TOYOTA TERCEL 1996 Service Repair Manual

RS03F-07
- SUPPLEMENTAL RESTRAINT SYSTEMWIRE HARNESS AND CONNECTOR
RS-39
1996 TERCEL (RM440U)
REPLACEMENT
REPLACEMENT REQUIREMENTS
In the following cases, replace the wire harness or connector.

If any part of the SRS wire harness or any connector has been found to be faulty in troubleshoot-
ing.

If any part of the SRS wire harness or any connector has been found to be faulty during checking
item 2-(b) or (c)
NOTICE:
If the wire harness used in the SRS is damaged, replace the whole wire harness assembly.
When the connector to the front airbag sensors can be repaired alone (when there is no damaged
to the wire harness), use the repair wire specially designed for the purpose.

BE0QP-02
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-1
1023 Author
: Date
:
1996 TERCEL (RM440U)
BODY ELECTRICAL SYSTEM
PRECAUTION
Take care to observe the following precautions when performing inspections or removal and replacement
of body electrical related parts.
1. HEADLIGHT SYSTEM
Halogen bulbs have pressurized gas inside and require special handling. They can burst if scratched or
dropped. Hold a bulb only by its plastic or metal case. Don't touch the glass part of a bulb with bare hands.
2. SRS (SUPPLEMENTAL RESTRAINT SYSTEM)
The TERCEL is equipped with an SRS (Supplemental Restraint System) such as the driver airbag and front
passenger airbag. Failure to carry out service operation in the correct sequence could cause the SRS to
unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including re-
moval or installation of parts, inspection or replacement), be sure to read the precautionary notices in the
RS section.
3. AUDIO SYSTEM

If the negative (-) terminal cable is disconnected from the battery, the preset AM, FM 1 and FM 2 sta-
tions stored in memory are erased, so be sure to note the stations and reset them after the terminal
is reconnected.

If the negative (-) terminal cable is disconnected from the battery, the ºANTI-THEFT SYSTEMº will
operate when the cable is reconnected, but the radio, tape player and CD player will not operate. Be
sure to input the correct ID number so that the radio, tape player and CD player can be operated again.
4. MOBILE COMMUNICATION SYSTEM
If the vehicle is equipped with a mobile communication system, refer to precautions in the IN section.

BE0QQ-05
BE-2
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U)
PROBLEM SYMPTOMS TABLE
The table below will be useful for you in troubleshooting these electrical problems. The most likely causes
of the malfunction are shown in the order of their probability. Inspect each part in the order shown, and re-
place the part when it is found to be faulty.
USA:
HEADLIGHT AND TAILLIGHT SYSTEM
TroubleParts nameSee page
ºLight-on warning systemº does not operate.
3. Integration Relay (I/P J/B)
4. DOME Fuse (Engine Room R/B)
5. GAUGE Fuse (I/P J/B)
6. TAIL Fuse (I/P J/B)
7. CIG/RAD Fuse (I/P J/B)
8. Wire Harness
9. Door Courtesy SwitchBE-16
-
-
-
-
-
BE-38
Only one side headlight does not light up.
1. HEAD Fuse (LH, RH) (Engine Room R/B)
2. Headlight Bulb
3. Wire Harness-
-
-
ºLo-Beamº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
ºHi-Beamº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
ºFlashº does not light up.1. Headlight Dimmer Switch
2. Wire HarnessBE-16
-
Headlight does not light up. (Taillight is normal)
1. Headlight Control Relay (Engine Room R/B)
2. Headlight Dimmer Switch
3. Light Control Switch
4. Headlight Bulb
5. Wire HarnessBE-16
BE-16
BE-16
-
-
Headlight does not light up. (Taillight does not light up)
1. Light Control Switch
2. Wire Harness
3. Headlight BulbBE-16
-
-
Only one side taillight does not light up.1. Taillight Bulb
2. Wire Harness-
-
Taillight does not light up. (Headlight is normal)
1. TAIL Fuse (I/P J/B)
2. Taillight Control Relay (I/P J/B)
3. Light Control Switch
4. Headlight Bulb
5. Wire Harness-
BE-16
BE-16
-
-
Taillight does not light up. (Headlight does not light up)
1. Light Control Switch
2. Headlight Bulb
3. Wire HarnessBE-16
-
-

- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-3
1996 TERCEL (RM440U)
CANADA:
HEADLIGHT AND TAILLIGHT SYSTEM
TroubleParts nameSee page
ºLight-on warning systemº does not operate.
1. Integration Relay (I/P J/B)
2. DOME Fuse (Engine Room R/B)
3. GAUGE Fuse (I/P J/B)
4. TAIL Fuse (I/P J/B)
5. CIG/RAD Fuse (I/P J/B)
6. Wire Harness
7. Door Courtesy SwitchBE-16
-
-
-
-
-
BE-38
Only one side headlight does not light up.1. Headlight Bulb
2. Wire Harness-
-
ºLo-Beamº does not light up. (ALL)1. Headlight Control Relay (Engine Room R/B)
2. Wire HarnessBE-16
-
ºLo-Beamº does not light up. (ONE SIDE)
1. HEAD LH-LWR Fuse (R/B No.5)
2. HEAD RH-LWR Fuse (R/B No.5)
3. Headlight Bulb
4. Wire Harness-
-
-
-
ºHi-Beamº does not light up. (ALL)
1. DRL Fuse (Engine Room R/B)
2. Headlight Dimmer Switch
3. D.R.L. Main Relay
4. D.R.L. No.4 Relay (R/B No.5)
5. Daytime Resistor
6. Wire Harness-
BE-16
BE-16
BE-16
BE-16
-
ºHi-Beamº does not light up. (ONE SIDE)
1. HEAD LH-UPR Fuse (R/B No.5)
2. HEAD RH-UPR Fuse (R/B No.5)
3. Headlight Bulb
4. Wire Harness-
-
-
-
ºFlashº does not light up.
1. DRL Fuse (Engine Room R/B)
2. Headlight Dimmer Switch
3. D.R.L. Main Relay
4. D.R.L. No.4 Relay (R/B No.5)
5. Daytime Resistor
6. Wire Harness-
BE-16
BE-16
BE-16
BE-16
-
Headlight does not light up. (Taillight is normal)
1. Headlight Control Relay (Engine Room R/B)
2. D.R.L. Main Relay
3. D.R.L. No.4 Relay (R/B No.5)
4. Daytime Resistor
5. Headlight Dimmer Switch
6. Light Control Switch
7. Headlight Bulb
8. Wire HarnessBE-16
BE-16
BE-16
BE-16
BE-16
BE-16
-
-
Headlight does not light up. (Taillight does not light up)
1. D.R.L. Main Relay
2. D.R.L. No.4 Relay (R/B No.5)
3. Daytime Resistor
4. Light Control Switch
5. Headlight Bulb
6. Wire HarnessBE-16
BE-16
BE-16
BE-16
-
-
Only one side taillight does not light up.1. Taillight Bulb
2. Wire Harness-
-
Taillight does not light up.
(Headlight is normal)
1. TAIL Fuse (I/P J/B)
2. Taillight Control Relay (I/P J/B)
3. Light Control Switch
4. Headlight Bulb
5. Wire Harness-
BE-16
BE-16
-
-

BE-4
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U) Taillight does not light up. (Headlight does not light up)
1. Light Control Switch
2. Headlight Bulb
3. Wire HarnessBE-16
-
-
Headlight does not light up with light control SW in HEAD.
1. Light Control Switch
2. D.R.L. Main Relay
3. D.R.L. No.4 Relay (R/B No.5)
4. Daytime Resistor
5. Wire HarnessBE-16
BE-16
BE-16
BE-16
-
Headlight does not go out with light control SW in OFF.1. Headlight Control Relay (Engine Room R/B)
2. Wire HarnessBE-16
-
Taillight does not light up with light control SW in TAIL.
1. Taillight Control Relay (I/P J/B)
2. Light Control Switch
3. Wire HarnessBE-16
BE-16
-
Taillight does not go out with light control SW in OFF.
1. Taillight Control Relay (I/P J/B)
2. Light Control Switch
3. Wire HarnessBE-16
BE-16
-
Headlight do not light up with engine running and light control SW
in OFF.
1. DOME Fuse (Engine Room R/B)
2. ECU-IG Fuse (I/P J/B)
3. DRL Fuse (Engine Room R/B)
4. D.R.L. Main Relay
5. D.R.L. No.4 Relay (R/B No.5)
6. Daytime Resistor
7. Wire Harness
8. Generator L Terminal
9. Parking Brake Switch
10.Brake Fluid Level Warning Switch-
-
-
BE-16
BE-16
BE-16
-
-
BE-38
BE-38
TURN SIGNAL AND HAZARD WARNING SYSTEM
TroubleParts nameSee page
ºHazardº and ºTurnº do not light up.
1. Hazard Warning Switch
2. Turn Signal Flasher
3. Wire HarnessBE-22
BE-22
-
No of blinks for Hazard.
(Turn is abnormal)1. Bulb
2. Turn Signal Flasher
3. Wire Harness-
BE-22
-
Hazard warning light does not light up.
(Turn signal is normal)1. HAZ-HORN Fuse (Engine Room R/B)
2. Wire Harness-
-
Hazard waning light does not light up in one direction.1. Hazard Warning Switch
2. Wire HarnessBE-22
-
Turn signal does not light up.
(Combination meter, wiper and washer do not operate.)
1. Ignition Switch
2. TURN Fuse (Engine Room R/B)
3. Turn Signal Switch
4. Wire HarnessBE-1 1
-
BE-22
-
Turn signal does not light up.
(Combination meter, wiper and washer are normal.)1. TURN Fuse (Engine Room R/B)
2. Turn Signal Switch
3. Wire Harness-
BE-22
-

- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-5
1996 TERCEL (RM440U)
INTERIOR LIGHT SYSTEM
TroubleParts nameSee page
Room light does not light up.
1. DOME Fuse (Engine Room R/B)
2. Room Light Switch
3. Door Courtesy Switch
4. Wire Harness
5. Bulb-
BE-24
BE-38
-
-
Room light always remains on.
1. Room Light Switch
2. Door Courtesy Switch
3. Wire HarnessBE-24
BE-38
-
BACK-UP LIGHT SYSTEM
TroubleParts nameSee page
Back-up Light does not light up.
1. GAUGE Fuse (I/P J/B)
2. Ignition Switch
3. Park/Neutral Position Switch (A/X)
4. Back-up Light Switch (M/X)
5. Wire Harness
6. Bulb-
BE-1 1
AX-2
AX-2
BE-26
-
-
Back-up light always remains on.1. Wire Harness-
Only one light does not light up.1. Bulb
2. Wire Harness-
-
STOP LIGHT SYSTEM
TroubleParts nameSee page
Stop light does not light up.
1. STOP Fuse (I/P J/B)
2. Stop Light Switch
3. Bulb
4. Wire Harness-
BE-28
-
-
Stop light always remains on.1. Stop Light Switch
2. Wire HarnessBE-28
-
Only one light does not light up.1. Bulb
2. Wire Harness-
-
WIPER AND WASHER SYSTEM
TroubleParts nameSee page
Wiper and washers do not operate.
1. WIPER Fuse (I/P J/B)
2. Wiper Switch
3. Wiper Motor
4. Wire Harness-
BE-30
BE-30
-
Wipers do not operate in LO, HI or MIST.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE-30
BE-30
-
Wipers do not operate in INT.
1. Wiper Switch
2. Wiper Motor
3. Wire HarnessBE-30
BE-30
-
Washer motor does not operate.
1. Washer Switch
2. Washer Motor
3. Wire HarnessBE-30
BE-30
-
Wipers do not operate when washer switch in ON.1. Washer Motor
2. Wire HarnessBE-30
-

BE-6
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U) Washer fluid does not operate.
1. Washer Hose and Nozzle-

At wiper switch HI position, the wiper blade is in contact with the
body.

When the wiper switch is OFF, the wiper blade does not retract
or the retract position is wrong.
1. *1 Wiper Switch
2. Wire harnessBE-30
-
*1: Inspect wiper arm and blade set position
COMBINATION METER (METER, GAUGES AND ILLUMINATION)
TroubleParts nameSee page
Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge
do not operate.3. GAUGE Fuse (Engine Room R/B)
4. Meter Circuit
5. Wire Harness-
BE-35
-
Speedometer does not operate.
1. Vehicle Speed Sensor
2. Meter Circuit
3. Wire HarnessBE-38
BE-35
-
Tachometer does not operate.
1. Igniter
2. ECM
3. Meter Circuit
4. Wire Harness-
-
BE-35
-
Fuel Gauge does not operate or operate abnormally.
1. Fuel Receiver Gauge
2. Fuel Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
Engine Coolant Temperature Gauge does not operate or operate
abnormally.
1. Engine Coolant Temperature Receiver Gauge
2. Engine Coolant Temperature Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
All illumination lights do not light up.
1. TAIL Fuse (I/P J/B)
2. Light Control Rheostat
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Only one illumination light does not light up.1. Bulb
2. Meter Circuit-
BE-35
COMBINATION METER (WARNING LIGHTS)
TroubleParts nameSee page
Warning lights do not light up.
(Except Discharge, SRS and Door Open)
1. Bulb
2. GAUGE Fuse (I/P J/B)
3. Ignition Switch
4. Meter Circuit
5. Wire Harness-
-
BE-1 1
BE-35
-
Brake Warning Light does not light up.
1. Bulb
2. Brake Fluid Level Warning Switch
3. Parking Brake Switch
4. Bulb Check Relay
5. Meter Circuit
6. Wire Harness-
BE-38
BE-38
-
BE-35
-
Seat Belt Warning Light does not light up.
1. Bulb
2. Seat Belt Retractor Switch
3. Integration Relay
4. Meter Circuit
5. Wire Harness-
BE-38
BE-38
BE-35
-

- BODY ELECTRICALBODY ELECTRICAL SYSTEM
BE-7
1996 TERCEL (RM440U) Fuel Level Warning Light does not light up.
1. Bulb
2. Fuel Level Warning Switch
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Low Oil Pressure Warning Light does not light up.
1. Bulb
2. Low Oil Pressure Warning Switch
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Door Open Warning Light does not light up.
1. Bulb
2. DOME Fuse (Engine Room R/B)
3. Door Courtesy Switch
4. Meter Circuit
5. Wire Harness-
-
BE-38
BE-35
-
Discharge Warning Light does not light up.
1. Bulb
2. IGN Fuse (I/P J/B)
3. Generator
4. Meter Circuit
5. Wire Harness-
-
-
BE-35
-
COMBINATION METER (INDICATOR LIGHTS)
TroubleParts nameSee page
SRS Indicator Light does not light up.
1. Bulb
2. Wire Harness
3. Airbag Sensor Assembly-
-
DI-146
ABS Indicator Light does not light up.
1. Bulb
2. Wire Harness
3. ABS ECU-
-
DI-109
Malfunction Indicator Light does not light up.
1. Bulb
2. ECM
3. Wire Harness-
-
-
O/D OFF Indicator Light does not light up.
1. Bulb
2. O/D Main Switch
3. ECM
4. Meter Circuit
5. Wire Harness-
-
-
BE-35
-
Turn Indicator Light does not light up.
1. Bulb
2. Turn Signal and Hazard Warning System
3. Meter Circuit
4. Wire Harness-
BE-21
BE-35
-
High Beam Indicator Light does not light up.
1. Bulb
2. Headlight System
3. Meter Circuit
4. Wire Harness-
BE-13
BE-35
-
Security Indicator Light does not light up.
1. Bulb
2. Theft Deterrent System
3. Meter Circuit
4. Wire Harness-
DI-215
BE-35
-

BE-8
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U)
DEFOGGER SYSTEM
TroubleParts nameSee page
Rear window defogger does not operate.
(w/Timer)
1. DEF M-Fuse (I/P J/B)
2. GAUGE Fuse (I/P J/B)
3. Defogger Switch
4. Defogger Relay
5. Defogger Wire
6. Wire Harness-
-
BE-46
BE-46
BE-46
-
Rear window defogger does not operate.
(w/o Timer)
1. DEF M-Fuse (I/P J/B)
2. Defogger Switch
3. Defogger Wire
4. Wire Harness-
BE-46
BE-46
-
POWER WINDOW CONTROL SYSTEM
TroubleParts nameSee page
Power window does not operate.
(Door lock does not operate.)1. POWER M-Fuse (R/B No.7)
2. Wire Harness-
-
Power window does not operate.
(Door lock is normal.)
1. GAUGE Fuse (I/P J/B)
2. Ignition Switch
3. POWER M-Fuse (R/B No.7)
4. Power Main Relay (R/B No.7)
5. Power Window Master Switch
6. Wire Harness-
BE-1 1
-
BE-49
BE-49
-
ºOne Touch Power Window Systemº does not operate.1. Power Window Master SwitchBE-49
Only one window glass does not move.
1. Power Window Master Switch
2. Power Window Switch
3. Power Window Motor
4. Wire HarnessBE-49
BE-49
BE-49
-
ºWindow Lock Systemº does not operate.1. Power Window Master SwitchBE-49
ºWindow Lock Illuminationº does not light up.1. Power Window Master SwitchBE-49

BE0QR-01
I05952
Engine Room R/B
R/B No.5 (CANADA models)
I/P J/BR/B No.7
- BODY ELECTRICALPOWER SOURCE
BE-9
1031 Author
: Date
:
1996 TERCEL (RM440U)
POWER SOURCE
LOCATION