filter TOYOTA TERCEL 1996 Service Owner's Manual

P20392
SST
MF-6
- MFIFUEL PUMP
530 Author
: Date
:
1996 TERCEL (RM440U)
(d) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and union bolt.
SST 09268-45012
Torque: 29.0 N´m (290 kgf´cm, 22 ft´lbf)
(e) Wipe off any splattered gasoline.
(f) Reconnect the negative (-) terminal cable to the battery.
(g) Connect the TOYOTA hand-held tester to the DLC3 (See
step 1 check fuel pump operation (a) to (f)).
(h) Turn the ignition switch ON.
(i) Measure the fuel pressure.
Fuel pressure:
281 - 287 kPa
(2.87 - 2.93 kgf/cm
2, 40.8 - 41.7 psi)
If pressure is high, replace the fuel pressure regulator.
(j) If pressure is low, check these parts:

Fuel hoses and connection

Fuel pump

Fuel filter

Fuel pressure regulator
(k) Remove the TOYOTA hand-held tester from the DLC3.
(l) Reinstall the fuse cover on instrument panel.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator.
(o) Measure the fuel pressure at idle.
Fuel pressure:
281 - 287 kPa (2.87 - 2.93 kgf/cm
2, 40.8 - 41.7 psi)
(p) Reconnect the vaccum sensing hose to the fuel pressure
regulator plug the hose end.
(q) Measure the fuel pressure at idle.
Fuel pressure:
226 - 265 kPa (2.3 - 2.6 kgf/cm
2, 33 - 37 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(r) Stop the engine.
(s) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injector.
(t) After checking fuel pressure, disconnect the negative (-)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268-45012
(u) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.

SF1PS-02
- MFIFUEL PUMP
MF-9
1996 TERCEL (RM440U)
REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER
3. DISCONNECT FUEL PUMP AND SENDER GAUGE
CONNECTOR
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page MF-1).
4. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM
FUEL TANK
CAUTION:
Remove the fuel filler cap to prevent the fuel from flowing
out.
(a) Using SST, disconnect the outlet pipe from the pump
bracket.
HINT:
At the time of installation, plaese refer to the following items. Us-
ing SST.
SST 09631-22020
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf) for use with SST
(See page MF-1)
(b) Remove the 8 bolts.
Torque: 3.4 N´m (35 kgf´cm, 31 in.´lbf)
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page MF-1).
(c) Disconnect the return hoses from the pump bracket.
(d) Pull out the pump bracket assembly.
NOTICE:

Do not damage the fuel pump filter.

Be careful that the arm of the sender gauge should
not bent.

SF1PT-01
MF-10
- MFIFUEL PUMP
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE FUEL CUTOFF VALVE FROM FUEL PUMP
BRACKET
Remove the 2 screws, retainer, fuel cut-off valve and gasket.
HINT:
At the time of installation, plaese refer to the following items.
Install a new gaskt.
Torque: 1.5 N´m (15 kgf´cm, 13 )in.´lbf
2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP
BRACKET
(a) Remove the screw and disconnect the lead wire from the
pump bracket.
(b) Disconnect the 3 lead wires.
(c) Remove the 2 screws and sender gauge.
3. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Pull out the lower side of the fuel pump from the pump
bracket.
(b) Disconnect the connector from the fuel pump.
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
(d) Remove the rubber cushion from the fuel pump.
4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
HINT:
At the time of installation, plaese refer to the following items.
Install the pump filter with a new clip.
(b) Pull out the pump filter.

SF1PV-02
P20397
Union Bolt
Gasket
SST (Hose)
Fuel Filter
(On Vehicle) SST (Union)
- MFIINJECTOR
MF-19
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION:
Keep injector clean of sparks during the test.
(a) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
(b) Connect SST (union and hose) to the fuel filter outlet with
2 gaskets and union bolts.
SST 09268-41046 (90405-09015)
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf)
(c) Remove the pressure regulator from the delivery pipe
(See page MF-14).
(d) Install a O-ring to the fuel inlet of pressure regulator.
(e) Connect SST (hose) to the fuel inlet of the pressure regu-
lator with SST (union) and the 2 bolts.
SST 09268-41046 (09268-41091)
Torque: 8.0 N´m (80 kgf´cm, 69 ft´lbf)
(f) Connect the fuel return hose to the fuel outlet of the pres-
sure regulator.
CAUTION:
Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(g) Remove the fuse cover on the instrument panel.

- MFIINJECTOR
MF-21
1996 TERCEL (RM440U)
SST 09268-41046, 09842-30070, 09843-18020
(d) Reinstall the pressure regulator to the delivery pipe (See
page MF-15).
(e) Reconnect the fuel inlet hose to the fuel filter outlet with
2 new gaskets and the union bolt.
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf)
(f) Turn the ignition switch OFF.
(g) Disconnect the TOYOTA hand- held tester from the
DLC3.
(h) Reinstall the fuse cover on the instrument panel.

LU08A-06
LU1169
Oil Pressure Gauge
Oil Pressure Switch
LU1107
Adhesive
- LUBRICATIONOIL AND FILTER
LU-1
616 Author
: Date
:
1996 TERCEL (RM440U)
OIL AND FILTER
INSPECTION
1. CHECK ENGINE OIL QUALITY
Check the oil for deterioration, entry of water, discoloring or thin-
ning.
If the oil quality is visibly poor, replace it.
Oil grade:
API grade or SH Energy-Conserving II or ILSAC multi-
grade engine oil. Recommended viscosity is as
shown in the illustration, with SAE 5W-30 being the
prefferred engine oil.
2. CHECK ENGINE OIL LEVEL
The oil level should be between the ºLº and ºFº marks on the dip-
stick.
If low, check for leakage and add oil up to the ºFº mark.
3. REMOVE OIL PRESSURE SWITCH AND INSTALL OIL
PRESSURE GAUGE
(a) Remove the bolt and air intake connector.
(b) M/T only
Remove the 3 bolts, release cylinder and tube from the
transaxle.
(c) Remove the oil pressure switch.
(d) Install the oil pressure gauge.
4. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
5. CHECK OIL PRESSURE
Oil pressure:
At idle speed
29 kPa (0.3 kgf/cm
2, 4.3 psi) or more
At 3,000 rpm
245 - 490 kPa (2.5 - 5.0 kgf/cm
2, 36 - 71 psi)
6. REMOVE OIL PRESSURE GAUGE AND REINSTALL
OIL PRESSURE SWITCH
(a) Remove the oil pressure gauge.
(b) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080, THREE BOND 1344,
LOCTITE 242 or eqivalent
(c) Reinstall the oil pressure switch.

LU-2
- LUBRICATIONOIL AND FILTER
617 Author
: Date
:
1996 TERCEL (RM440U)
(d) M/T only
Install the release cylinder and tube with the 3 bolts.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
(e) Install the air intake connector with the bolt.
7. START ENGINE AND CHECK FOR LEAKS

LU08B-04
P20919
SST
LU0490
SST
- LUBRICATIONOIL AND FILTER
LU-3
1996 TERCEL (RM440U)
REPLACEMENT
CAUTION:

Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
tion, used engine oil contains potentially harmful
contaminants which may cause skin cancer. Ade-
quate means of skin protection and washing facilities
should be provided.

Care should be taken, therefore, when changing en-
gine oil, to minimize the frequency and length of time
your skin is exposed to used engine oil. Protective
clothing and gloves, that cannot be penetrated by oil,
should be worn. Wash your skin throughly with soap
and water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline, thinners, or
solvents.

In order to preserve the environment, used oil must
be disposed of only at designated disposal sites.
1. DRAIN ENGINE OIL
(a) Remove the oil filler cap.
(b) Remove the oil drain plug and drain the oil into a contain-
er.
2. REPLACE OIL FILTER
(a) Using SST, remove the oil filter.
SST 09228-06501
(b) Clean the filter contact surface on the filter mounting.
(c) Lubricate the filter rubber gasket with engine oil.
(d) Tighten filter until the gasket contacts seat of the filter
mounting. Then using SST, give it an additional 3/4 turn
to seat the filter.
SST 09228-06501
3. FILL WITH ENGINE OIL
(a) Clean and install the oil drain plug with a new gasket.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
(b) Fill the engine with new oil.
Oil grade: See step 1 in oil oressure check
Oil capacity:
Drain and refill w/ Oil filter change
w/o Oil filter change2.8 liters (3.0 US qts, 2.5 lmp. qts)
2.6 liters (2.7 US qts, 2.3 lmp. qts)
Dry fill3.7 liters (3.9 US qts, 3.3 lmp. qts)

LU-4
- LUBRICATIONOIL AND FILTER
1996 TERCEL (RM440U)
4. START ENGINE AND CHECK FOR LEAKS
5. CHECK ENGINE OIL LEVEL