inside diameter STD
Maximum
180 mm (7.087 in.)
181 mm (7.126 in.)
Rear brake lining thickness STD4.0 mm (0.157 in.)Rear brake lining thickness STD
Minimum
4.0 mm (0.157 in.)
1.0 mm (0.039 in.)
Rear brake drum to shoe clearance0.6 mm (0.024 in.)
Parking brake lever travel at 196 N (20 kgf, 44.1 lbf)5 - 8 clicks
Page 165 of 1202
SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Page 185 of 1202
- DIAGNOSTICSENGINE
DI-1 1
1996 TERCEL (RM440U)
Proceed to matrix chart of problem symp-
toms on page DI-19.
7. ENGINE OPERATING CONDITION
NOTICE:
The values given below for ºNormal Conditionº are representative values, so a vehicle may still be
normal even if its value from those listed here. So do not decide whether a part is faulty or not solely
according to the ºNormal Conditionº here.
CARB mandated signals:
TOYOTA hand-held tester displayMeasurement ItemNormal Condition*
FUEL SYS #1
Fuel System Bank 1
OPEN: Air-fuel ratio feedback stopped
CLOSED: Air-fuel ratio feedback operating
Idling after warming up: CLOSED
CALC LOAD
Calculator Load:
Current intake air volume as a proportion of max.
intake air volumeIdling: 19.7 - 47.4 %
Racing without load (2,500rpm): 18.8 - 46.4 %
COOLANT TEMP.Engine Coolant Temp. Sensor ValueAfter warming up: 80 - 95°C (176 - 203°F)
SHORT FT #1Short-term Fuel Trim Bank 10 ± 20%
LONG FT #1Long-term Fuel Trim Bank 10 ± 20%
ENGINE SPDEngine SpeedIdling: 700 - 800 rpm
VEHICLE SPDVehicle SpeedVehicle Stopped: 0 km/h (0 mph)
IGN ADVANCEIgnition Advance:
Ignition Timing of Cylinder No. 1Idling: BTDC 7 - 14°
INTAKE AIRIntake Air Temp. Sensor ValueEquivalent to Ambient Temp.
MAPAbsolute Pressure Inside Intake Manifold
Idling: 20 - 48 kPa
Racing without load (2,500 rpm):
19 - 47 kPa
THROTTLE POS
Voltage Output of Throttle Position Sensor
Calculated as a percentage:
0 V "0%, 5 V "100%Throttle Fully Closed: 6 - 16 %
Throttle Fully Open: 64 - 98 %
O2S B1, S1Voltage Output of Heated Oxygen Sensor
Bank 1, Sensor 1Idling: 0.1 - 0.9 V
O2FT B1, S1Oxygen Sensor Fuel Trim Bank 1, Sensor 1
(Same as SHORT FT #1)0 ± 20 %
O2S B1, S2Voltage Output of Oxygen Sensor
Bank 1, Sensor 2Driving at 50 km/h (31 mph): 0.1 - 0.9 V
*: If no conditions are specifically stated for ºldlingº, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.
Page 187 of 1202
DI4LF-02
- DIAGNOSTICSENGINE
DI-13
1996 TERCEL (RM440U)
DIAGNOSTIC TROUBLE CODE CHART
HINT:
Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument
or other factors.
If a malfunction code is displayed during the DTC check in check mode, check the circuit for that code listed
in the table below, for details of each code, turn to the page referred to under the ''See page '' for the respec-
tive ''DTC No.'' in the DTC chart.
SAE Controlled:
DTC No.
(See Page)Detection ItemTrouble AreaMIL*Memory
P0105
(DI-20)
Manifold Absolute
Pressure/Barometric
Pressure Circuit
MalfunctionOpen or short in manifold absolute pressure sensor circuit
Manifold absolute pressure sensor
ECM
P0106
(DI-23)
Manifold Absolute
Pressure/Barometric
Pressure Circuit
Range/Performance Problem
Manifold absolute pressure sensor
P0110
(DI-24)Intake Air Temp. Circuit
MalfunctionOpen or short in intake air temp. sensor circuit
Intake air temp. sensor
ECM
P0115
(DI-28)Engine Coolant Temp. Circuit
MalfunctionOpen or short in engine coolant temp. sensor circuit
Engine coolant temp. sensor
ECM
P0116
(DI-32)Engine Coolant Temp. Circuit
Range/Performance ProblemEngine coolant temp. sensor
Cooling system
P0120
(DI-33)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
MalfunctionOpen or short in throttle position sensor circuit
Throttle position sensor
ECM
P0121
(DI-37)Throttle/Pedal Position
Sensor/Switch ºAº Circuit
Range/Performance Problem
Throttle position sensor
P0125
(DI-38)Insufficient Coolant Temp. for
Closed Loop Fuel ControlOpen or short in oxygen sensor circuit
Oxygen sensor
P0130
(DI-41)Oxygen Sensor Circuit
Malfunction (Bank 1 Sensor 1)Heated oxygen sensor
Fuel trim malfunction
P0133
(DI-44)Oxygen Sensor Circuit
Slow Response
(Bank 1 Sensor 1)
Oxygen sensor
P0136
(DI-45)Heated Oxygen Sensor Circuit
Malfunction
(Bank 1 Sensor 2)
Heated oxygen sensor
P0141
(DI-47) Heated Oxygen Sensor Heater
Circuit Malfunction
(Bank 1 Sensor 2)Open or short in heater circuit of heated oxygen sensor
Heated oxygen sensor heater
ECM
*: MIL lights up