TOYOTA TERCEL 1996 Service Repair Manual

IN00U-36
N17080
Filler Cap
Float
Reservoir
 Grommet
Clip
Slotted Spring Pin
: Specified torque
 Non-reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
 Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
- INTRODUCTIONHOW TO USE THIS MANUAL
IN-1
1 Author
: Date
:
1996 TERCEL (RM440U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN-16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:

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)

IN07B-01
N13014
B A
P01214
- INTRODUCTIONIDENTIFICATION INFORMATION
IN-3
3 Author
: Date
:
1996 TERCEL (RM440U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the vehicle
identification number plate and the certification label, as shown
in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.

IN0CO-12
FI1066
Z11554
Seal Lock Adhesive
IN-4
- INTRODUCTIONREPAIR INSTRUCTIONS
4 Author
: Date
:
1996 TERCEL (RM440U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (-) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (-)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non-reusable parts
(1) Always replace cotter pins, gaskets, O-rings, oil
seals, etc. with new ones.
(2) Non-reusable parts are indicated in the component
illustrations by the ºº symbol.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.

BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation Part Name Symbol Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKERFUSE
M-FUSE
H-FUSE
FL
CB
- INTRODUCTIONREPAIR INSTRUCTIONS
IN-5
5 Author
: Date
:
1996 TERCEL (RM440U)
(3) Precoated parts are indicated in the component il-
lustrations by the º
º symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening
torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor-
rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.

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.

IN0002
Example
- INTRODUCTIONREPAIR INSTRUCTIONS
IN-7
7 Author
: Date
:
1996 TERCEL (RM440U)
(7) When checking continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals
from bending.
(8) When using a vacuum gauge, never force the hose
onto a connector that is too large. Use a step-down
adapter for adjustment. Once the hose has been
stretched, it may leak air.
(m) Installation and removal of vacuum hose:
(1) When disconnecting vacuum hoses, use tags to
identify how they should be reconnected to.
(2) After completing a job, double check that the vacu-
um hoses are properly connected. A label under the
hood shows the proper layout.
(n) Unless otherwise stated, all resistance is measured at an
ambient temperature of 20°C (68°F). Because the resis-
tance may be outside specifications if measured at high
temperatures immediately after the vehicle has been run-
ning, measurement should be made when the engine has
cooled down.

IN0II-01
Z14535
RearFront crossmember
Rear axle beam
Safety stand and swing arm type lift Front
Front
CAUTION:
Before jacking-up the front and rear, make sure the
car is not carrying any extra weight. JACK POSITION
PANTOGRAPH JACK POSITION
SUPPORT POSITION IN-8
- INTRODUCTIONREPAIR INSTRUCTIONS
1996 TERCEL (RM440U)
REPAIR INSTRUCTIONS
VEHICLE LIFT AND SUPPORT LOCATIONS

IN07J-05
BO4111
Negative Cable
- INTRODUCTIONFOR ALL OF VEHICLES
IN-9
9 Author
: Date
:
1996 TERCEL (RM440U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The TERCEL is equipped with an SRS (Supplemental
Restraint System), such as the driver airbag and front
passenger airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the negative (-) terminal cable from
the battery (See page DI-148).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back-up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (-) terminal cable from the battery, the SRS
may deploy.)
When the negative (-) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back-up power supply from anoth-
er battery.

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.