TOYOTA TERCEL 1996 Service Repair Manual

SR0L2-03
R11193
R13112
Fulcrum
Length
SST
Z14367
B AB
B
BB
SR-62
- STEERINGPOWER STEERING GEAR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
NOTICE:
Do not damage the turn pressure tubes.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. CONNECT PRESSURE FEED AND RETURN TUBES
Using SST, connect the tube.
SST 09631-22020
Torque: 36 N´m (366 kgf´cm, 27 ft´lbf)
HINT:

Use a torque wrench with a fulcrum length of 300 mm
(11.81 in.).

This torque value is effective in case that SST is parallel
to a torque wrench.
4. CONNECT TUBE CLAMP
Torque the bolt.
Torque: 13 N´m (130 kgf´cm, 9 ft´lbf)
5. M/T:
CONNECT CONTROL CABLES
(a) Connect the 2 cables to the control lever housing.
(b) Install the 2 clips to the cables.
(c) Install the 2 clips and washers.
6. CONNECT 2 VACUUM HOSES
7. INSTALL ENGINE REAR MOUNT BRACKET
Torque the 2 bolts.
Torque: 48 N´m (490 kgf´cm, 35 ft´lbf)
8. INSTALL ENGINE REAR MOUNT INSULATOR
Torque the 6 bolts.
Torque:
Bolt A: 64 N´m (650 kgf´cm, 47 ft´lbf)
Bolt B: 78 N´m (800 kgf´cm, 58 ft´lbf)

- STEERINGPOWER STEERING GEAR
SR-63
1996 TERCEL (RM440U)
9. INSTALL FRONT EXHAUST PIPE
(a) Connect the 2 rings.
(b) Install the bolt and clamp over a new gasket.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
(c) Install the 2 bolts and compression springs over a new
gasket.
Torque: 62 N´m (630 kgf´cm, 46 ft´lbf)
10. INSTALL OXYGEN SENSOR
Install the sensor.
Torque: 44 N´m (450 kgf´cm, 32 ft´lbf)
11. CONNECT SLIDING YOKE (See page SR-20)
12. INSTALL COLUMN HOLE COVER
Torque the 2 bolts and nut.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
13. CONNECT RH AND LH TIE ROD ENDS
(See page SA-10)
14. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
15. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20)
16. w/ Airbag:
INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
17. BLEED POWER STEERING SYSTEM
(See page SR-5)
18. CHECK STEERING WHEEL CENTER POINT
19. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
20. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20)
21. CHECK FRONT WHEEL ALIGNMENT
(See page SA-4)

RS02V-04
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS-1
984 Author
: Date
:
1996 TERCEL (RM440U)
SRS AIRBAG
PRECAUTION
NOTICE:

The TERCEL is equipped with an SRS, which comprises a driver airbag and front passenger
airbag. Failure to carry out service operations in the correct sequence could cause the SRS to
unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mis-
take is made in servicing the SRS, it is possible the SRS may fail to operate when required. Be-
fore performing servicing (including removal or installation of parts, inspection or replace-
ment), be sure to read the following items carefully, then follow the correct procedure described
in the repair manual.

Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most impor-
tant source of information when troubleshooting the SRS, always inspect the DTCs before dis-
connecting the battery.

Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad, front
passenger airbag assembly and airbag sensor assembly should be inspected.
(See page RS-9, RS-22, RS-34)

Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

Never disassemble and repair the steering wheel pad, front passenger airbag assembly or air-
bag sensor assembly in order to reuse it.

If the steering wheel pad, front passenger airbag assembly or airbag sensor assembly has been
dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace
them with new ones.

Use a volt/ohmmeter with high impedance (10 kW/V minimum) for troubleshooting the system's
electrical circuits.

Information labels are attached to the periphery of the SRS components. Follow the instruction
on the notices.

After work on the SRS is completed, check the SRS warning light. (See page DI-148)

If the vehicle is equipped with a mobile communication system, refer to the precaution in the
IN section.
CAUTION:

Work must be started 90 seconds after the ignition switch is turned to the ºLOCKº position and
the negative (-) terminal cable is disconnected from the battery. (The SRS is equipped with a
back-up power source so that if work is started within 90 seconds of disconnecting the nega-
tive (-) terminal cable of the battery, the SRS may be deployed.)

When the negative (-) terminal cable is disconnected from the battery, the memory of the clock
and audio system will be canceled. So before starting work, make a record of the contents mem-
orized in the audio memory system. When work is finished, reset the audio systems as before
and adjust the clock. To avoid erasing the memory of each memory system, never use a back-
up power supply from outside the vehicle.

Before repairs, remove the airbag sensor if shocks are likely to be applied to the sensor during
repairs.

Do not expose the steering wheel pad, front passenger airbag assembly or airbag sensor as-
sembly directly to hot air or flames.

RS0Q8-02
N12248
R09725
Spiral Cable
H05490
N12151
RS-2
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TERCEL (RM440U)
OPERATION
1. STEERING WHEEL PAD (with AIRBAG)
The inflater and bag of the SRS are stored in the steering wheel
pad and cannot be disassembled. The inflater contains a squib,
igniter charge, gas generant, etc., and inflates the bag when
instructed by the airbag sensor assembly.
2. SPIRAL CABLE (in COMBINATION SWITCH)
A spiral cable is used as an electrical joint from the vehicle body
side to the steering wheel.
3. FRONT PASSENGER AIRBAG ASSEMBLY
The inflater and bag of the SRS are stored in the front passen-
ger airbag assembly and cannot be disassembled. The inflater
contains a squib, igniter charge and gas generant, etc., and in-
flates the bag when instructed by the airbag sensor assembly.
4. SRS WARNING LIGHT
The SRS warning light is located on the cluster finish panel. It
goes on to alert the driver of trouble in the system when a mal-
function is detected in the airbag sensor assembly. In normal
operating conditions when the ignition switch is turned to the
ACC or ON position, the light goes on for about 6 seconds and
then goes off.
5. AIRBAG SENSOR ASSEMBLY
The airbag sensor assembly is mounted on the floor inside the
console box. The airbag sensor assembly consists of airbag
sensor, safing sensor, diagnosis circuit, ignition control and
drive circuit, etc. It receives signals from the airbag sensor and
judges whether the SRS must be activated or not.

Z05953
Spacer
Housing
Female
Male
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS-3
1996 TERCEL (RM440U)
6. SRS CONNECTORS
No.ItemApplication
(1)Terminal Twin-Lock MechanismConnectors 1, 2, 3, 4, 5, 6, 7
(2)Airbag Activation Prevention MechanismConnectors 2, 3, 4
(3)Electrical Connection Check MechanismConnectors 1
(4)Connector Twin-Lock MechanismConnectors 2, 3, 4
(a) All connectors in the SRS are colored in yellow to distin-
guish them from other connectors. Connectors having
special functions and specifically designed for SRS are
used in the locations shown above to ensure high reliabil-
ity. These connectors use durable gold-plated terminals.
(1) Terminal Twin-Lock Mechanism
Each connector has a two-piece construction con-
sisting of a housing and a spacer. This secures the
locking of the terminal by two locking devices (the
spacer and the lance) to prevent terminals from
coming out.

R10587

When Connector is Connected
Short Spring Plate
Housing
Terminal
Short Spring Plate Connectors
When Connector is Disconnected
Housing
SquibShort Spring Plate ONContacting Male TerminalShort Spring PlateSquib
Closed Circuit RS-4
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TERCEL (RM440U)
(2) Airbag Activation Prevention Mechanism
Each connector contains a short spring plate. When
the connector is disconnected, the short spring
plate automatically connects the power source and
grounding terminals of the squib.
HINT:
The illustratration shows connectors º2º, º3º and º4º. Connector
1 has short spring plates on the female terminal side.

R13061
Terminal for
Diagnosis
Disconnection Detection PinTerminal for
Diagnosis
Half Connection
Complete Connection
Z05490
Secondary Lock
Primary Lock Lock
Lock
Primary Lock Incomplete
(Secondary Lock Prevented)Primary Lock Complete
(Secondary Lock Permitted)Twin-Lock Completed
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
RS-5
1996 TERCEL (RM440U)
(3) Electrical Connection Check Mechanism
This mechanism is designed to electrically check if
connectors are connected correctly and complete-
ly. The electrical connection check mechanism is
designed so that the connection detection pin con-
nects with the diagnosis terminals when the con-
nector housing lock is in the locked condition.
(4) Connector Twin-Lock Mechanism
With this mechanism connectors (male and female
connectors) are locked by two locking devices to in-
crease connection reliability.
If the primary lock is incomplete, ribs interfere and prevent the
secondary lock.

Z14034
Fig.1
Power Source
Safing
Sensor
Squibs
Deceleration
Sensor Fig.2 RS-6
- SUPPLEMENTAL RESTRAINT SYSTEMSRS AIRBAG
1996 TERCEL (RM440U)
(b) When the vehicle is involved in a frontal collision in the
hatched area (Fig. 1) and the shock is larger than the pre-
determined level, the SRS is activated automatically. A
safing sensor is designed to go on at a smaller decelera-
tion rate than the airbag sensors. As illustrated in Fig. 2,
ignition is caused when a safing sensor and the decelera-
tion sensor go on simultaneously. When a deceleration
force acts on the sensors, two squibs in the driver airbag
and front passenger airbag ignite and generate gas. The
gas discharging into the driver and front passenger air-
bags rapidly increases the pressure inside the bags
breaking open the steering wheel pad and instrument
panel door. Bag inflation then ends, and the bags deflate
as the gas is discharged through discharge holes at the
bag's rear or side.

RS02X-13
- SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
RS-7
990 Author
: Date
:
1996 TERCEL (RM440U)
STEERING WHEEL PAD AND SPIRAL CABLE
COMPONENTS

RS02Y-09
RS-8
- SUPPLEMENTAL RESTRAINT SYSTEMSTEERING WHEEL PAD AND SPIRAL CABLE
1996 TERCEL (RM440U)
REMOVAL
(See page SR-13)