lock 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 1 of 1202
IN00U-36
N17080
Filler Cap
Float
Reservoir
Grommet
Clip
Slotted Spring Pin
: Specified torque
Non-reusable partCylinder
Piston
Push Rod
Washer
Snap Ring
Boot
Gasket
Lock Nut
Clevis Pin
Clevis
N´m (kgf´cm, ft´lbf)
12 (120, 9)
15 (155, 11)
- INTRODUCTIONHOW TO USE THIS MANUAL
IN-1
1 Author: Date:
1996 TERCEL (RM440U)
HOW TO USE THIS MANUAL
GENERAL INFORMATION
1. INDEX
An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you
in finding your way through the manual, the section title and major heading are given at the top of every page.
2. PRECAUTION
At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained
in that section.
Read these precautions before starting any repair task.
3. TROUBLESHOOTING
TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the
cause. The fundamentals of how to proceed with troubleshooting are described on page IN-16.
Be sure to read this before performing troubleshooting.
4. PREPARATION
Preparation lists the SST (Special Service Tools), recommended tools, equipment, lubricant and SSM (Spe-
cial Service Materials) which should be prepared before beginning the operation and explains the purpose
of each one.
5. REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It identifies the components and shows how the
parts fit together.
Example:
Page 3 of 1202
IN07B-01
N13014
B A
P01214
- INTRODUCTIONIDENTIFICATION INFORMATION
IN-3
3 Author: Date:
1996 TERCEL (RM440U)
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION AND
ENGINE SERIAL NUMBER
1. VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is stamped on the vehicle
identification number plate and the certification label, as shown
in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
2. ENGINE SERIAL NUMBER
The engine serial number is stamped on the engine block, as
shown in the illustration.
Page 4 of 1202
IN0CO-12
FI1066
Z11554
Seal Lock Adhesive
IN-4
- INTRODUCTIONREPAIR INSTRUCTIONS
4 Author: Date:
1996 TERCEL (RM440U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order
to facilitate reassembly.
(c) Installation and removal of battery terminal:
(1) Before performing electrical work, disconnect the
negative (-) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in-
spection or repair, first disconnect the negative (-)
terminal cable.
(3) When disconnecting the terminal cable, to prevent
damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a
clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after
loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is
properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non-reusable parts
(1) Always replace cotter pins, gaskets, O-rings, oil
seals, etc. with new ones.
(2) Non-reusable parts are indicated in the component
illustrations by the ºº symbol.
(f) Precoated parts
Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened or
caused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
Page 9 of 1202
IN07J-05
BO4111
Negative Cable
- INTRODUCTIONFOR ALL OF VEHICLES
IN-9
9 Author: Date:
1996 TERCEL (RM440U)
FOR ALL OF VEHICLES
PRECAUTION
1. FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND
SEAT BELT PRETENSIONER
(a) The TERCEL is equipped with an SRS (Supplemental
Restraint System), such as the driver airbag and front
passenger airbag.
Failure to carry out service operations in the correct se-
quence could cause the supplemental restraint system to
unexpectedly deploy during servicing, possibly leading to
a serious accident.
Further, if a mistake is made in servicing the supplemental
restraint system, it is possible the SRS may fail to operate
when required. Before servicing (including removal or
installation of parts, inspection or replacement), be sure
to read the following items carefully, then follow the cor-
rect procedure described in this manual.
(b) GENERAL NOTICE
(1) Malfunction symptoms of the supplemental re-
straint system are difficult to confirm, so the diag-
nostic trouble codes become the most important
source of information when troubleshooting. When
troubleshooting the supplemental restraint system,
always inspect the diagnostic trouble codes before
disconnecting the negative (-) terminal cable from
the battery (See page DI-148).
(2) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery.
(The supplemental restraint system is equipped
with a back-up power source so that if work is
started within 90 seconds of disconnecting the neg-
ative (-) terminal cable from the battery, the SRS
may deploy.)
When the negative (-) terminal cable is discon-
nected from the battery, memory of the clock and
audio systems will be cancelled. So before starting
work, make a record of the contents memorized by
the each memory system. Then when work is fin-
ished, reset the clock and audio systems as before.
To avoid erasing the memory of each memory sys-
tem, never use a back-up power supply from anoth-
er battery.
Page 13 of 1202
- INTRODUCTIONFOR ALL OF VEHICLES
IN-13
13 Author: Date:
1996 TERCEL (RM440U)
(f) AIRBAG SENSOR ASSEMBLY
(1) Never reuse the airbag sensor assembly involved
in a collision when the SRS has deployed.
(2) The connectors to the airbag sensor assembly
should be connected or disconnected with the sen-
sor mounted on the floor. If the connectors are con-
nected or disconnected while the airbag sensor as-
sembly is not mounted to the floor, it could cause
undesired deployment of the supplemental re-
straint system.
(3) Work must be started after 90 seconds from the
time the ignition switch is turned to the ºLOCKº posi-
tion and the negative (-) terminal cable is discon-
nected from the battery, even if only loosing the set
bolts of the airbag sensor assembly.
(g) WIRE HARNESS AND CONNECTOR
The SRS wire harness is integrated with the instrument
panel wire harness assembly and floor wire harness as-
sembly. The wires for the SRS wire harness are encased
in a yellow corrugated tube. All the connectors for the sys-
tem are also a standard yellow color. If the SRS wire har-
ness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it as
shown on page RS-37.
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 24 of 1202
V08423 Knock Sensor 1
GRECM
KNK
E1 12
E6
WIRING DIAGRAM
Wiring Diagram
This shows a wiring diagram of the circuit.
Use this diagram together with ELECTRICAL
WIRING DIAGRAM to thoroughly understand the
circuit.
Wire colors are indicated by an alphabetical code.
B = Black, L = Blue, R = Red, BR = Brown,
LG = Light Green, V = Violet, G = Green,
O = Orange, W = White, GR = Gray, P = Pink,
Y = Yellow, SB = Sky Blue
The first letter indicates the basic wire color and
the second letter indicates the color of the stripe.
DTC P0325Knock Sensor 1 Circuit Malfunction
CIRCUIT DESCRIPTION
Knock sensor is fitted to the cylinder block to detect engine knocking. This sensor contains a piezoelectric element which
generates a voltage when it becomes deformed, which occurs when the cylinder block vibrates due to knocking. If engine
knocking occurs, ignition timing is retarded to suppress it.
DTC No. DTC Detection Condition Trouble Area
P0325No knock sensor 1 signal to ECM with engine speed,
1,200 rpm or more. Open or short in knock sensor1 circuit
Knock sensor 1 (looseness)
ECM
If the ECM detects the above diagnosis conditions, it operates the fall safe function in which the corrective retard angle
value is set to the maximum value.
Diagnostic Trouble Code No. and Detection Item
Circuit Description
The major role and operation, etc. of the circuit
and its component parts are explained.
Indicates the diagnostic trouble code, diagnostic
trouble code set parameter and suspect area of
the problem.
IN-24
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMS
1996 TERCEL (RM440U)
6. CIRCUIT INSPECTION
How to read and use each page is shown below.
Page 25 of 1202
V08425
LOCK
KNK
E6 Connector
(a) Remove the glove compartment (See page SF-68).
(b) Disconnect the E6 connector from the ECM.
INSPECTION PROCEDURE
Replace knock sensor. 1 Check continuity between terminal KNK of ECM connector and body ground.
OK:
Check knock sensor (See page SF-61).Measure the resistance between terminal KNK of the ECM connec-
tor and body ground.
Resistance: 1 MW or higher
Connector being checked is connected. Indicates the condition of the connector of ECU during the check.
PREPARATION:
CHECK:
2Go to step 3.
OK OK
NG
Indicates the position of the ignition switch during the check.
Check from the connector back side.
(with harness)
Ignition Switch LOCK (OFF)
Ignition Switch START
LOCKIgnition Switch ON
Ignition Switch ACC
STARTON
ACC
Indicates the place to check the voltage or resistance.
Indicates the connector position to checked, from the front or back side.
Connector being checked is disconnected. Check from the connector front side. (without harness)
In this case, care must be taken not to bend the terminals.
E6 Connector KNKWire Harness
E6 Connector KNK
A00255 AB0117
A00265
Inspection Procedure
Use the inspection procedure to determine if
the circuit is normal or abnormal, and, if it is
abnormal, use it to determine whether the
problem is located in the sensors, actuators,
wire harness or ECU.
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-25
1996 TERCEL (RM440U)
Page 27 of 1202
FI7187
IN0379
Sensor Side
ECU Side
IN0378
Sensor SideECU Side
IN0380
Sensor SideECU Side
IN0381
Pull Lightly
Looseness of Crimping
- INTRODUCTIONHOW TO TROUBLESHOOT ECU CONTROLLED
SYSTEMSIN-27
1996 TERCEL (RM440U)
2. CONNECTOR HANDLING
When inserting tester probes into a connector, insert them from
the rear of the connector. When necessary, use mini test leads.
For water resistant connectors which cannot be accessed from
behind, take good care not to deform the connector terminals.
3. CONTINUITY CHECK (OPEN CIRCUIT CHECK)
(a) Disconnect the connectors at both ECU and sensor
sides.
(b) Measure the resistance between the applicable terminals
of the connectors.
Resistance: 1 W or less
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
4. RESISTANCE CHECK (SHORT CIRCUIT CHECK)
(a) Disconnect the connectors on both ends.
(b) Measure the resistance between the applicable terminals
of the connectors and body ground. Be sure to carry out
this check on the connectors on both ends.
Resistance: 1 MW or higher
HINT:
Measure the resistance while lightly shaking the wire harness
vertically and horizontally.
5. VISUAL CHECK AND CONTACT PRESSURE CHECK
(a) Disconnect the connectors at both ends.
(b) Check for rust or foreign material, etc. in the terminals of
the connectors.
(c) Check crimped portions for looseness or damage and
check that the terminals are secured in lock portion.
HINT:
The terminals should not come out when pulled lightly from the
back.