airbag TOYOTA TERCEL 1996 Service Service Manual

AB0119
H00260
Airbag Sensor Assembly ON
LA
W01935
AB0119
H00269
Airbag Sensor
Assembly
P Squib
D SquibSpiral
Cable
ON
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI-183
1996 TERCEL (RM440U)
3 Check SRS warning light circuit.
PREPARATION:
(a) Connect negative (-) terminal cable to battery.
(b) Turn ignition switch to ACC or ON.
CHECK:
Measure voltage LA terminal of harness side connector of air-
bag sensor assembly.
OK:
Voltage: 10 - 14 V
NG Check SRS warning light bulb / repair SRS
warning light circuit.
OK
4 Does SRS warning light come on?
PREPARATION:
(a) Disconnect negative (-) terminal cable from the battery.
(b) Connect airbag sensor assembly connector.
(c) Connect negative (-) terminal cable to battery, and wait
at least 2 seconds.
(d) Turn ignition switch to ACC or ON.
CHECK:
Check operation of SRS warning light.
NO Check terminal LA of airbag sensor assembly.
If normal, replace airbag sensor assembly.
YES
From the results of the above inspection, the malfunctioning part can now be considered normal.
To make sure of this, use the simulation method to check.

R15077
Airbag Sensor
Assembly
4
IK*1 2
Tc DLC1
E18
AA
BR
EA1Driver Side J/B
311P-B BR
ECJunction
ConnectorP-B P-B
IF
Tc
(w/ Front Passenger Airbag)
*1: Tc - 7
(w/o Front Passenger Airbag)
*1: Tc - 5
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI-185
1996 TERCEL (RM440U)
Tc Terminal Circuit
CIRCUIT DESCRIPTION
By connecting terminals Tc and E1 of the DLC1 the airbag sensor assembly is set in the DTC output mode.
The DTCs are displayed by the blinking of the SRS warning light.
WIRING DIAGRAM
DI4ML-02

AB0117 AB0118 AB0119
R12658H00032
LOCK
ACC
ON
or
Airbag Sensor Assembly
Tc
DI-188
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
1996 TERCEL (RM440U)
4 Check airbag sensor assembly.
PREPARATION:
(a) Turn ignition switch to LOCK.
(b) Disconnect negative (-) terminal cable from the battery,
and wait at least 90 seconds.
(c) Remove steering wheel pad (See page SR-13).
(d) Disconnect connector of front passenger airbag assem-
bly (See page RS-21).
(e) Disconnect connector of airbag sensor assembly
(See page RS-33)
(f) Insert service wire into terminal Tc from back side as
shown.
(g) Connect airbag sensor assembly connector with service
wire.
(h) Connect negative (-) terminal cable to battery.
(i) Turn ignition switch to ACC or ON and wait at least 20 se-
conds.
(j) Connect service wire of terminal Tc to body ground.
CHECK:
Check operation of SRS warning light.
OK:
SRS waning light comes on.
NOTICE:
Never make a mistake with the terminal connection posi-
tion as this will cause a malfunction.
OK Check harness between airbag sensor assem-
bly and DLC1.
NG
Replace airbag sensor assembly.

AB0117
R14303
H00033
Airbag Sensor Assembly
Tc
LOCK
- DIAGNOSTICSSUPPLEMENTAL RESTRAINT SYSTEM
DI-189
1996 TERCEL (RM440U)
If the DTC is displayed without a DTC check procedure, do the following trou-
bleshooting.
1 Check resistance between terminal Tc of airbag sensor assembly and body
ground.
PREPARATION:
(a) Turn ignition switch to LOCK.
(b) Disconnect negative (-) terminal cable from the battery,
and wait at least 90 seconds.
(c) Disconnect airbag sensor assembly connector.
CHECK:
Check resistance between terminal Tc of airbag sensor assem-
bly connector and body ground.
OK:
Resistance: 1MW or higher
NG Repair or replace harness or connector.
OK
Replace airbag sensor assembly.

SR05M-03
- STEERINGSTEERING SYSTEM
SR-1
921 Author
: Date
:
1996 TERCEL (RM440U)
STEERING SYSTEM
PRECAUTION

Care must be taken to replace parts properly because they could affect the performance of the
steering system and result in a driving hazard.

The TERCEL is equipped with 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 deployed during servicing, possibly leading to a serious acci-
dent. Before servicing (including removal or installation of parts, inspection or replacement),
be sure to read the precautionary notices in the RS section.

SR17R-02
R12031
Torx ScrewScrew Case
R11976
Airbag
Connector
CorrectWrong
R11977
SST Matchmarks
- STEERINGNON-TIL T STEERING COLUMN
SR-13
1996 TERCEL (RM440U)
REMOVAL
1. w/ Airbag:
REMOVE STEERING WHEEL PAD
NOTICE:

If the airbag connector is disconnected with the igni-
tion switch at ON or ACC, DTCs will be recorded.

Never use airbag parts from another vehicle. When
replacing parts, replace with new ones.
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench, loosen the 2 torx screws.
HINT:
Loosen the 2 screws until the groove along the screw circumfer-
ence catches on the screw case.
(c) Pull the wheel pad from the steering wheel and discon-
nect the airbag connector.
CAUTION:

When storing the wheel pad, keep the upper surface
of the pad facing upward.

Never disassemble the wheel pad.
NOTICE:
When removing the wheel pad, take care not to pull the air-
bag wire harness.
2. w/o Airbag:
REMOVE STEERING WHEEL PAD
(a) Remove the screw.
(b) Remove the 3 clips.
3. REMOVE STEERING WHEEL
(a) Disconnect the connector.
(b) Remove the steering wheel set nut.
(c) Place matchmarks on the steering wheel and main shaft
assembly.
(d) Using SST, remove the wheel.
SST 09950-50010 (09951-05010, 09952-05010,
09953-05020, 09954-05020)

R12213
A
B
Matchmarks
Manual Steering: SR-14
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
4. REMOVE CENTER UPPER INSTRUMENT CLUSTER
FINISH PANEL
(a) Remove the screw.
(b) Remove the 3 clips.
5. REMOVE UPPER AND LOWER COLUMN COVERS
Remove the 6 screws.
6. REMOVE FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Remove the clip and trim.
7. REMOVE LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Remove the 2 opening covers from the instrument cover.
(b) Remove the 2 screws and disconnect the hood lock re-
lease lever from the instrument cover.
(c) Remove the 4 panel cover set bolts.
(d) Remove the lower pad insert from the instrument cover.
8. REMOVE NO.2 HEATER TO REGISTER DUCT
(a) Disconnect the junction block No.1 with the 3 screws.
(b) Remove the clip.
9. REMOVE COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Disconnect the 3 connectors.
(b) w/ Airbag:
Disconnect the airbag connector.
(c) w/ Airbag:
Remove the 3 screws.
10. REMOVE SPIRAL CABLE (See page BE-14)
NOTICE:
Do not disassemble the cable or apply oil to it.
11. REMOVE COLUMN HOLE COVER
Remove the 4 nuts.
12. DISCONNECT SLIDING YOKE
(a) Place matchmarks on the yoke and steering pinion shaft/
control valve shaft.
(b) Loosen bolt A and remove bolt B.

SR17V-02
R12213
A
B
Matchmarks
Manual Steering: SR-20
- STEERINGNON-TIL T STEERING COLUMN
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL STEERING COLUMN ASSEMBLY
(a) Torque the 4 column assembly set nuts.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(b) Connect the connector.
2. CONNECT SLIDING YOKE
(a) Align the matchmarks on the sliding yoke and steering
pinion shaft/control valve shaft.
(b) Torque the bolt B.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
(c) Torque the bolt A.
Torque: 25 N´m (260 kgf´cm, 19 ft´lbf)
3. INSTALL COLUMN HOLE COVER
Torque the 4 nuts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
4. w/ Airbag:
INSTALL SPIRAL CABLE (See page BE-14)
5. INSTALL COMBINATION SWITCH WITH SPIRAL
CABLE
(a) Tighten the 3 screws.
(b) w/ Airbag:
Connect the airbag connector.
(c) Connect the 3 connectors.
6. INSTALL NO.2 HEATER TO REGISTER DUCT
(a) Install the clip.
(b) Connect the junction block No.1 with the 3 screws.
7. INSTALL LOWER INSTRUMENT COVER AND
INSTRUMENT PANEL LOWER PAD INSERT
(a) Install the pad insert to cover.
(b) Tighten the 4 panel set bolts.
(c) Connect the hood lock release lever with the 2 screws.
(d) Install the 2 opening covers.
8. INSTALL FRONT DOOR SCUFF PLATE AND COWL
SIDE TRIM
Install the clip and trim.
9. INSTALL UPPER AND LOWER COLUMN COVERS
Tighten the 6 screws.
10. INSTALL CENTER UPPER INSTRUMENT CLUSTER
FINISH PANEL
(a) Connect the connector.
(b) Tighten screw.

W01455
Torx ScrewScrew Case
- STEERINGNON-TIL T STEERING COLUMN
SR-21
1996 TERCEL (RM440U)
11. CENTER SPIRAL CABLE
(a) Check that the front wheels are facing straight ahead.
(b) Turn the cable counterclockwise by hand until it becomes
harder to turn the cable.
(c) Then rotate the cable clockwise about 2.5 turns to align
the green marks.
HINT:
The spiral cable turns clockwise about 2.5 turns to either left or
right of the center.
12. INSTALL STEERING WHEEL
(a) Align the matchmarks on the steering wheel and main
shaft assembly.
(b) Torque the steering wheel set nut.
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
(c) Connect the connector.
13. w/ Airbag:
INSTALL STEERING WHEEL PAD
NOTICE:

Make sure the wheel pad is installed with the speci-
fied torque.

If the wheel pad has been dropped, or there are
cracks, dents or other defects in the case or connec-
tor, replace the wheel pad with a new one.

When installing the wheel pad, take care that the wir-
ings do not interfere with other parts and that they are
not pinched between other parts.
(a) Connect the airbag connector.
(b) Install the wheel pad after confirming that the circumfer-
ence groove of the torx screws are caught on the screw
case.
(c) Using a torx socket wrench, torque the 2 screws.
Torque: 8.8 N´m (90 kgf´cm, 78 in.´lbf)
14. w/o Airbag:
INSTALL STEERING WHEEL PAD
15. CHECK STEERING WHEEL CENTER POINT

SR0KW-02
- STEERINGMANUAL STEERING GEAR
SR-45
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL MANUAL STEERING GEAR ASSEMBLY
Install the gear assembly from the LH of the vehicle.
2. INSTALL 2 GROMMETS AND BRACKETS
Torque the 2 bolts and nuts.
Torque: 58 N´m (590 kgf´cm, 43 ft´lbf)
3. CONNECT SLIDING YOKE (See page SR-20)
4. INSTALL COLUMN HOLE COVER
Torque the 4 nuts.
Torque: 4.9 N´m (50 kgf´cm, 43 in.´lbf)
5. CONNECT RH AND LH TIE ROD ENDS (See page SA-10)
6. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
HINT:
Do it with the front of the vehicle jacked up.
7. w/ Airbag:
CENTER SPIRAL CABLE (See page SR-20)
8. INSTALL STEERING WHEEL
(a) Install the wheel at straight-ahead position.
(b) Temporarily tighten the wheel set nut.
(c) Connect the connector.
9. CHECK STEERING WHEEL CENTER POINT
10. w/ Airbag:
TORQUE STEERING WHEEL SET NUT
Torque: 34 N´m (350 kgf´cm, 25 ft´lbf)
11. w/ Airbag:
INSTALL STEERING WHEEL PAD (See page SR-20)
12. CHECK FRONT WHEEL ALIGNMENT (See page SA-4)