Toyota Tercel 1996 User Manual

IN-1

INTRODUCTION - HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

IN00U-36

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 (Special 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:

Filler Cap

Float

Clevis Pin

Reservoir

Gasket

Clip

Boot

Grommet

Slotted Spring Pin

12 (120, 9)

Clevis

15 (155, 11)

Snap Ring

Washer

Lock Nut

Push Rod

Piston

Cylinder

N´m (kgf´cm, ft´lbf)

: Specified torque

Non-reusable part

N17080

1996 TERCEL (RM440U)

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IN-2

INTRODUCTION - HOW TO USE THIS MANUAL

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:

Illustration: what to do and where

Task heading : what to do

21. CHECK PISTON STROKE OF OVERDRIVE BRAKE

(a)Place SST and a dial indicator onto the overdrive brake piston as shown in the illustration.

SST 09350-30020 (09350-06120)

Set part No.

Component part No.

Detailed text : how to do task

(b)Measure the stroke applying and releasing the compressed air (392 785 kPa, 4 8 kgf/cm2 or 57 114 psi) as shown in the illustration.

Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in.)

Specification

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 information. 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 reference.

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)

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IN-3

INTRODUCTION - IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATION

IN07B-01

VEHICLE IDENTIFICATION AND ENGINE SERIAL NUMBER

A

B

N13014

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.

P01214

1996 TERCEL (RM440U)

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IN-4

INTRODUCTION - REPAIR INSTRUCTIONS

FI1066

Seal Lock Adhesive

Z11554

1996 TERCEL (RM440U)

REPAIR INSTRUCTIONS

IN0CO-12

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 inspection 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 other abrasive objects.

(5)Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installation. 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 º º 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.

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IN-5

INTRODUCTION - REPAIR INSTRUCTIONS

(3)Precoated parts are indicated in the component illustrations by the º º symbol.

(g)When necessary, use a sealer on gaskets to prevent leaks.

(h)Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.

(i)Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work procedure. A list of SST and SSM can be found in Preparation section in this manual.

	Medium Current Fuse and High Current Fuse	(j) When replacing fuses, be sure the new fuse has the cor-
		rect amperage rating. DO NOT exceed the rating or use
	Equal Amperage Rating
		one with a lower rating.

BE1367

Illustration	Symbol	Part Name	Abbreviation
		FUSE	FUSE
		MEDIUM CURRENT FUSE	M-FUSE
		HIGH CURRENT FUSE	H-FUSE
		FUSIBLE LINK	FL
		CIRCUIT BREAKER	CB
			V00076
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IN-6

INTRODUCTION - REPAIR INSTRUCTIONS

(k)Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper 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 electricity.)

		(2) To disconnect vacuum hoses, pull off the end, not
WRONG	CORRECT	the middle of the hose.

IN0253

WRONG CORRECT

IN0252

1996 TERCEL (RM440U)

(3)To pull apart electrical connectors, pull on the connector 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 electronic components, air filter and emission-related components from water.

(6)Never use an impact wrench to remove or install temperature switches or temperature sensors.

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IN-7

INTRODUCTION - REPAIR INSTRUCTIONS

(7)When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.

(8)When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak air.

	Example	(m) Installation and removal of vacuum hose:
		(1) When disconnecting vacuum hoses, use tags to
		identify how they should be reconnected to.
		(2) After completing a job, double check that the vacu-
		um hoses are properly connected. A label under the
		hood shows the proper layout.
		(n) Unless otherwise stated, all resistance is measured at an
		ambient temperature of 20°C (68°F). Because the resis-
	IN0002	tance may be outside specifications if measured at high
		temperatures immediately after the vehicle has been run-
		ning, measurement should be made when the engine has
		cooled down.

1996 TERCEL (RM440U)

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IN-8

INTRODUCTION - REPAIR INSTRUCTIONS

REPAIR INSTRUCTIONS

IN0II-01

VEHICLE LIFT AND SUPPORT LOCATIONS

Front

JACK POSITION
Front	Front crossmember
Rear	Rear axle beam

CAUTION:

Before jacking-up the front and rear, make sure the car is not carrying any extra weight.

PANTOGRAPH JACK POSITION

SUPPORT POSITION

Safety stand and swing arm type lift

Z14535

1996 TERCEL (RM440U)

IN-9

INTRODUCTION - FOR ALL OF VEHICLES

FOR ALL OF VEHICLES

IN07J-05

PRECAUTION

1.FOR VEHICLES EQUIPPED WITH SRS AIRBAG AND SEAT BELT PRETENSIONER

Negative Cable

BO4111

(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 sequence 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 correct procedure described in this manual.

(b)GENERAL NOTICE

(1)Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic 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 position and the negative (-) terminal cable is disconnected 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 negative (-) terminal cable from the battery, the SRS may deploy.)

When the negative (-) terminal cable is disconnected 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 finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-up power supply from another battery.

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IN-10

INTRODUCTION - FOR ALL OF VEHICLES

(3)Even in cases of a minor collision where the SRS does not deploy, the steering wheel pad (See page RS-9 ) and front passenger airbag assembly (See page RS-22 ) should be inspected.

(4)Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

(5)Before repairs, remove the airbag sensor if shocks are likely to be attached to the sensor during repairs.

(6)Never disassemble and repair the airbag sensor assembly, steering wheel pad or front passenger airbag.

(7)If the airbag sensor assembly, steering wheel pad or front passenger airbag have been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones.

(8)Do not directly expose the airbag sensor assembly, steering wheel pad or front passenger airbag to hot air or flames.

(9)Use a volt/ohmmeter with high impedance (10 kΩ/V minimum) for troubleshooting of the electrical circuit.

(10)Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.

(11)After work is completed, check the SRS warning light for the supplemental restraint system (See page DI-148 ).

(c)SPIRAL CABLE (in Combination Switch)

The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may result. Refer to RS-19 of this manual concerning correct steering wheel installation.

Match Marks

R09725

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IN-1 1

INTRODUCTION - FOR ALL OF VEHICLES

(d)STEERING WHEEL PAD (with Airbag)

(1)When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up.

Storing the pad with its metallic surface facing upward may lead to a serious accident if the airbag deploys for some reason. In addition do not store a steering wheel pad on top of another one.

(2)Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.)

(3)Grease should not be attached to the steering wheel pad and the pad should not be cleaned with detergents of any kind.

(4)Store the steering wheel pad where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.

(5)When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work.

(6)When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page RS-1 1).

Perform the operation in a safe place away from electrical noise.

Example:

CORRECT WRONG

Z13953

Example:

Z13950

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IN-12

INTRODUCTION - FOR ALL OF VEHICLES

(e)FRONT PASSENGER AIRBAG ASSEMBLY

(1)Always store a removed or new front passenger airbag assembly with the airbag deployment direction facing up.

Storing the airbag assembly with the airbag deployment direction facing down could cause a serious accident if the airbag deploys.

(2)Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.)

(3)Grease should not be attached to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind.

(4)Store the airbag assembly where the ambient temperature remains below 93°C (200°F), without high humidity and away from electrical noise.

(5)When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work.

(6)When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal (See page RS-24 ).

Perform the operation in a safe place away from electrical noise.

Example:

CORRECT

WRONG

Z13952

Example:

Z13951

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IN-13

INTRODUCTION - FOR ALL OF VEHICLES

(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 sensor mounted on the floor. If the connectors are connected or disconnected while the airbag sensor assembly is not mounted to the floor, it could cause undesired deployment of the supplemental restraint system.

(3)Work must be started after 90 seconds from the time the ignition switch is turned to the ºLOCKº position and the negative (-) terminal cable is disconnected 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 assembly. The wires for the SRS wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page RS-37 .

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IN-14

INTRODUCTION - FOR ALL OF VEHICLES

2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION:

If large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer.

(a)Use only unleaded gasoline.

(b)Avoid prolonged idling.

Avoid running the engine at idle speed for more than 20 minutes.

(c)Avoid spark jump test.

(1)Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.

(2)While testing, never race the engine.

(d)Avoid prolonged engine compression measurement.

Engine compression tests must be done as rapidly as possible.

(e)Do not run engine when fuel tank is nearly empty.

This may cause the engine to misfire and create an extra load on the converter.

(f)Avoid coasting with ignition turned off.

(g)Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

3.IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM

For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions.

(1)Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic system.

(2)Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the vehicle's electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component.

(3)Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses.

(4)Check that the antenna and feeder are correctly adjusted.

(5)Do not install powerful mobile communications system.

4.FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER

CAUTION:

Observe the following items for safety reasons:

Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool's instruction book or TOYOTA hand-held tester's operator manual should be read thoroughly.

Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA handheld tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.)

Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or TOYOTA hand-held tester.

1996 TERCEL (RM440U)

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INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED	IN-15
SYSTEMS

HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS

IN07E-05

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.

	System	Page
1.	Engine	DI-1
2.	Anti-Lock Brake System	DI-109
3.	Supplemental Restraint System	DI-146
4.	Power Door Lock Control System	DI-190
5.	Theft Deterrent System	DI-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 (Bus line) 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.

1996 TERCEL (RM440U)

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IN-16	INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED
	SYSTEMS

IN07F-06

HOW TO PROCEED WITH TROUBLESHOOTING

Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic procedure is shown. Details are provided in Diagnostics section, showing the most effective methods for each circuit. Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit.

Vehicle Brought to Workshop

1

1Customer Problem Analysis

2Symptom Confirmation and Diagnostic Trouble Code Check

Ask the customer about the conditions and the environment when the problem occurred.

3

Symptom Simulation

2, 3

4

6

7

8

Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes.

(When the problem symptoms do not appear during confirmation, use the symptom simulation method described later on.)

Diagnostic Trouble

Code Chart

5

Problem Symptoms Table

Circuit Inspection or Parts Inspection

Repair

Confirmation Test

End

4, 5, 6

Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part which should be checked using the diagnostic trouble code chart or the problem symptoms table.

7

Check and repair the affected system or part in accordance with the instructions in Step 6.

8

After completing repairs, confirm that the problem has been eliminated.

(If the problem is not reproduced, perform the confirmation test under the same conditions and in the same environment as when it occurred for the first time.)

1996 TERCEL (RM440U)

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED	IN-17
SYSTEMS

1.CUSTOMER PROBLEM ANALYSIS

In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgment. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.

Important Point in the Problem Analysis:

The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in Diagnostics section for each system for your use.

Important Points in the Customer Problem Analysis

What ----- Vehicle model, system name

When ----- Date, time, occurrence frequency

Where ----- Road conditions

Under what conditions? ----- Running conditions, driving conditions, weather conditions

How did it happen? ----- Problem symptoms

(Sample) Engine control system check sheet.

CUSTOMER PROBLEM ANALYSIS CHECK

ENGINE CONTROL SYSTEM Check Sheet			Inspector's
			Name
Customer's Name				Model and Model
				Year
Driver's Name				Frame No.
Data Vehicle				Engine Model
Brought in
License No.				Odometer Reading	km
					miles

Problem Symptoms

Engine does

Engine does not crank

No initial combustion

No complete combustion

not Start

Difficult to

Engine cranks slowly

Start

Other

Poor Idling

Incorrect first idle

Idling rpm is abnormal

High (

rpm)

Low (

rpm)

Rough idling

Other

Poor

Hesitation

Back fire

Muffler explosion (after-fire)

Surging

Drive ability

Knocking

Other

Soon after starting

After accelerator pedal depressed

Engine Stall

After accelerator pedal released

During A/C operation

Shifting from N to D

Other

Others

Data Problem

Constant

Sometimes (

times per

day/month)

1996 TERCEL (RM440U)

IN-18	INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED
	SYSTEMS

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.

	System	Diagnostic Trouble	Input Signal Check	Diagnostic Test
		Code Check	(Sensor Check)	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 diagnostic 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.

DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE

	Diagnostic Trouble	Confirmation	Diagnostic Trouble	Problem Condition
	Code Check (Make a
		of Symptoms	Code Check
	note of and then clear)
	Diagnostic Trouble	Problem symptoms	Same diagnostic	Problem is still occurring in the diagnostic
	Code Display	exist	trouble code is	circuit
			displayed
			Normal code is	The problem is still occurring in a place
			displayed	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		The problem occurred in the diagnostic
		symptoms exist		circuit in the past
	Normal Code Display	Problem symptoms	Normal code is	The problem is still occurring in a place
		exist	displayed	other than in the diagnostic circuit
		No problem	Normal code is	The problem occurred in a place other
		symptoms exist	displayed	than in the diagnostic circuit in the past

1996 TERCEL (RM440U)

INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED	IN-19
SYSTEMS

Taking into account the points on the previous page, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utilize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnostic trouble code troubleshooting or to troubleshooting of problem symptoms table.

Diagnostic trouble code check

Making a note of and clearing of the diagnostic trouble codes displayed

Symptom confirmation

	Problem symptoms		No problem symptoms
			exist
	exist
		Simulation test using the symptom
		simulation methods

Diagnostic trouble code check

Diagnostic trouble code displayed

Problem symptoms exist

Troubleshooting of problem indicated by diagnostic trouble code

Normal code displayed

Problem symptoms exist

Troubleshooting of each problem symptom

Normal code displayed

No problem symptoms exist

System Normal

If a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire harness and connectors (See page IN-26 ).

1996 TERCEL (RM440U)

IN-20	INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED
	SYSTEMS

3.SYMPTOM SIMULATION

The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter how much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong guess somewhere, which will only lead to a standstill. For example, for a problem which only occurs when the engine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the problem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the external causes are applied to the vehicle in a stopped condition.

Important Points in the Symptom Simulation Test:

In the symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To do this, narrow down the possible problem circuits according to the symptoms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom.

1 VIBRATION METHOD: When vibration seems to be the major cause.

CONNECTORS

Slightly shake the connector vertically and horizontally.

Shake Slightly

WIRE HARNESS

Slightly shake the wire harness vertically and horizontally. The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thoroughly.

PARTS AND SENSOR

Apply slight vibration with a finger to the part of the sensor considered to be the problem cause and check that the malfunction occurs.

HINT:

Applying strong vibration to relays may result in open relays.

Swing Slightly

Vibrate Slightly

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2 HEAT METHOD: When the problem seems to occur when the suspect area is heated.

Heat the component that is the likely cause of the malfunction with a hair dryer or similar object. Check to see if the malfunction occurs.

NOTICE:

(1)Do not heat to more than 60°C (140°F). (Temperature is limited not to damage the components.)

(2)Do not apply heat directly to parts in the ECU.

M a l f u n c- tion

3 WATER SPRINKLING METHOD: When the malfunction seems to occur on a rainy day or in a high-humidity condition.

Sprinkle water onto the vehicle and check to see if the malfunction occurs.

NOTICE:

(1)Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface.

(2)Never apply water directly onto the electronic components.

HINT:

If a vehicle is subject to water leakage, the leaked water may contaminate the ECU. When testing a vehicle with a water leakage problem, special caution must be taken.

4 OTHER: When a malfunction seems to occur when electrical load is excessive.

Turn on all electrical loads including the heater blower, head	ON
lights, rear window defogger, etc. and check to see if the mal-
function occurs.

B02389

B02390

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	SYSTEMS

4.DIAGNOSTIC TROUBLE CODE CHART

The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshooting using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with troubleshooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example.

DTC No.

Indicates the diagnostic trouble code.

Page or Instructions

Indicates the page where the inspection procedure for each circuit is to be found, or gives instructions for checking and repairs.

Trouble Area

Indicates the suspect area of the problem.

Detection Item

Indicates the system of the problem or contents of the problem.

DIAGNOSTIC TROUBLE CODE CHART

HINT:

Parameters listed in the chart may not be exactly the same as your reading due to the type of instrument or other factors.

If a malfunction code is displayed during the DTC check mode, check the circuit for the code listed in the table below. For details of each code, turn to the page referred to under the ºSee pageº for the respective ºDTC No.º in the DTC chart.

SAE CONTROLLED

	DTC No.		Detection Item	Trouble Area	MIL*	Memory
	(See page)
	P0100			Open or short in mass air flow meter circuit
			Mass Air Flow Circuit Malfunction	Mass air flow meter
	(DI-24)
				ECM
	P0101		Mass Air Flow Circuit	Mass air flow meter
	(DI-28)		Range/ Performance Problem
				Open or short in intake air temp. sensor
	P0110		Intake Air Temp. Circuit	circuit
	(DI-29)		Malfunction	Intake air temp. sensor
				ECM
	P0115		Engine Coolant Temp.	Open or short in engine coolant temp. sensor circuit
				Engine coolant temp. sensor
	(DI-33)		Circuit Malfunction
				ECM
	P0116		Engine Coolant Temp.	Engine coolant temp. sensor
	(DI-37)		Circuit Range/ Performance Problem	Cooling system
			Throttle/ Pedal Position Sensor/Switch	Open or short in throttle position sensor circuit
				Throttle position sensor
			ºAº Circuit Malfunction
				ECM
			Throttle/ Pedal Position Sensor/ Switch
			ºAº Circuit Range / Performance Prob-	Throttle position sensor
			lem

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SYSTEMS

5.PROBLEM SYMPTOMS TABLE

The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot the problem when a ºNormalº code is displayed in the diagnostic trouble code check but the problem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked.

HINT:

When the problem is not detected by the diagnostic system even though the problem symptom is present, it is considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system.

Page

Indicates the page where the flow chart for each circuit is located.

Circuit Inspection, Inspection Order

Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers.

Problem Symptom	Circuit or Part Name
	Indicates the circuit or part which needs to be checked.

PROBLEM SYMPTOMS TABLE

	Symptom				Suspected Area				See page
	Engine does not crank (Does not start)			1. Starter and starter relay					ST-2
									ST-17
				1. ECM power source circuit					DI-147
	No initial combustion (Does not start)			2. Fuel pump control circuit					DI-151
				3. ECM					IN-29
	No complete combustion (Does not start)			1. Fuel pump control circuit					DI-151
				1. Starter signal circuit					DI-144
	Engine cranks normally (Difficult to start)			2. Fuel pump control circuit					DI-151
				3. Compression					EM-3
	Cold engine (Difficult to start)			1.	Starter signal circuit				DI-144
									DI-151
				2.	Fuel pump control circuit
	Hot engine			1.	Starter signal circuit				DI-144
				2.	Fuel pump control circuit				DI-151
	High engine idle speed (Poor idling)			1.	A/C signal circuit (Compressor circuit)				AC-88
				2.	ECM power source circuit
		idling)		1.	A/C signal circuit
				2.	Fuel pump control circuit
				1. Compression
				2.	Fuel pump control circuit

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6.CIRCUIT INSPECTION

How to read and use each page is shown below.

Diagnostic Trouble Code No. and Detection Item

Circuit Description

The major role and operation, etc. of the circuit and its component parts are explained.

DTC	P0325		Knock 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
	No knock sensor 1 signal to ECM with engine speed,		Open or short in knock sensor1 circuit
P0325			Knock sensor 1 (looseness)
	1,200 rpm or more.
			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.

WIRING DIAGRAM

ECM

Knock Sensor 1

GR	12 KNK
	E6

E1

Indicates the diagnostic trouble code, diagnostic trouble code set parameter and suspect area of the problem.

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.

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Indicates the position of the ignition switch during the check.

LOCK	ON

Ignition Switch LOCK (OFF)	Ignition Switch ON
START	ACC
Ignition Switch START	Ignition Switch ACC

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.

INSPECTION PROCEDURE

1 Check continuity between terminal KNK of ECM connector and body ground.

LOCK		PREPARATION:
KNK		(a) Remove the glove compartment (See page SF-68).
		(b) Disconnect the E6 connector from the ECM.
		CHECK:
		Measure the resistance between terminal KNK of the ECM connec-
		tor and body ground.
	E6 Connector	OK:
AB0117			Resistance: 1 MΩ or higher
A00265	A00255
		OK	Go to step 3.
NG

2 Check knock sensor (See page SF-61).

OK	Replace knock sensor.

Indicates the place to check the voltage or resistance.

Indicates the connector position to checked, from the front or back side.

Wire Harness

Check from the connector back side. (with harness)

Check from the connector front side. (without harness) In this case, care must be taken not to bend the terminals.

Indicates the condition of the connector of ECU during the check.	KNK
KNK

E6 Connector

E6 Connector

Connector being checked is connected.

Connector being checked is disconnected.

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	SYSTEMS

IN05X-13

FI0046

FI0047

FI0048

HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE

1.CONNECTOR CONNECTION AND TERMINAL IN-

SPECTION

For troubleshooting, diagnostic trouble code charts or problem symptom table are provided for each circuit with detailed inspection procedures on the following pages.

When all the component parts, wire harnesses and connectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is performed without the problem symptoms occurring, refer to Step 8 to replace the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method.

The instructions ºCheck wire harness and connectorº and

ºCheck and replace ECUº which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear.

OPEN CIRCUIT:

This could be due to a disconnected wire harness, faulty contact in the connector, a connector terminal pulled out, etc. HINT:

It is rarely the case that a wire is broken in the middle of it. Most cases occur at the connector. In particular, carefully check the connectors of sensors and actuators

Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a deformation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no abnormality is found in the wire harness and connector

check, but the problem disappears after the check, then the cause is considered to be in the wire harness or connectors.

SHORT CIRCUIT:

This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT:

When there is a short circuit between the wire harness and body ground, check thoroughly whether the wire harness is caught in the body or is clamped properly.

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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.

FI7187

	Sensor Side	ECU Side	3.	CONTINUITY CHECK (OPEN CIRCUIT CHECK)
			(a)	Disconnect the connectors at both ECU and sensor
				sides.

IN0379

	ECU Side	(b) Measure the resistance between the applicable terminals
		of the connectors.
Sensor Side		Resistance: 1 Ω or less
		HINT:
		Measure the resistance while lightly shaking the wire harness
		vertically and horizontally.

IN0378

ECU Side

Sensor Side

IN0380

Pull Lightly

Looseness of Crimping

IN0381

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 MΩ 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.

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Fig. 1

					ECU
	Sensor	C OPEN		B	A
		1	1	1	1
		2	2	2	2

Z17004

(d)Prepare a test male terminal and insert it in the female ter-

minal, then pull it out.

NOTICE:

When testing a gold-plated female terminal, always use a gold-plated male terminal.

HINT:

When the test terminal is pulled out more easily than others, there may be poor contact in that section.

6.CHECK OPEN CIRCUIT

For the open circuit in the wire harness in Fig. 1, perform º(a) Continuity Checkº or º(b) Voltage Checkº to locate the section.

Fig. 2

ECU

	Sensor	C	B	A
				1
		1	1
		2	2	2

Z17005

(a)Check the continuity.

(1)Disconnect connectors ºAº and ºCº and measure the resistance between them.

In the case of Fig. 2:

Between terminal 1 of connector ºAº and terminal 1 of connector ºCº → No continuity (open)

Between terminal 2 of connector ºAº and terminal 2 of connector ºCº → Continuity

Therefore, it is found out that there is an open circuit between terminal 1 of connector ºAº and terminal 1 of connector ºCº.

Fig. 3

ECU

Sensor

C	B2	1 B1	A
1	1	1	1
2	2	2	2

B04722

(2)Disconnect connector ºBº and measure the resistance between the connectors.

In the case of Fig. 3:

Between terminal 1 of connector ºAº and terminal 1 of connector ºB1º → Continuity

Between terminal 1 of connector ºB2º and terminal 1 of connector ºCº → No continuity (open)

Therefore, it is found out that there is an open circuit between terminal 1 of connector ºB2º and terminal 1 of connector ºCº.

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Fig. 4

					5V
Sensor	0V
					A
	C			B 1		5V
			5V
1					1
2				2	2

Z17007

(b)Check the voltage.

In a circuit in which voltage is applied (to the ECU connector terminal), an open circuit can be checked for by conducting a voltage check.

As shown in Fig. 4, with each connector still connected, measure the voltage between body ground and terminal 1 of connector ºAº at the ECU 5V out-

put terminal, terminal 1 of connector ºBº, and terminal 1 of connector ºCº, in that order.

If the results are:

5V: Between Terminal 1 of connector ºAº and Body Ground 5V: Between Terminal 1 of connector ºBº and Body Ground 0V: Between Terminal 1 of connector ºCº and Body Ground Then it is found out that there is an open circuit in the wire harness between terminal 1 of ºBº and terminal 1 of ºCº.

Fig. 5

C	SHORT B	A
1	1	1
2	2	2

Z17008

7.CHECK SHORT CIRCUIT

If the wire harness is ground shorted as in Fig. 5, locate the section by conducting a ºcontinuity check with groundº.

Fig. 6

ECU

	Sensor	C	B	A
		1	1	1
		2	2	2

Z17009

Check the continuity with ground.

(1)Disconnect connectors ºAº and ºCº and measure the resistance between terminal 1 and 2 of connector ºAº and body ground.

In the case of Fig. 6:

Between terminal 1 of connector ºAº and body ground → Continuity (short)

Between terminal 2 of connector ºAº and body ground → No continuity

Therefore, it is found out that there is a short circuit between terminal 1 of connector ºAº and terminal 1 of connector ºCº.

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Fig. 7

ECU

	Sensor	C	B2	B1	A
		1	1	1	1
		2	2	2	2

Z17808

(2)Disconnect connector ºBº and measure the resistance between terminal 1 of connector ºAº and body ground, and terminal 1 of connector ºB2º and body ground.

In the case of Fig. 7:

Between terminal 1 of connector ºAº and body ground → No continuity

Between terminal 1 of connector ºB2º and body ground → Continuity (short)

Therefore, it is found out that there is a short circuit between terminal 1 of connector ºB2º and terminal 1 of connector ºCº.

8.CHECK AND REPLACE ECU

First check the ECU ground circuit. If it is faulty, repair it. If it is normal, the ECU could be faulty, so replace the ECU with a normal functioning one and check that the symptoms appear.

(1) Measure the resistance between the ECU ground

Example

terminal and the body ground.

Resistance: 1 Ω or less

Ground

IN0383

ECU Side

Ground

W/H Side

Ground

IN0384

(2)Disconnect the ECU connector, check the ground terminals on the ECU side and the wire harness side for bend and check the contact pressure.

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