light TOYOTA TERCEL 1996 Service Manual PDF

BE3843N14684I09778
HEAD
(-)(+)
Disconnect
DI-234
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
HINT:
The flow chart below is based on the premise that the headlights flash normally whenever the light control
switch is operated. If headlight operation is not normal when the light control switch is operated, proceed
to troubleshooting on page BE-2.
1 Check voltage between terminal HEAD of theft deterrent ECU connector and
body ground.
PREPARATION:
Disconnect the theft deterrent ECU connector.
CHECK:
Measure voltage between terminal HEAD of theft deterrent
ECU connector and body ground.
OK:
Voltage: 10 - 14V
OK Check and replace theft deterrent ECU.
NG
Check and repair harness and connector between theft deterrent ECU and headlight control
relay.

N20822
Battery MAIN FL 1
F6 F7ALT B-R
Taillight
LH Taillight
RH 2
EA2B-R
G 1J1Instrument Panel Junction Block
Taillight Control Relay
TAIL4
1E
8
1L
G G LGTheft Deterrent ECU
23
T4 TAIL
1
B
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-235
1996 TERCEL (RM440U)
Taillight Control Relay Circuit
CIRCUIT DESCRIPTION
When the theft deterrent system is activated, it causes the Tr in the ECU to switch on and off at approximately
0.4 sec. intervals. This switches the taillight control relay on and off, thus flashing the taillights (See the wiring
diagram below).
In this condition, if any of the following operations is done, the Tr in the ECU goes off and the taillight control
relay switches off, thus stopping the taillights flashing:
(1) Unlock the front LH or RH door with key.
(2) Turn the ignition switch to ACC or ON position.
(3) Unlock the doors with the wireless door lock control system.
(4) Wait for approximately 60 seconds.
WIRING DIAGRAM
DI4N9-01

BE3843N14685I09779
TAIL (-)
(+)
Disconnect
DI-236
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
HINT:
The flow chart below is based on the premise that the taillights light up normally whenever the light control
switch is operated. If taillight operation is not normal when the light control switch is operated, proceed to
troubleshooting on page BE-2.
1 Check voltage between terminal TAIL of theft deterrent ECU connector and body
ground.
PREPARATION:
Disconnect the theft deterrent ECU connector.
CHECK:
Measure voltage between terminal TAIL of theft deterrent ECU
connector and body ground.
OK:
Voltage: 10 - 14V
OK Check and replace theft deterrent ECU.
NG
Check and repair harness and connector between theft deterrent ECU and taillight control relay.

N12894
L3 Luggage Compartment
Door Courtesy Switch 1R-YIE210
R-YT44 Theft Deterrent ECU
DSWL
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-239
1996 TERCEL (RM440U)
Luggage Compartment Door Courtesy Switch Circuit
CIRCUIT DESCRIPTION
The luggage compartment door courtesy switch goes on when the luggage compartment door is opened
and goes off when the luggage compartment door is closed.
WIRING DIAGRAM
INSPECTION PROCEDURE
1 Check operation of luggage compartment door courtesy light.
CHECK:
Check that luggage compartment door courtesy light goes off when luggage compartment door courtesy
switch is pushed, and comes on when switch is not pushed.
NG Check and repair luggage compartment door
courtesy light circuit (See page BE-24).
OK
DI4NB-02

N12896
Rear LeftR-W R-W
Rear Right R-W 2
1 Security Diode1
R-W
Instrument Panel
Junction Block11
1L6
1CR-W3
T4 CTY Front Right1
(2Dr) R
(4Dr) R-G8
IE2R-G19
T4 DSWP Door Courtesy Switch
Front Leftto Door Light
11
IE2R7
T4DSWD Theft Deterrent ECU
F8
F9
11
R11R12 R DI-244
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
Door Courtesy Switch Circuit
CIRCUIT DESCRIPTION
The door courtesy switch goes on when the door is opened and goes off when the door is closed.
WIRING DIAGRAM
DI4ND-01

- DIAGNOSTICSTHEFT DETERRENT SYSTEM
DI-245
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check operation of open door warning light.
CHECK:
Check that open door warning light comes on when each door is opened, and goes off when all doors are
closed.
NG Check and repair open door warning light cir-
cuit.
OK
2 Check for open in harness and connector between theft deterrent ECU and door
courtesy switch (See page IN-26).
OK Check and replace theft deterrent ECU.*1
NG
Repair or replace harness or connector.
*1: When there is a malfunction that the theft deterrent system cannot be set, proceed to the next numbered
circuit inspection shown on matrix chart (See page DI-223).

P19787
SST(A)
SST(B)
Spark Plug Side
Z07669
B
A
BB
A
B
- ENGINE MECHANICALVALVE CLEARANCE
EM-5
426 Author
: Date
:
1996 TERCEL (RM440U)
(b) Turn the crankshaft pulley 1 revolution (360°) and align
its groove with the timing mark º0º of the No.1 timing belt
cover.
(c) Check only the valves indicated as shown. Measure the
valve clearance (See procedure in step (a)).
6. ADJUST VALVE CLEARANCE
(a) Remove the adjusting shim.
(1) Turn the crankshaft to position the cam lobe of the
camshaft on the adjusting valve points upward.
(2) Position the notch of the valve lifter so that the shim
can be removed with a small screwdriver as shown
in the illustration.
(3) Using SST (A), press down the valve lifter and place
SST (B) between the camshaft and valve lifter
flange. Remove SST (A).
SST 09248-55040 (09248-05410, 09248-05420)
HINT:

Apply SST (B) at slight angle on the side marked with º9º,
at the position shown in the illustration.

Set SST (A) at position A, if position A is too narrow, at
position B, as shown in the illustration.
(4) Remove the adjusting shim with a small screwdriver
and magnetic finger.

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

EM1OD-01
P20154
Oil Pan
P20153
Ground Strap
P20536
Timing Mark
P20159
EM-12
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE RH ENGINE UNDER COVER
2. w/ A/C and/or w/ PS:
REMOVE DRIVE BELT
3. REMOVE GENERATOR DRIVE BELT
4. SLIGHTY JACK UP ENGINE
5. SLIGHTLY JACK UP ENGINE
Raise the engine enough to remove the weight from the engine
mounting on the right side.
6. REMOVE RH ENGINE MOUNTING INSULATOR
(a) Remove the bolt and disconnect the ground strap.
(b) Remove the through bolt, 2 bolts, nut and mounting insu-
lator.
7. REMOVE NO.2 TIMING BELT COVER
Remove the 4 bolts, timing belt cover and gasket.
8. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
NOTICE:
Always turn the crankshaft clockwise.
(b) Check that the hole of the camshaft timing pulley on the
side with the 5E mark is aligned with the timing mark of the
No.1 bearing cap.
If not, turn the crankshaft pulley 1 complete revolution (360°).
9. w/ A/C and/or w/ PS:
REMOVE NO.2 CRANKSHAFT PULLEY
Remove the 4 bolts and No.2 crankshaft pulley.

P20556
P20558
P20535
Tension
P20555
EM-18
- ENGINE MECHANICALTIMING BELT
1996 TERCEL (RM440U)
(b) Using the crankshaft pulley bolt, turn the crankshaft and
align the timing marks of the crankshaft timing pulley and
oil pump body.
6. INSTALL TIMING BELT
NOTICE:
The engine should be cold.
HINT:
When re-using timing belt:
Align the points marked during removal, and install the belt with
the arrow pointing in the direction of engine revolution.
(a) Remove any oil or water on the pulleys, and keep them
clean.
NOTICE:
Only wipe the pulleys; do not use any cleansing agent.
(b) Install the timing belt, and check the tension between the
crankshaft timing pulley and camshaft timing pulley.
7. CHECK VALVE TIMING
(a) Loosen the No.1 idler pulley mount bolt, until the pulley is
moved slightly by the spring tension.