lock TOYOTA TERCEL 1996 Service Owner's Guide

SS0LI-04
SS-30
- SERVICE SPECIFICATIONSAUTOMATIC TRANSAXLE (A242L)
160 Author
: Date
:
1996 TERCEL (RM440U)
AUTOMATIC TRANSAXLE (A242L)
SERVICE DATA
Governor pressure Vehicle speed reference
30 km/h (19 mph)
60 km/h (37 mph)
90 km/h (56 mph)
59 - 137 kPa (0.6 - 1.4 kgf/cm2, 9 - 20 psi)
196 - 275 kPa (2.0 - 2.8 kgf/cm2, 28 - 40 psi)
363 - 441 kPa (3.7 - 4.5 kgf/cm2, 53 - 64 psi)
Line pressure (Wheel locked)
Engine Idling D position
R position
AT stall (Throttle valve fully opened) D position
R position
373 - 422 kPa (3.8 - 4.3 kgf/cm2, 54 - 61 psi)
549 - 706 kPa (5.6 - 7.2 kgf/cm2, 80 - 102 psi)
902 - 1,049 kPa (9.2 - 10.7 kgf/cm2, 131 - 152 psi)
1,638 - 1,902 kPa (16.7 - 19.4 kgf/cm2, 238 - 276 psi)
Engine stall revolution D and R positions2,300 ± 200 rpm
Time lag N " D position
N " R positionLess than 1.2 seconds
Less than 1.5 seconds
Engine idle speed (A/C OFF) N position750 ± 50 rpm
Throttle cable adjustment (Throttle valve fully opened)
Between boot end face and inner cable stopper
0 - 1 mm (0 - 0.04 in.)
Torque converter clutch installation distance
Drive plate runoutMax.
Torque converter clutch runout Max.More than 13.0 mm (0.512 in.)
0.20 mm (0.0079 in.)
0.30 mm (0.0118 in.)
Differential oil seal drive in depth LH side
RH side5.3 ± 0.5 mm (0.209 ± 0.020 in.)
3.1 ± 0.5 mm (0.122 ± 0.020 in.)
Speedometer driven gear oil seal drive in depth25.0 mm (0.98 in.)
Shift Point
D position
Throttle valve fully opened 1 "2
2 " 3
3 " 2
2 " 1
Throttle valve fully closed 3 O/D
L position
Throttle valve fully closed 2 " 1
45 - 61 km/h (28 - 38 mph)
89 - 106 km/h (55 - 66 mph)
83 - 102 km/h (52 - 63 mph)
83 - 43 km/h (19 - 27 mph)
19 - 33 km/h (12 - 21 mph)
44 - 56 km/h (27 - 35 mph)
Lock-up point
D position
Throttle valve fully closed Lock-up ON
Lock-up OFF
65 - 76 km/h (40 - 47 mph)
61 - 72 km/h (38 - 45 mph)

SS0LP-06
- SERVICE SPECIFICATIONSSUSPENSION AND AXLE
SS-33
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
FRONT:
Disc brake dust cover x Steering knuckle8.38574 in.´lbf
Lower ball joint x Steering knuckle981,00072
Steering knuckle x Shock absorber2452,500181
Lower ball joint x Lower suspension arm8082059
Tie rod end lock nut4748035
Tie rod end x Steering knuckle4950036
Disc brake caliper x Steering knuckle8890065
Drive shaft lock nut2162,200159
Piston rod x Suspension support4747534
Suspension support x Body3940029
Flexible hose x Shock absorber2930022
Lower suspension arm x BodyFront side1421,450105Lower sus ension arm x Body Front side
Rear side
142
74
1,450
750
105
55
Hub nut1031,05076
ABS speed sensor x Steering knuckle7.88069 in.´lbf
REAR:
Piston rod x Suspension support3435025
Suspension support x Body3940029
Shock absorber x Axle beam6869050
Backing plate x Axle beam7071051
Parking brake cable x Backing plate7.88069 in.´lbf
Brake line x Wheel cylinder1515511
Body x Axle beam1421,450105
Lateral control rod x Axle beam8385061
Lateral control rod x Body11 31,15083
ABS speed sensor x Axle beam7.88069 in.´lbf
ABS speed sensor wire x Axle beam5.45548 in.´lbf

SS0M3-10
- SERVICE SPECIFICATIONSBRAKE
SS-35
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Master cylinder x Piston stopper bolt101007
Master cylinder x Reservoir1.717.515.2 in.´lbf
Master cylinder x Brake booster131309
Brake line union nut1515511
Brake booster clevis lock nut2526019
Brake booster x Pedal bracket1414510
Front disc brake caliper installation bolt2525518
Bleeding plug8.38574 in.´lbf
Front disc brake torque plate x Steering knuckle8890065
Front disc brake caliper x Flexible hose3031022
Rear drum brake wheel cylinder x Backing plate101007
ABS actuator assembly x Body1919514
ABS actuator x ABS actuator bracket assembly5.45548 in.´lbf
ABS actuator x ABS actuator No. 3 bracket1919514
Front speed sensor x Steering knuckle8.08271 in.´lbf
Front speed sensor wire harness clamp installation bolt5.05144 in.´lbf
Rear speed sensor x Axle beam8.08271 in.´lbf
Rear speed sensor wire harness clamp installation bolt5.05144 in.´lbf

SS0N2-05
- SERVICE SPECIFICATIONSSTEERING
SS-37
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
STEERING COLUMN
Steering support x Column tube5.45548 in.´lbf
Control valve shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Steering column assembly set nut2526019
Steering wheel set nut3435025
Steering wheel pad set screw8.89078 in.´lbf
PS VANE PUMP
Pressure port union x Front housing6970051
Suction port union x Front housing131309
Pressure feed tube x Pressure port union5455040
PS vane pump pulley set nut4344032
PS vane pump assembly set nut Bolt A4344032 PS vane um assembly set nut Bolt A
Bolt B
43
39
440
400
32
30
MANUAL STEERING GEAR
Pinion bearing adjusting screw lock nut for use with SST
for use without SST85
11 3871
1,15063
83
Rack guide spring cap lock nut for use with SST
for use without SST41
56419
57530
42
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Manual steering gear bracket x Body5859043
Pinion shaft x Sliding yoke2526019
Steering main shaft x Sliding yoke2526019
Column hole cover x Body4.95043 in.´lbf
PS GEAR
Cylinder end stopper5960043
Self-locking nut5960043
Rack housing cap5960043
Rack guide spring cap lock nut for use with SST
for use without SST31
44316
45023
33
Rack x Rack end for use with SST
for use without SST43
59434
60031
43
Tie rod end lock nut4748035
Turn pressure tube union nut for use with SST
for use without SST20
25203
25015
18
Air control valve2930022
PS gear bracket x Body5859043
Engine rear mount insulator Bolt A6465047 Engine rear mount insulator Bolt A
Bolt B
64
78
650
800
47
58
Engine rear mount bracket x Transaxle4849035
Front exhaust pipe x Exhaust manifold6263046
Front exhaust pipe clamp1919014
Front exhaust pipe x Oxygen sensor4445032

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

DI-14
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0171
(DI-49)System too Lean
(Fuel Trim)
Air intake (hose loose)
Fuel line pressure
Injector blockage
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0172
(DI-49)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0300
(DI-52)Random/Multiple Cylinder
Misfire DetectedIgnition system
Injector
FlliP0301
P0302
P0303
P0304
(DI-52)Misfire Detected
- Cylinder 1
- Cylinder 2
- Cylinder 3
- Cylinder 4Fuel line pressure
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0325
(DI-57)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM

P0335
(DI-60)Crankshaft Position Sensor
Circuit ºAº Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM

P0340
(DI-63)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM

P0420
(DI-73)Catalyst System Efficiency
Below ThresholdThree-way catalytic converter
Open or short in (heated) oxygen sensor circuit
(Heated) oxygen sensor

P0500
(DI-76)Vehicle Speed Sensor
Malfunction
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Speedometer cable
ECM

P0505
(DI-78)Idle Control System
Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in AC1 switch circuit
Air intake (hose loose)

*: 


MIL lights up

- DIAGNOSTICSENGINE
DI-23
1996 TERCEL (RM440U)
DTC P0106 Manifold Absolute Pressure/Barometric
Presure Circuit Range/Performance Problem
CIRCUIT DESCRIPTION
Refer to DTC P0105 on page DI-20.
DTC No.DTC Detection ConditionTrouble Area
P0106
Conditions (a) and (b) continue with engine speed
400 - 1,000 rpm:
(2 trip detection logic)
(a) Closed throttle position switch: ON
(b) Manifold absolute pressure sensor output > 3.0 V

Manifold absolute pressure sensor
WIRING DIAGRAM
Refer to DTC P0105 on page DI-20.
INSPECTION PROCEDURE
HINT:
If DTC P0105 and P0106 are output simultaneously, manifold absolute pressure sensor circuit may be open.
Perform troubleshooting of DTC P0105 first.
1 Are there any other codes (besides DTC P0106) being output?
YES Go to relevant DTC chart.
NO
2 Check manifold absolute pressure sensor (See page MF-48).
NG Replace manifold absolute pressure sensor.
OK
Check vacuum line for manifold absolute
pressure sensor for blockage.
DI1E4-05

- DIAGNOSTICSENGINE
DI-49
1996 TERCEL (RM440U)
DTC P0171 System too Lean (Fuel Trim)
DTC P0172 System too Rich (Fuel Trim)
CIRCUIT DESCRIPTION
ºFuelº trim refers to the feedback compensation value compared against the basic injection time. Fuel trim
includes short-term fuel trim and long-term fuel trim.
ºShort-term fuel trimº is the short-term fuel compensation used to maintain the air-fuel ratio at its ideal
theoretical value. The signal from the oxygen sensor indicates whether the air-fuel ratio is RICH or LEAN
compared to the ideal theoretical value, triggering a reduction in fuel volume if the air-fuel ratio is rich, and
an increase in fuel volume if it is lean.
ºLong-term fuel trimº is overall fuel compensation carried out long-term to compensate for continual devi-
ation of the short-term fuel trim form the central value due to individual engine differences, wear over time
and changes in the usage environment.
If both the short-term fuel trim and long-term fuel trim are LEAN or RICH beyond a certain value, it is de-
tected as a malfunction and the MIL lights up.
DTC No.DTC Detection ConditionTrouble Area
P0171
When the air-fuel ratio feedback is stable after engine warming
up, the fuel trim is considerably in error on the RICH side
(2 trip detection logic)

Air intake (hose loose)

Fuel line pressure

Injector blockage

Heated oxygen sensor malfunction

Manifold absolute pressure sensor

Engine coolant temp. sensor
P0172
When the air-fuel ratio feedback is stable after engine warming
up, the fuel trim is considerably in error on the LEAN side.
(2 trip detection logic)

Fuel line pressure

Injector blockage, leak

Heated oxygen sensor malfunction

Manifold absolute pressure sensor

Engine coolant temp. sensor
HINT:

When DTC P0171 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 is re-
corded, the actual air-fuel ratio is on the RICH side.

If the total of the short-term fuel trim value and long-term fuel trim value is within + 25 %, the system
is functioning normally.

If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 is recorded. The MIL then
comes on.
DI052-09

A15700
- DIAGNOSTICSENGINE
DI-57
1996 TERCEL (RM440U)
DTC P0325 Knock Sensor 1 Circuit Malfunction
CIRCUIT DESCRIPTION
A knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric
element which generates a voltage when it becomes deformed, which occurs when the cylinder block vi-
brates due to knocking. If engine knocking occurs, ignition timing is retarded to suppress it.
DTC No.DTC Detection ConditionTrouble Area
P0325
No knock sensor 1 signal to ECM with engine speed 1,200 rpm
or more
(2 trip detection logic)
Open or short in knock sensor 1 circuit

Knock sensor 1 (looseness)

ECM
If the ECM detects the above diagnosis conditions, it operates the fail-safe function in which the corrective
retard angle value is set to the maximum value.
WIRING DIAGRAM
DI012-20