Temperature TOYOTA TERCEL 1996 Service Manual PDF

SR05Q-17
R11229
NormalAbnormal
R11025Engine Idling Engine Stopped5 mm (0.20 in.)
or less SR-6
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
INSPECTION
1. CHECK FLUID LEVEL
(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil
reservoir.
If necessary, add fluid.
Fluid: ATF DEXRON® II or III
HINT:
Check that the fluid level is within the HOT LEVEL range on the
reservoir cap dipstick. If the fluid is cold, check that it is within
the COLD LEVEL range.
(c) Start the engine and run it at idle.
(d) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80°C (176°F)
(e) Check for foaming or emulsification.
If there is foaming or emulsification, bleed power steering sys-
tem. (See page SR-5)
(f) With the engine idling, measure the fluid level in the oil
reservoir.
(g) Stop the engine.
(h) Wait a few minutes and remeasure the fluid level in the oil
reservoir.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed power steering system.
(See page SR-5)
(i) Check the fluid level.

Q10145
Attachment
Attachment
IN
OUT
Pressure Feed TubeSST
PS Vane Pump
Z15498
Oil
Reservoir
PS Vane
Pump PS Gear
SST Closed
- STEERINGPOWER STEERING FLUID
SR-7
1996 TERCEL (RM440U)
2. CHECK STEERING FLUID PRESSURE
(a) Disconnect the pressure feed tube from the PS vane
pump. (See page SR-24)
(b) Connect SST, as shown in the illustration below.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
NOTICE:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel from lock to lock several times to
boost fluid temperature.
Fluid temperature: 80 °C (176 °F)
(f) With the engine idling, close the valve of the SST and ob-
serve the reading on the SST.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:

Do not keep the valve closed for more than 10 se-
conds.

Do not let the fluid temperature become too high.

Z15499
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open
Z15500
Oil
Reservoir
PS Vane
Pump PS Gear
SST Open Lock Position SR-8
- STEERINGPOWER STEERING FLUID
1996 TERCEL (RM440U)
(g) With the engine idling, open the valve fully.
(h) Measure the fluid pressure at engine speeds of 1,000 rpm
and 3,000 rpm.
Difference fluid pressure:
490 kPa (5 kgf/cm
2, 71 psi) or less
NOTICE:
Do not turn the steering wheel.
(i) With the engine idling and valve fully opened, turn the
steering wheel to full lock position.
Minimum fluid pressure:
6,374 kPa (65 kgf/cm
2, 925 psi)
NOTICE:

Do not maintain lock position for more than 10 se-
conds.

Do not let the fluid temperature become too high.
(j) Disconnect the SST.
(k) Connect the pressure feed tube (See page SR-33).
(l) Bleed the power steering system.

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
-

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)

N13603
1
4
Z08045
Engine Coolant Temperature Gauge
Ignition
Switch
BatterySender
Gauge
Z07424
Engine Coolant Temperature Gauge
BatteryTest Bulb
(3.4 W)
N12804
A
BC
DE F
N12806
A B
C BE-40
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
(b) Submerge the switch in fuel, and check that the bulb goes
out.
If operation is not as specified, replace the sender gauge.
7. INSPECT RECEIVER ENGINE COOLANT
TEMPERATURE GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON, and check that the receiver
gauge needle indicates COOL.
(c) Ground terminal on the wire harness side connecter
through a 3.4 W test bulb.
(d) Turn the ignition switch ON, check that the bulb lights up
and the receiver gauge needle moves to the hot side.
If operation is as specified, replace the sender gauge. Then, re-
check the system.
If operation is not as specified, measure the receiver gauge re-
sistance.
8. INSPECT ENGINE COOLANT TEMPERATURE
RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer:
Between terminalsResistance (W)
D - EApprox. 51.0
D - FApprox. 148.6
E - FApprox. 199.6
w/o Tachometer:
Between terminalsResistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
HINT:
Connect the test leads so that the current from the ohmmeter
can flow according to the above order. This circuit includes the
diode.

AC2WA-02
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-3
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control set at ºMAX COOLº
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to item 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sigh glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect-
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I01386
AC-4
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
2. INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in which the trouble is located by using a man-
ifold gauge set. Read the manifold gauge pressure when these
conditions are established.
Test conditions:
Temperature at the air inlet with the switch set
at RECURC is 30 - 35 °C (86 - 95 °F).
Engine running at 1,500 rpm.
Blower speed control switch set at high.
Temperature control set at max. cool.
HINT:
It should be noted that the gauge indications may vary slightly
due to ambient temperature conditions.
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm
2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm
2)