ignition TOYOTA TERCEL 1996 Service User Guide

PP198-01
PP-24
- PREPARATIONIGNITION
71 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION
RECOMMENDED TOOLS
09082-00040TOYOTA Electrical Tester.
09200-00010Engine Adjust Kit .

PP199-01
- PREPARATIONIGNITION
PP-25
1996 TERCEL (RM440U)
EQUIPMENT
Spark plug cleaner

SS0N5-03
- SERVICE SPECIFICATIONSENGINE MECHANICAL
SS-5
135 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MECHANICAL
SERVICE DATA
Compression
pressureat 250 rpm STD
Minimum
Difference of pressure between each cylinder1,275 kPa (13.0 kgf/cm2, 185 psi) or more
981 kPa (10.0 kgf/cm2, 142 psi)
98 kPa (1.0 kgf/cm2, 14 psi) or less
Valve clearanceat cold Intake
Exhaust
Adjusting shim (for repair part) No. 02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
340.15 - 0.25 mm (0.006 - 0.010 in.)
0.31 - 0.41 mm (0.012 - 0.016 in.)
2.500 mm (0.0984 in.)
2.550 mm (0.1004 in.)
2.600 mm (0.1024 in.)
2.650 mm (0.1043 in.)
2.700 mm (0.1063 in.)
2.750 mm (0.1083 in.)
2.800 mm (0.1102 in.)
2.850 mm (0.1122 in.)
2.900 mm (0.1142 in.)
2.950 mm (0.1161 in.)
3.000 mm (0.1181 in.)
3.050 mm (0.1201 in.)
3.100 mm (0.1220 in.)
3.150 mm (0.1240 in.)
3.200 mm (0.1260 in.)
3.250 mm (0.1280 in.)
3.300 mm (0.1299 in.)
Ignition timingw/ Terminals TE1 and E1 connected of DLC110° BTDC @ idle
Idle speed-750 ± 50 rpm
Idler pulley tension
springFree length
Installed load at 47.4 mm (1.866 in.)38.4 mm (1.512 in.)
32 N (3.3 kgf, 7.3 lbf)
Cylinder headWarpage
Cylinder block side Maximum
Manifold sideMaximum
Valve guide bore diameter STD
O/S 0.05
Valve seat
Refacing angleIntake
Exhaust
Contacting angle
Contacting width
0.05 mm (0.0020 in.)
0.05 mm (0.0020 in.)
11.000 - 11.027 mm (0.4331 - 0.4342 in.)
11.050 - 11.077 mm (0.4350 - 0.4361 in.)
30°, 45°, 60°, 75°
30°, 45°, 75°
45°
1.0 - 1.4 mm (0.039 - 0.055 in.)
Valve guide
bushingInside diameter
Outside diameter (for repair part) STD
O/S 0.056.010 - 6.030 mm (0.2366 - 0.2374 in.)
11.048 - 11.059 mm (0.4350 - 0.4354 in.)
11.098 - 11.109 mm (0.4369 - 0.4374 in.)
ValveValve overall length STD Intake
Exhaust
Minimum Intake
Exhaust
Valve face angle
Stem diameterIntake
Exhaust
Stem oil clearance STD Intake
Exhaust
Maximum Intake
Exhaust
Margin thickness STD
Minimum93.45 mm (3.6791 in.)
93.89 mm (3.6965 in.)
92.95 mm (3.6594 in.)
93.39 mm (3.6768 in.)
44.5°
5.970 - 5.985 mm (0.2350 - 0.2356 in.)
5.965 - 5.980 mm (0.2348 - 0.2354 in.)
0.025 - 0.060 mm (0.0010 - 0.0024 in.)
0.030 - 0.065 mm (0.0012 - 0.0026 in.)
0.08 mm (0.0031 in.)
0.10 mm (0.0039 in.)
0.8 - 1.2 mm (0.031 - 0.047 in.)
0.5 mm (0.020 in.)

SS0ND-04
- SERVICE SPECIFICATIONSIGNITION
SS-17
147 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION
SERVICE DATA
High-tension cordResistance Maximum25 kW per cord
Spark plugRecommended spark plug ND
NGK
Correct electrode gapK16TR11
BKR5EKB-1 1
1.1 mm (0.043 in.)
Ignition coilPrimary coil resistance at cold
at hot
Secondary coil resistance at cold
at hot0.67 - 1.05 W
0.85 - 1.23 W
9.3 - 16.0 kW
11.7 - 18.8 kW
Camshaft position
sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W
Crankshaft
position sensorResistance at cold
at hot985 - 1,600 W
1,265 - 1,890 W

SS0NE-01
SS-18
- SERVICE SPECIFICATIONSIGNITION
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Spark plug x Cylinder head1818013
Ignition coil x Cylinder head8.58575 in.´lbf
Camshaft position sensor x Cylinder head88069 in.´lbf
Crankshaft position sensor x Oil pump88069 in.´lbf

SS0ME-05
SS-40
- SERVICE SPECIFICATIONSBODY ELECTRICAL
170 Author
: Date
:
1996 TERCEL (RM440U)
BODY ELECTRICAL
SERVICE DATA
INTEGRATION RELAY
Key Unlock Warning System:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
3 - Ground (Constant)Battery positive voltage
9 - Ground (Ignition switch LOCK or ACC)No voltage
9 - Ground (Ignition switch ON)Battery positive voltage
12 - Ground (Constant)Battery positive voltage
DAYTIME RUNNING LIGHT MAIN RELAY
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
18 - Ground (Ignition switch LOCK or ACC)No voltage
18 - Ground (Ignition switch ON)Battery positive voltage
4 - Ground (Constant)Battery positive voltage
6 - Ground (Constant)Battery positive voltage
10 - Ground (Constant)Battery positive voltage
11 - Ground (Engine stop)No voltage
11 - Ground (Engine running)Battery positive voltage
15 - Ground (Constant)Battery positive voltage
TURN SIGNAL FLASHER
Flashes/Minute60 - 120
SPEEDOMETER (USING A SPEEDOMETER TESTER)
Standard indication (mph)Allowable range (mph)
2018 - 24
4038 - 45
6059 - 67
8079 - 88
100100 - 110
Standard indication (km/h)Allowable range (km/h)
2016 - 26
4038 - 48
6059 - 69
8076 - 90
10096 - 110
120114 - 131
140134 - 152
160152 - 174
TACHOMETER (ON-VEHICLE)DC 13.5 V 25°C (77°F)
Standard indication (rpm)Allowable range (rpm)
700610 - 750
3,0002,850 - 3,150
5,0004,850 - 5,150
7,0006,790 - 7,210

- SERVICE SPECIFICATIONSBODY ELECTRICAL
SS-41
171 Author
: Date
:
1996 TERCEL (RM440U) FUEL RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 115.8
A - CApprox. 177.2
B - CApprox. 61.4
w/o Tachometer:Resistance (W)
A - BApprox. 171.2
A - CApprox. 272.8
B - CApprox. 101.6
FUEL SENDER GAUGE
Float position: mm (in.)Resistance (W)
F: Approx. 13.0 ± 3 (0.512 ± 0.118)Approx. 3 ± 1.0
1/2: Approx. 61.0 (2.402)Approx. 29 ± 4.8
E: Approx. 124.0 ± 3 (4.882 ± 0.118)Approx. 110 ± 7.7
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 51.0
A - CApprox. 148.6
B - CApprox. 199.6
w/o Tachometer:Resistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
DEFOGGER SWITCH
Timer Circuit:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
6 - Ground (Ignition switch LOCK or ACC)No voltage
6 - Ground (Ignition switch ON)Battery positive voltage

S00840
- DIAGNOSTICSENGINE
DI-5
1996 TERCEL (RM440U)Terminal No.
Connection / Voltage or ResistanceCondition
7Bus + Line / Pulse generationDuring transmission
4Chassis Ground - Body Ground / 1 W or lessAlways
5Signal Ground - Body Ground / 1 W or lessAlways
16Battery Positive - Body Ground / 9 - 14 VAlways
HINT:
If your display shows ºUNABLE TO CONNECT TO VEHICLEº
when you have connected the cable of the OBD II scan tool or
TOYOTA hand-held tester to DLC3, turned the ignition switch
ON and operated the scan tool, there is a problem on the ve-
hicle side or tool side.

If communication is normal when the tool is connected to
another vehicle, inspect DLC3 on the original vehicle.

If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool its self, so consult the Service Department listed in
the tool's instruction manual.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter.
(2) When the engine started, the MIL should go off. If
the lamp remains on, the diagnosis system has de-
tected a malfunction or abnormality in the system
(b) Check the DTC.
NOTICE:
TOYOTA hand-held tester only: When the diagnosis sys-
tem is switched from the normal mode to the check mode,
it erases all DTC and freeze frame data recorded in the nor-
mal mode. So before switching modes, always check the
DTC and freeze frame data, and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J 1978) or TOYOTA hand-held tester.
(2) Connect the OBD II scan tool or TOYOTA hand-
held tester to DLC3 in the fuse box at the lower left
of the instrument panel.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand-held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand-held
tester to check the DTC and freezed frame data;
note them down (For operating instructions, see the
OBD II scan tool's instruction book.).
(5) See page DI-13 to confirm the details of the
DTC.

FI3605
Flashing
ON
OFF
0.13 Seconds
DI-6
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand-held tester) to check the DTC, use
the normal mode. For code on the DTC chart subject to º2
trip detection logicº, turn the ignition switch OFF after the
symptom is simulated the first time. Then repeat the simu-
lation process again. When the problem has been simu-
lated twice, the MIL lights up and the DTC are recorded in
the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand-held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.

Battery positive voltage 11V or more.

Throttle valve fully closed.

Transmission in ºPº or ºNº position.

Air conditioning switched OFF.
(2) Turn the ignition switch OFF.
(3) Prepare the TOYOTA hand-held tester.
(4) Connect the TOYOTA hand-held tester to DLC3 in
the fuse box at the lower left of the instrument panel.
(5) Turn the ignition switch ON and switch the TOYOTA
hand-held tester ON.
(6) Switch the TOYOTA hand-held tester normal mode
to check mode. (Check that the MIL flashes.)
(7) Switch the engine. (The MIL goes out after the en-
gine start.)
(8) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTC, etc.
(9) After simulating the malfunction conditions, use the
TOYOTA hand-held tester diagnosis selector to
check the DTC and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch OFF switches the diagnosis system from check mode to
normal mode, so all DTC, etc. are erased.
(10) After checking the DTC, inspect the applicable cir-
cuit.

- DIAGNOSTICSENGINE
DI-7
1996 TERCEL (RM440U)
(b) Clear the DTC.
The following actions will erase the DTC and freezed
frame data.
(1) Operating the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand-held tester to erase the
codes. (See the OBD II scan tool's instruction book
for operating instructions.)
(2) Disconnecting the battery terminals or EFI fuse.
NOTICE:
If the TOYOTA hand-held tester switches the ECM from
normal mode to check mode or vice-versa, or if the igni-
tion switch is turned from ON to ACC or OFF during check
mode, the DTC and freezed frame data will be erased.
4. FAIL-SAFE CHART
If any of the following codes is recorded, the ECM enters fail-safe mode.
DTC No.Fail-Safe OperationFail-Safe Deactivation Conditions
P0105Ignition timing fixed at 5° BTDCReturned to normal condition
P0110Intake air temp. is fixed at 20°C (68°F)Returned to normal condition
P0115Engine coolant temp. is fixed at 80°C (176°F)Returned to normal condition
P0120VTA is fixed at 0°
The following condition must be repeated at least 2 times
consecutively
When closed throttle position switch is ON:
0.1 V
VTA
0.95 V
P0141The heater circuit in which an abnormality is detected is
turned offIgnition switch OFF
P0325Max. timing retardationIgnition switch OFF
P1300Fuel cutIGF signal is detected for 4 consecutive ignitions
5. CHECK FOR INTERMITTENT PROBLEMS
HINT:
TOYOTA hand-held tester only:
By putting the vehicle's ECM in check mode, 1 trip detection logic is possible instead of 2 trip detection logic
and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems.
(a) Clear the DTC (See page DI-13).
(b) Set the check mode (See page DI-13).
(c) Perform a simulation test (See page IN-26).
(d) Check the connector and terminal (See page IN-26).
(e) Handle the connector (See page IN-26).
6. BASIC INSPECTION
When the malfunction code is not confirmed in the DTC check, troubleshooting should be performed in the
order for all possible circuits to be considered as the causes of the problems. In many cases, by carrying
out the basic engine check shown in the following flow chart, the location causing the problem can be found
quickly and efficiently. Therefore, use of this check is essential in engine troubleshooting.
1 Is battery positive voltage 11V or more when engine is stopped ?
NO Charge or replace battery.