belt TOYOTA TERCEL 1996 Service Service Manual

Z00038
DENSO BorroughsSR1F5-01
CH0087
CORRECT
WRONG
WRONG
R11541
PS Vane
Pump
CORRECTWRONG C
D
E
F
- STEERINGDRIVE BELT
SR-3
923 Author
: Date
:
1996 TERCEL (RM440U)
DRIVE BELT
INSPECTION
1. CHECK DRIVE BELT TENSION
Using a belt tension gauge, measure the belt tension.
Belt tension gauge:
DENSO BTG-20 (95506-00020) or
Borroughs No. BT-33-73F
Drive belt tension:
New belt: 140 - 180 lbf
Used belt: 80 - 120 lbf
NOTICE:
After installing the belt, check that it fits properly in the
ribbed grooves.
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
2. VEHICLES WITH BELT TENSION ADJUSTING BOLT:
ADJUST DRIVE BELT TENSION
(a) Loosen the bolts A and B.
(b) Loosen the lock nuts D and E.
(c) Adjust adjusting bolt F so that its protrusion above nut C
is ± 0 mm (0 in.).
(d) Fix nut C using lock nut D.
(e) Push up the PS pump body so that there is no free play
in the belt. Turn adjusting bolt F to obtain the play in the
correct belt tension as specified above.
NOTICE:
Ensure that the pump body and nut C are positioned cor-
rectly, as shown before turning bolt F to adjust the bet ten-
sion.
(f) Torque the bolt A.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)

SR-4
- STEERINGDRIVE BELT
924 Author
: Date
:
1996 TERCEL (RM440U)
(g) Torque the bolt B.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(h) Loosen adjusting bolt F by 4 or 5 turns.
NOTICE:
Check that there is a gap of 5 mm (0.20 in.) or more between
the tip of nut C and the pump body.
(i) Fix adjusting bolt F with lock nut E.
(j) Recheck the belt tension.

SR0KM-03
SR-24
- STEERINGPOWER STEERING VANE PUMP
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT RETURN HOSE
NOTICE:
Take care not to spill fluid on the drive belt.
2. DISCONNECT PRESSURE FEED TUBE
Remove the union bolt and gasket.
3. REMOVE DRIVE BELT
Loosen the 2 pump assembly set bolts.
4. REMOVE PS VANE PUMP ASSEMBLY
Remove the 2 pump assembly set bolts.

SR0KQ-03
- STEERINGPOWER STEERING VANE PUMP
SR-33
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL PS VANE PUMP ASSEMBLY
Temporarily tighten the 2 bolts (A and B).
2. INSTALL DRIVE BELT
(a) Adjust drive belt tension (See page SR-3).
(b) Torque the A bolt.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(c) Torque the B bolt.
Torque: 39 N´m (400 kgf´cm, 30 ft´lbf)
3. CONNECT PRESSURE FEED TUBE
Torque the union bolt over a new gasket.
Torque: 54 N´m (550 kgf´cm, 40 ft´lbf)
4. CONNECT RETURN HOSE
5. BLEED POWER STEERING SYSTEM
(See page SR-5)

BE-6
- BODY ELECTRICALBODY ELECTRICAL SYSTEM
1996 TERCEL (RM440U) Washer fluid does not operate.
1. Washer Hose and Nozzle-

At wiper switch HI position, the wiper blade is in contact with the
body.

When the wiper switch is OFF, the wiper blade does not retract
or the retract position is wrong.
1. *1 Wiper Switch
2. Wire harnessBE-30
-
*1: Inspect wiper arm and blade set position
COMBINATION METER (METER, GAUGES AND ILLUMINATION)
TroubleParts nameSee page
Tachometer, Fuel Gauge and Engine Coolant Temperature Gauge
do not operate.3. GAUGE Fuse (Engine Room R/B)
4. Meter Circuit
5. Wire Harness-
BE-35
-
Speedometer does not operate.
1. Vehicle Speed Sensor
2. Meter Circuit
3. Wire HarnessBE-38
BE-35
-
Tachometer does not operate.
1. Igniter
2. ECM
3. Meter Circuit
4. Wire Harness-
-
BE-35
-
Fuel Gauge does not operate or operate abnormally.
1. Fuel Receiver Gauge
2. Fuel Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
Engine Coolant Temperature Gauge does not operate or operate
abnormally.
1. Engine Coolant Temperature Receiver Gauge
2. Engine Coolant Temperature Sender Gauge
3. Meter Circuit
4. Wire HarnessBE-38
BE-38
BE-35
-
All illumination lights do not light up.
1. TAIL Fuse (I/P J/B)
2. Light Control Rheostat
3. Meter Circuit
4. Wire Harness-
BE-38
BE-35
-
Only one illumination light does not light up.1. Bulb
2. Meter Circuit-
BE-35
COMBINATION METER (WARNING LIGHTS)
TroubleParts nameSee page
Warning lights do not light up.
(Except Discharge, SRS and Door Open)
1. Bulb
2. GAUGE Fuse (I/P J/B)
3. Ignition Switch
4. Meter Circuit
5. Wire Harness-
-
BE-1 1
BE-35
-
Brake Warning Light does not light up.
1. Bulb
2. Brake Fluid Level Warning Switch
3. Parking Brake Switch
4. Bulb Check Relay
5. Meter Circuit
6. Wire Harness-
BE-38
BE-38
-
BE-35
-
Seat Belt Warning Light does not light up.
1. Bulb
2. Seat Belt Retractor Switch
3. Integration Relay
4. Meter Circuit
5. Wire Harness-
BE-38
BE-38
BE-35
-

N12792
N12793
Junction Block Side BE-12
- BODY ELECTRICALIGNITION SWITCH AND KEY UNLOCK WARNING
SWITCH
1996 TERCEL (RM440U)
(f) Connect the negative (-) lead from the battery to terminal
8.
(g) Disconnect the negative (-) lead from the battery to termi-
nal 4.
(h) Check that the chime stops sounding.
If operation is not as specified, replace the relay.
4. INSPECT INTEGRATION RELAY CIRCUIT
Remove the relay from the instrument panel junction block and
inspect the connectors on the junction block side.
Tester connectionConditionSpecified condition
4 - GroundKey unlock warning switch OFFNo continuity
4 - GroundKey unlock warning switch ONContinuity
5 - GroundBuckle switch OFF
(Seat belt unfastened)No continuity
5 - GroundBuckle switch ON
(Seat belt fastened)Continuity
7 - GroundConstantContinuity
8 - GroundDriver's door courtesy switch OFFNo continuity
8 - GroundDriver's door courtesy switch ONContinuity
11 - GroundLight control switch OFFNo continuity
11 - GroundLight control switch TAIL or HEADContinuity
2 - GroundIgnition switch LOCK or ACCNo voltage
2 - GroundIgnition switch ONBattery positive voltage
3 - GroundConstantBattery positive voltage
9 - GroundIgnition switch LOCK or ACCNo voltage
9 - GroundIgnition switch ONBattery positive voltage
12 - GroundConstantBattery positive voltage
If the circuit is as specified, try replacing the relay with a new
one.
If the circuit is not as specified, inspect the circuits connected
to other parts.

I05919
Door Courtesy Switches Seat Belt
Retractor Switch
Fuel Sender Gauge

Fuel Level Warning Switch
Engine Coolant Temperature Gauge
Low Oil Pressure Warning Switch
Park/Neutral Position SwitchDoor Courtesy Switches
BE-34
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)

I16684
No.Wiring Connector Side
1
2
3
4
5
6
7GAUGE Fuse
10
11
12
13
1
2
3
4
5
7
8
1
2
3
4
5
6
7
8
9
10Generator
IGN Fuse
SRS Fuse
Airbag Sensor Assembly
Seat Belt Buckle Switch
Low Oil Pressure Warning Switch
Igniter
TAIL Fuse
Door Courtesy Switch
DOME Fuse
Fuel Level Warning Switch
Engine Coolant Temperature Sender Gauge
ABS ECU
ECM
O/D Off Switch
Light Control Rheostat
Ground
Headlight Dimmer Switch
Turn Signal Switch (Left) Ground
Fuel Sender Gauge
Theft Deterrent ECU
Speed Control Unit
Ground
Starter Relay
Brake Fluid Level Warning Switch
and Parking Brake Switch
Turn Signal Switch (Right) A
B
C
F
E
T: Fuel Receiver Gauge
: Engine Coolant Temperature Receiver Gauge
: Tachometer
Hi-Grade
SRS Warning Illumination Open Door Warning Hi-Beam Indicator Security Indicator Left Turn Indicator Right Turn Indicator Discharge Warning Seat Belt Warning O/D Off Indicator Brake WarningBulb Check Relay Malfunction Indicator Low Oil Pressure Warning ABS Warning Fuel Lever Warning Speed Sensor
A5 B7 A12 C2 A2
A6
B5 C9 B4 A7 B3 B1 A10 B8 B9 C7 C4
A4 A11 A13C1 C5C3 C10A3 C8C6 A1TE F BE-36
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)

I16685
No.Wiring Connector Side
1
2
3
4
5
6
7GAUGE Fuse
10
11
12
13
1
3
4
5
7
1
2
3
4
5
6
7
8
9
10Generator
IGN Fuse
SRS Fuse
Airbag Sensor Assembly
Seat Belt Buckle Switch
Low Oil Pressure Warning Switch
Igniter
TAIL Fuse
Door Courtesy Switch
DOME Fuse
Fuel Level Warning Switch
ABS ECU
ECM
O/D Off Switch
Light Control Rheostat
Headlight Dimmer Switch
Turn Signal Switch (Left) Ground
Fuel Sender Gauge
Theft Deterrent ECU
Speed Control Unit
Ground
Starter Relay
Brake Fluid Level Warning Switch
and Parking Brake Switch
Turn Signal Switch (Right) A
B
C
F
E
T: Fuel Receiver Gauge
: Engine Coolant Temperature Receiver Gauge
: Tachometer
8
9Ground
Engine Coolant Temperature Sender Gauge
A4 A11 A13C1 C5C3 C10A3 C8C6 A1
A5 B7 A12 C2 A2
A6
B5 C9 B4 A7 B3 B1 A10 A8 A9 C7 C4
SRS Warning Illumination Open Door Warning Hi-Beam Indicator Security Indicator Left Turn Indicator Right Turn Indicator Discharge Warning Seat Belt Warning O/D Off Indicator Brake WarningBulb Check Relay Malfunction Indicator Low Oil Pressure Warning ABS Warning
Fuel Lever Warning Speed Sensor TE F Lo-Grade
- BODY ELECTRICALCOMBINATION METER
BE-37
1996 TERCEL (RM440U)

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.