TOYOTA TERCEL 1996 Service Repair Manual

BO348-01
N12255
Front BO-50
- BODYINSTRUMENT PANEL
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE DEFROSTER NOZZLE
2. REMOVE NO. 3 HEATER TO REGISTER DUCT
3. REMOVE NO. 1 HEATER TO REGISTER DUCT
4. REMOVE NO. 1 REGISTER
5. REMOVE NO. 3 REGISTER
6. REMOVE NO. 2 REGISTER
7. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY
(a) Remove the 2 bolts, 2 nuts and the front passenger airbag
assembly.
(b) Remove the airbag door.
CAUTION:

Do not store the front passenger airbag assembly
with the airbag deployment direction facing down.

Never disassemble the front passenger airbag as-
sembly.
NOTICE:

When installing the instrument panel, take care that
the airbag wire harness does not interfere with other
parts and is not pinched between other parts.

When installing the instrument panel box, carefully
pull out the airbag wire harness from the glove
compartment upper hole.
8. REMOVE CENTER BRACKET
9. REMOVE LOWER RH PANEL
10. REMOVE LOWER LH PANEL
11. REMOVE INSTRUMENT PANEL WIRE HARNESS

BO1IF-03
- BODYINSTRUMENT PANEL
BO-51
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page BO-50).

BO349-01
BO-52
- BODYINSTRUMENT PANEL
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page BO-48).

BO34D-01
N20165
Front Seat
Seatback Cover

Hog Ring
Seat Cushion CoverSeatback Frame

Hog Ring
Seat Cushion Frame
Seat Adjuster Inner
Reclining Connecting Rod
Reclining Adjuster Release
Handle
Seat Cushion Outer Shield Seat Adjuster Outer Seat Truck Handle Seat Cushion Inner ShieldFront Seat Inner Belt

Non-reusable part
- BODYSEAT
BO-53
1147 Author
: Date
:
1996 TERCEL (RM440U)
SEAT
COMPONENTS

N12506
Rear Seat
Bench Type:

Hog Ring
Seatback Pad
Seatback Cover
Seat Cushion Cover
Seat Cushion Pad
Separate Type:
Seatback Board
Seatback Lock Seatback Lock

Hog Ring
Hog Ring
Seatback Cover
Seat Cushion

Non-reusable part BO-54
- BODYSEAT
1148 Author
: Date
:
1996 TERCEL (RM440U)

BO1J3-03
N20164
2 Door:
Rear Seat
Outer BeltPackage Tray Trim Side Cover
Center Belt
Front Seat
Outer Belt
Front Seat
Inner Belt LH:
Rear Seat
Inner Belt
w/ CRS, Tether Anchor:
CRS, Tether Anchor
- BODYSEAT BELT
BO-55
1149 Author
: Date
:
1996 TERCEL (RM440U)
SEAT BELT
COMPONENTS

N20163
4 Door:
Adjustable AnchorCenter Pillar Upper GarnishPackage Tray Trim Side Cover
Rear Seat
Outer Belt
Center Belt
Rear Seat
Inner Belt
Front Seat
Outer Belt
Front Seat
Inner BeltCRS, TETHER ANCHOR
(CANADA ONLY)
BO-56
- BODYSEAT BELT
1150 Author
: Date
:
1996 TERCEL (RM440U)

BO34E-01
BO0632
BO0633
15°
45°
- BODYSEAT BELT
BO-57
1996 TERCEL (RM440U)
INSPECTION
CAUTION:
Replace the seat belt assembly (outer belt, inner belt, bolts
or nuts and sill-bar) if it has been used in a severe impact.
The entire assembly should be replaced even if damage is
not obvious.
Emergency Locking Retractor (ELR) and Automatic Lock-
ing Retractor (ALR) type
1. All seat belt:
RUNNING TEST (IN SAFE AREA)
(a) Fasten the front seat belts.
(b) Drive the car at 10 mph (16 km/h) and make a very hard
stop.
(c) Check that the belt is locked and cannot be extended at
this time.
HINT:
Conduct this test in a safe area. If the belt does not lock, remove
the belt mechanism assembly and conduct the following static
check. Also, whenever installing a new belt assembly, verify the
proper operation before installation.
2. Driver 's seat belt (ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Tilt the retractor slowly.
(d) Make sure that the belt can be pulled out at a tilt of 15 de-
grees or less, and cannot be pulled out at over 45 degrees
of tilt.
If a problem is found, replace the assembly.
3. Except driver's seat belt (ALR/ ELR):
STATIC TEST
(a) Make sure that the belt locks when pulled out quickly.
(b) Remove the locking retractor assembly.
(c) Pull out the whole belt and measure the length of the
whole belt. Then retract the belt slightly and pull it out
again.
(d) Make sure that the belt cannot be extended further.
If a problem is found, replace the assembly.

N10070
Fall Length minus
200 mm (7.87 in.)
BO0635
BO-58
- BODYSEAT BELT
1996 TERCEL (RM440U)
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees of tilt.
If a problem is found, replace the assembly.
4. Manual Type:
TESTING
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.

AC2810
AC1DR-02
AC2811
N11084
Wrong Okay
HI LO HILO
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-1
1153 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.