brake TOYOTA TERCEL 1996 Service Repair Manual
[x] Cancel search | Manufacturer: TOYOTA, Model Year: 1996, Model line: TERCEL, Model: TOYOTA TERCEL 1996Pages: 1202, PDF Size: 17.43 MB
Page 2 of 1202
Illustration:
what to do and where
21. CHECK PISTON STROKE OF OVERDRIVE BRAKE
(a)
Task heading : what to do
SST 09350-30020 (09350-06120)
Set part No. Component part No.
Detailed text : how to do task
(b)
Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in.)
Specification
Place SST and a dial indicator onto the overdrive brake pis-
ton as shown in the illustration.
Measure the stroke applying and releasing the compressed
air (392 785 kPa, 4 8 kgf/cm
2 or 57 114 psi) as shown
in the illustration. IN-2
- INTRODUCTIONHOW TO USE THIS MANUAL
2 Author: Date:
1996 TERCEL (RM440U)
The procedures are presented in a step-by-step format:
The illustration shows what to do and where to do it.
The task heading tells what to do.
The detailed text tells how to perform the task and gives other information such as specifications
and warnings.
Example:
This format provides the experienced technician with a FAST TRACK to the information needed. The upper
case task heading can be read at a glance when necessary, and the text below it provides detailed informa-
tion. Important specifications and warnings always stand out in bold type.
6. REFERENCES
References have been kept to a minimum. However, when they are required you are given the page to refer
to.
7. SPECIFICATIONS
Specifications are presented in bold type throughout the text where needed. You never have to leave the
procedure to look up your specifications. They are also found in Service Specifications section for quick ref-
erence.
8. CAUTIONS, NOTICES, HINTS:
CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other
people.
NOTICES are also presented in bold type, and indicate the possibility of damage to the components
being repaired.
HINTS are separated from the text but do not appear in bold. They provide additional information to
help you perform the repair efficiently.
9. SI UNIT
The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of
Unit), and alternately expressed in the metric system and in the English System.
Example:
Torque: 30 N´m (310 kgf´cm, 22 ft´lbf)
Page 6 of 1202
IN0253
WRONG CORRECT
IN0252
WRONG CORRECT IN-6
- INTRODUCTIONREPAIR INSTRUCTIONS
6 Author: Date:
1996 TERCEL (RM440U)
(k) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the prop-
er locations (See page IN-8).
Cancel the parking brake on the level place and
shift the transmission in Neutral (or N position).
When jacking up the front wheels of the vehicle at
first place stoppers behind the rear wheels.
When jacking up the rear wheels of the vehicle at
first place stoppers before the front wheels.
When either the front or rear wheels only should be
jacked up, set rigid racks and place stoppers in front
and behind the other wheels on the ground.
After the vehicle is jacked up, be sure to support it
on rigid racks . It is extremely dangerous to do any
work on a vehicle raised on a jack alone, even for
a small job that can be finished quickly.
(l) Observe the following precautions to avoid damage to the
following parts:
(1) Do not open the cover or case of the ECU unless
absolutely necessary. (If the IC terminals are
touched, the IC may be destroyed by static electric-
ity.)
(2) To disconnect vacuum hoses, pull off the end, not
the middle of the hose.
(3) To pull apart electrical connectors, pull on the con-
nector itself, not the wires.
(4) Be careful not to drop electrical components, such
as sensors or relays. If they are dropped on a hard
floor, they should be replaced and not reused.
(5) When steam cleaning an engine, protect the elec-
tronic components, air filter and emission-related
components from water.
(6) Never use an impact wrench to remove or install
temperature switches or temperature sensors.
Page 15 of 1202
IN07E-05
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-15
15 Author: Date:
1996 TERCEL (RM440U)
HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS
GENERAL INFORMATION
A large number of ECU controlled systems are used in the TERCEL. In general, the ECU controlled system
is considered to be a very intricate system requiring a high level of technical knowledge and expert skill to
troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of
these systems is not complex. If you have adequate understanding of the system and a basic knowledge
of electricity, accurate diagnosis and necessary repair can be performed to locate and fix the problem. This
manual is designed through emphasis of the above standpoint to help service technicians perform accurate
and effective troubleshooting, and is compiled for the following major ECU controlled systems:
The troubleshooting procedure and how to make use of it are described on the following pages.
SystemPage
1. EngineDI-1
2. Anti-Lock Brake SystemDI-109
3. Supplemental Restraint SystemDI-146
4. Power Door Lock Control SystemDI-190
5. Theft Deterrent SystemDI-215
Before using the scan tool or tester, the scan tool's instruction book or tester's operator manual should
be read thoroughly.
If the scan tool or tester cannot communicate with ECU controlled systems when you have connected
the cable of the scan tool or tester to DLC3, turned the ignition switch ON and operated the scan tool,
there is a problem on the vehicle side or tool side.
(1) If communication is normal when the tool is connected to another vehicle, inspect the diagnosis
data link line (Busline) or ECU power circuit of the vehicle.
(2) If communication is still not possible when the tool is connected to another vehicle, the problem
is probably in the tool itself, so perform the Self Test procedures outline in the Tester Operator's
Manual.
Page 18 of 1202
DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE
Diagnostic Trouble
Code Check (Make a
note of and then clear)Confirmation
of SymptomsDiagnostic Trouble
Code CheckProblem Condition
Diagnostic Trouble
Code DisplayProblem symptoms
existSame diagnostic
trouble code is
displayedProblem is still occurring in the diagnostic
circuit
Normal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit
(The diagnostic trouble code displayed
first is either for a past problem or it is a
secondary problem)
No problem
symptoms existThe problem occurred in the diagnostic
circuit in the past
Normal Code DisplayProblem symptoms
existNormal code is
displayedThe problem is still occurring in a place
other than in the diagnostic circuit
No problem
symptoms existNormal code is
displayedThe problem occurred in a place other
than in the diagnostic circuit in the past
IN-18- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TERCEL (RM440U)
2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK
The diagnostic system in the TERCEL fulfills various functions. The first function is the Diagnostic Trouble
Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory
at the time of occurrence, to be output by the technician during troubleshooting. Another function is the Input
Signal Check which checks if the signals from various switches are sent to the ECU correctly.
By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can
be performed effectively. Diagnostic functions are incorporated in the following systems in the TERCEL.
SystemDiagnostic Trouble
Code CheckInput Signal Check
(Sensor Check)Diagnostic Test
Mode (Active Test)
1. Engine
(with Check Mode)
2. Anti-Lock Brake System
3. Supplemental Restraint System
4. Power Door Lock Control System
5. Theft Deterrent System
In diagnostic trouble code check, it is very important to determine whether the problem indicated by the diag-
nostic trouble code is still occurring or occurred in the past but returned to normal at present. In addition,
it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic
trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes
should be checked before and after the symptom confirmation to determine the current conditions, as shown
in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting
for normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent
to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble
code check.
Page 31 of 1202
IN04Q-07
- INTRODUCTIONTERMS
IN-31
31 Author: Date:
1996 TERCEL (RM440U)
TERMS
ABBREVIATIONS USED IN THIS MANUAL
AbbreviationsMeaning
ABSAnti-Lock Brake System
ACAlternating Current
ACCAccessory
ACISAcoustic Control Induction System
ACSDAutomatic Cold Start Device
A.D.D.Automatic Disconnecting Differential
A/FAir-Fuel Ratio
AHCActive Height Control Suspension
ALRAutomatic Locking Retractor
ALTAlternator
AMPAmplifier
ANTAntenna
APPROX.Approximately
A/TAutomatic Transmission (Transaxle)
AT FAutomatic Transmission Fluid
AUTOAutomatic
AUXAuxiliary
AV GAverage
AV SAdaptive Variable Suspension
BABrake Assist
BACSBoost Altitude Compensation System
BATBattery
BDCBottom Dead Center
B/LBi-Level
B/SBore-Stroke Ratio
BTDCBefore Top Dead Center
BVSVBimetallic Vacuum Switching Valve
Calif.California
CBCircuit Breaker
CCoCatalytic Converter For Oxidation
CDCompact Disc
CFCornering Force
CGCenter Of Gravity
CHChannel
COMB.Combination
CPECoupe
CPSCombustion Pressure Sensor
CPUCentral Processing Unit
CRSChild Restraint System
CTRCenter
C/VCheck Valve
CVControl Valve
Page 32 of 1202
IN-32
- INTRODUCTIONTERMS
32 Author: Date:
1996 TERCEL (RM440U) CW
Curb Weight
DCDirect Current
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLIDistributorless Ignition
DOHCDouble Over Head Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
EBDElectronic Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro-Deposited Coating
EDICElectric Diesel Injection Control
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGR-VMExhaust Gas Recirculation-Vacuum Modulator
ELREmergency Locking Retractor
ENGEngine
ESAElectronic Spark Advance
ETCSElectronic Throttle Control System
EVPEvaporator
E-VR VElectric Vacuum Regulating Valve
EXHExhaust
FEFuel Economy
FFFront-Engine Front-Wheel-Drive
F/GFuel Gage
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront-Engine Rear-Wheel-Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront-Wheel-Drive
GASGasoline
GSAGear Shift Actuator
GNDGround
HACHigh Altitude Compensator
Page 34 of 1202
IN-34
- INTRODUCTIONTERMS
34 Author: Date:
1996 TERCEL (RM440U) NA
Natural Aspiration
No.Number
O/DOverdrive
OEMOriginal Equipment Manufacturing
OHCOverhead Camshaft
OHVOverhead Valve
OPTOption
O/SOversize
P & BVProportioning And Bypass Valve
PCSPower Control System
PCVPositive Crankcase Ventilation
PKBParking Brake
PPSProgressive Power Steering
PSPower Steering
PTOPower Take-Of f
R & PRack And Pinion
R/BRelay Block
RBSRecirculating Ball Type Steering
R/FReinforcement
RFSRigid Front Suspension
RHRight-Hand
RHDRight-Hand Drive
RLYRelay
ROMRead Only Memory
RrRear
RRRear-Engine Rear-Wheel Drive
RRSRigid Rear Suspension
RWDRear-Wheel Drive
SDNSedan
SENSensor
SICSStarting Injection Control System
SMTSequential Manual Transmission
SOCState Of Charge
SOHCSingle Overhead Camshaft
SPECSpecification
SPISingle Point Injection
SRSSupplemental Restraint System
SSMSpecial Service Materials
SSTSpecial Service Tools
STDStandard
STJCold-Start Fuel Injection
SWSwitch
SYSSystem
T/ATransaxle
TACHTachometer
TBIThrottle Body Electronic Fuel Injection
Page 41 of 1202
- MAINTENANCEINSIDE VEHICLE
MA-3
41 Author: Date:
1996 TERCEL (RM440U)
13. ACCELERATOR PEDAL
Check the pedal for smooth operation and uneven pedal effort or catching.
14. CLUTCH PEDAL (See page CL-2)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper freeplay.
15. BRAKE PEDAL (See page BR-6)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and freeplay.
(c) Check the brake booster function.
16. BRAKES
At a safe place, check that the brakes do not pull to one side when applied.
17. PARKING BRAKE (See page BR-8)
(a) Check that the lever has the proper travel.
(b) On a safe incline, check that the vehicle is held securely with only the parking brake applied.
18. AUTOMATIC TRANSMISSION ºPARKº MECHANISM
(a) Check the lock release button of the selector lever for proper and smooth operation.
(b) On a safe incline, check that the vehicle is held securely with the selector lever in the P position and
all brakes released.
Page 42 of 1202
MA003-28
MA-4
- MAINTENANCEUNDER HOOD
42 Author: Date:
1996 TERCEL (RM440U)
UNDER HOOD
GENERAL MAINTENANCE
1. GENERAL NOTES
Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.
Every service item in the periodic maintenance schedule must be performed.
Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).
Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.
Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. WINDSHIELD WASHER FLUID
Check that there is sufficient fluid in the tank.
3. ENGINE COOLANT LEVEL
Check that the coolant level is between the FULL and LOW lines on the see-through reservoir.
4. RADIATOR AND HOSES
(a) Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs.
(b) Check the hoses for cracks, kinks, rot or loose connections.
5. BATTERY ELECTROLYTE LEVEL
Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case.
If level is low, add distilled water only.
6. BRAKE AND CLUTCH FLUID LEVELS
(a) Check that the brake fluid level is near the upper level line on the see-through reservoir.
(b) Check that the clutch fluid level is within ±5 mm (0.20 in.). of the reservoir hem.
7. ENGINE DRIVE BELTS
Check drive belt for fraying, cracks, wear or oiliness.
8. ENGINE OIL LEVEL
Check the level on the dipstick with the engine turned off.
9. POWER STEERING FLUID LEVEL
(a) Check the level.
(b) The level should be in the HOT or COLD range depending on the fluid temperature.
10. AUTOMATIC TRANSMISSION FLUID LEVEL
(a) Park the vehicle on a level surface.
(b) With the engine idling and the parking brake applied, shift the selector into all positions from the P to
L, and then shift into the P position.
(c) Turn and pull out the dipstick and wipe off the fluid with a clean rag. Reinsert the dipstick and check
that the fluid level is in the HOT range.
(d) Do this check with the fluid at normal driving temperature (70 - 80°C, 158 - 176°F).
If the If the level is at the low side, add fluid.
NOTICE:
Do not overfill.
HINT:
Wait until the engine cools down (approx. 30 min.) before checking the fluid level after extended driving at
high speeds, in hot weather, in heavy traffic or pulling a trailer.
11. EXHAUST SYSTEM
Visually inspect for cracks, holes or loose supports.
If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located
and corrected.
Page 44 of 1202
P19770
MA00S-13
MA-6
- MAINTENANCEBRAKE
44 Author: Date:
1996 TERCEL (RM440U)
BRAKE
INSPECTION
1. INSPECT BRAKE LINE PIPES AND HOSES
HINT:
Check in a well lighted area. Check the entire circumference
and length of the brake hoses using a mirror as required. Turn
the front wheels fully right or left before checking the front brake.
(a) Check all brake lines and hoses.
Check for damage.
Check for wear.
Check for deformation.
Check for cracks.
Check for corrosion.
Check for leaks.
Check for bends.
Check for twists.
(b) Check all clamps for tightness and connections for leak-
age.
(c) Check that the hoses and lines are clear of sharp edges,
moving parts and the exhaust system.
(d) Check that the lines installed in grommets pass through
the center of the grommets.
2. INSPECT FRONT BRAKE PADS AND DISCS (See page
BR-26)
HINT:
If a squealing or scraping noise comes from the brake during
driving, check the pad wear indicator to see if it is contacting the
disc. If so, the disc pad should be replaced.
3. INSPECT REAR BRAKE LININGS AND DRUMS (See
page BR-32)