TOYOTA TERCEL 1996 Service Repair Manual

N13603
1
4
Z08045
Engine Coolant Temperature Gauge
Ignition
Switch
BatterySender
Gauge
Z07424
Engine Coolant Temperature Gauge
BatteryTest Bulb
(3.4 W)
N12804
A
BC
DE F
N12806
A B
C BE-40
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
(b) Submerge the switch in fuel, and check that the bulb goes
out.
If operation is not as specified, replace the sender gauge.
7. INSPECT RECEIVER ENGINE COOLANT
TEMPERATURE GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON, and check that the receiver
gauge needle indicates COOL.
(c) Ground terminal on the wire harness side connecter
through a 3.4 W test bulb.
(d) Turn the ignition switch ON, check that the bulb lights up
and the receiver gauge needle moves to the hot side.
If operation is as specified, replace the sender gauge. Then, re-
check the system.
If operation is not as specified, measure the receiver gauge re-
sistance.
8. INSPECT ENGINE COOLANT TEMPERATURE
RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer:
Between terminalsResistance (W)
D - EApprox. 51.0
D - FApprox. 148.6
E - FApprox. 199.6
w/o Tachometer:
Between terminalsResistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
HINT:
Connect the test leads so that the current from the ohmmeter
can flow according to the above order. This circuit includes the
diode.

BE0044
Ignition
Switch
BatteryWarning Light
BE0146
BE1217
Ignition
Switch
BatteryWarning Light
BE1601
ON OFF
- BODY ELECTRICALCOMBINATION METER
BE-41
1996 TERCEL (RM440U)
If resistance value is not as specified, replace the receiver
gauge.
9. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Disconnect the connector from the warning switch and
ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
10. INSPECT LOW OIL PRESSURE SWITCH CONTINUITY
(a) Disconnect the connector from the switch.
(b) Check that there is continuity between terminal and
ground with the engine stopped.
(c) Check that there is no continuity between terminal and
ground with the engine running.
HINT:
Oil pressure should be over 49 kPa (0.5 kgf/cm
2, 7.1 psi).
If operation is not as specified, replace the switch.
11. INSPECT BRAKE SYSTEM WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
12. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
CONTINUITY
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.

Z11183
BE0044
Ignition
Switch
BatteryWarning Light
BE1428
ON
OFF
Z17684
Ignition
Switch
BatteryWarning Light
Wire Harness Side
N20834
OFF
ON BE-42
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
13. INSPECT PARKING BRAKE SWITCH CONTINUITY
(a) Check that there is continuity between terminal and
switch body with the switch ON (switch pin released).
(b) Check that there is no continuity between terminal and
switch body with the switch OFF (switch pin pushed in).
If operation is not as specified, replace the switch or inspect
ground point.
14. INSPECT OPEN DOOR WARNING LIGHT
(a) Disconnect the connectors from the door courtesy switch
and ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does not light up, test the bulb.
15. INSPECT OPEN DOOR COURTESY SWITCH
CONTINUITY
(a) Check that there is continuity between terminals and the
switch body with the switch ON (switch pin released:
opened door).
(b) Check that there is no continuity between terminals and
the switch body with the switch OFF (switch pin pushed
in: closed doors).
If operation is not as specified, replace the switch.
16. INSPECT SEAT BELT WARNING LIGHT
(a) Disconnect the connector from the driver's seat belt re-
tractor assembly.
(b) Connect terminals 1 and 2 on the wire harness side con-
nector.
(c) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
17. INSPECT SEAT BELT RETRACTOR SWITCH
CONTINUITY
(a) Check that there is continuity between terminals on the
switch side connector with the switch ON (belt down-
ward).
(b) Check that there is continuity between terminals on the
switch side connector with the switch OFF (belt upward).
If continuity is not as specified, replace the retractor assembly.

N12807
N12808
BE1348
OFFBright
(0 W)
Dark
(10 W)
- BODY ELECTRICALCOMBINATION METER
BE-43
1996 TERCEL (RM440U)
18. INSPECT INTEGRATION RELAY OPERATION
(a) Connect the positive (+) lead from the battery to terminals
3 and 9.
(b) Connect the terminal 2 to terminal 9 through the 3.4 W test
bulb.
(c) Connect the negative (-) lead from the battery to terminal
7.
(d) Check that the bulb lights and the chime sounds for 4 -
8 seconds.
(e) Return to step (a), and operate the chime again.
(f) Connect the negative (-) lead from the battery to terminal
3.
(g) Check that the chime stops sounding.
HINT:
Check the chime within a period of 4 to 8 seconds.
If operation is not as specified, replace the relay.
19. INSPECT INTEGRATION RELAY CIRCUIT
(See page BE-1 1)
20. INSPECT LIGHT CONTROL RHEOSTAT
(a) Turn the rheostat knob OFF, and check that there is no
continuity between terminals.(Rheostat knob turned to
fully counterclockwise.)
(b) Gradually, turn the rheostat knob from the dark side to
bright side, and check that the resistance decreases from
10 to 0 W .(Rheostat knob turned to clockwise.)
If operation is not as specified, replace the rheostat.

BE0150
Repair Point
Masking TapeBroken
WireBE26R-01
BE0151
BE-44
- BODY ELECTRICALDEFOGGER SYSTEM
1066 Author
: Date
:
1996 TERCEL (RM440U)
DEFOGGER SYSTEM
ON-VEHICLE REPAIR
REPAIR DEFOGGER WIRE
(a) Clean the broken wire tips with a grease, wax and silicone
remover.
(b) Place the masking tape along both sides of the wire to be
repaired.
(c) Thoroughly mix the repair agent (Dupont paste No.
4817).
(d) Using a fine tip brush, apply a small amount to the wire.
(e) After a few minutes, remove the masking tape.
(f) Do not repair the defogger wire for at least 24 hours.

BE0RD-03
Z18218
Defogger Relay
I/P J/B

DEF M-Fuse

GAUGE Fuse
Defogger WireDefogger SwitchDefogger Switch
- BODY ELECTRICALDEFOGGER SYSTEM
BE-45
1996 TERCEL (RM440U)
LOCATION

BE26S-01
Z14866
Relay Side
1
2
3 4 5 6
Z14867
2
3
6
ON
Z08467
Wire Harness Side
Z14868
ON BE-46
- BODY ELECTRICALDEFOGGER SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. w/ Timer:
INSPECT DEFOGGER SWITCH CONTINUITY
Check that there is continuity between terminals 1 and 3.
If continuity is not as specified, check the bulb.
2. INSPECT DEFOGGER TIMER OPERATION
(a) Connect the positive (+) lead from the battery to terminal
2 and the negative (-) lead to terminal 4.
(b) Connect the positive (+) lead from the battery to terminal
6 through a 3.4 W tester bulb.
(c) Push the defogger switch ON, check that the indicator
light and test bulb light up for 12 to 18 minutes, then the
indicator light and test bulb lights go out.
If operation is not as specified, replace the switch.
3. INSPECT DEFOGGER TIMER CIRCUIT
Disconnect the connector from the switch and inspect the con-
nector on the wire harness side, as shown in the chart.
Tester connectionConditionSpecified condition
4 - GroundConstantContinuity
2 - GroundIgnition switch LOCK or ACCNo voltage
2 - GroundIgnition switch ONBattery positive voltage
6 - GroundIgnition switch LOCK or ACCNo voltage
6 - GroundIgnition switch ONBattery positive voltage
-Connect terminals 4 and 6.Defogger system operation is normal
If the circuit is not as specified, replace the switch.
4. w/o Timer:
INSPECT DEFOGGER SWITCH CONTINUITY
ConditionTester connectionSpecified condition
Switch OFF2 - 6No continuity
Switch ON2 - 4 - 6Continuity
Illumination circuit1 - 3Continuity
If continuity is not as specified, replace the switch.

Z05657
1
2 3
51
2
3
5
BE4029
Tester Probe
Heat Wire
Tin Foil
BE0123
At Center
BE0124
0 VoltsSeveral
Volts
Broken
Wire
- BODY ELECTRICALDEFOGGER SYSTEM
BE-47
1996 TERCEL (RM440U)
5. INSPECT DEFOGGER RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2Continuity
Apply B+ between
terminals 1 and 2.3 - 5Continuity
If continuity is not as specified, replace the relay.
6. INSPECT DEFOGGER WIRE
NOTICE:
When cleaning the glass, use a soft, dry cloth, and wipe the
glass in the direction of the wire. Take care not to damage
the wires. Do not use detergents or glass cleaners with
abrasive ingredients. When measuring voltage, wind a
piece of tin foil around the top of the negative probe and
press the foil against the wire with your finger, as shown.
(a) Turn the ignition switch ON.
(b) Turn the defogger switch ON.
(c) Inspect the voltage at the center of each heat wire, as
shown.
VoltageCriteria
Approx. 5 VOkay (No break in wire)
Approx.10 V or 0 VBroken wire
HINT:
If there is approximately 10 V, the wire is broken between the
center of the wire and the positive (+) end. If there is no voltage,
the wire is broken between the center of the wire and ground.
(d) Place the voltmeter positive (+) lead against the defogger
positive (+) terminal.
(e) Place the voltmeter negative (-) lead with the foil strip
against the heat wire at the positive (+) terminal end and
slide it toward the negative (-) terminal end.
(f) The point where the voltmeter deflects from zero to sever-
al V is the place where the heat wire is broken.
HINT:
If the heat wire is not broken, the voltmeter indicates 0 V at the
positive (+) end of the heat wire but gradually increases to about
12 V as the meter probe is moved to the other end.

BE0RF-02
Z18219
Power Window Motors Power Window Master Switch
Ignition Switch
Power Window Switch
R/B No.7

POWER Fuse

POWER Main Relay
I/P J/B

GAUGE FusePower Window Switch
Power Window MotorsPower Window Switch BE-48
- BODY ELECTRICALPOWER WINDOW CONTROL SYSTEM
1070 Author
: Date
:
1996 TERCEL (RM440U)
POWER WINDOW CONTROL SYSTEM
LOCATION

BE0RG-04
Z06846
- BODY ELECTRICALPOWER WINDOW CONTROL SYSTEM
BE-49
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT POWER WINDOW MASTER SWITCH
CONTINUITY
Front Driver's Switch (Window unlock and lock):
Switch positionTester connectionSpecified condition
UP6 - 7 - 8
1 - 2 - 13Continuity
OFF1 - 2 - 6 - 13Continuity
DOWN1 - 2 - 6
7 - 8 - 13Continuity
Front Passenger's Switch:
Switch positionTester connectionSpecified condition
UP7 - 8 - 12Continuity
UP and window lock1 - 2 - 5
7 - 8 - 12Continuity
OFF5 - 12Continuity
OFF and window lock1 - 2 - 5 - 12Continuity
DOWN5 - 7 - 8Continuity
DOWN
and window lock1 - 2 - 12
5 - 7 - 8Continuity
Rear Left Switch:
Switch positionTester connectionSpecified condition
UP7 - 8 - 10Continuity
UP and window lock7 - 8 - 10Continuity
OFF9 - 10Continuity
OFF and window lock1 - 2 - 9Continuity
DOWN7 - 8 - 9Continuity
DOWN
and window lock1 - 2 - 9 - 10Continuity
Rear Right Switch:
Switch positionTester connectionSpecified condition
UP7 - 8 - 11Continuity
UP and window lock1 - 2 - 14
7 - 8 - 11Continuity
OFF11 - 14Continuity
OFF and window lock1 - 2 - 11 - 14Continuity
DOWN7 - 8 - 14Continuity
DOWN
and window lock1 - 2 - 11
7 - 8 - 14Continuity
If continuity is not as specified, replace the master switch.