TOYOTA TERCEL 1996 Service Repair Manual

EC0JO-01
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC-7
520 Author
: Date
:
1996 TERCEL (RM440U)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
COMPONENTS

EC0JP-01
EC-8
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT AND CLEAN FILTER IN EGR VACUUM MOD-
ULATOR
(a) Remove the cap and filter.
(b) Check the filter for contamination or damage.
(c) Using compressed air, clean the filter.
(d) Reinstall the filter and cap.
HINT:
Install the filter with the coarser surface facing the stmospheric
side (outward).
2. INSTALL VACUUM GAUGE
Using 3 - way connector, connect a vacuum gauge to the EGR
valve vacuum hose as shown in the illustration.
3. INSPECT SEATING OF EGR VALVE
Start the engine and check that the engine starts and runs at
idle.
4. INSPECT OPERATION VSV WITH COLD ENGINE
(a) The engine coolant temperature shold be below 45°C
(113°F).
(b) Check that the vacuum gauge indicates zero at 2,500
rpm.
5. INSPECT OPERATION OF VSV AND EGR VACUUM
MODULATOR WITH HOT ENGINE
(a) Warm up the engine to above 60°C (140°F).
(b) Check that the vacuum gauge indicates low vacuum at
2,500 rpm.
(c) Check that the vacuum gauge indicates zero at idle.
(d) Disconnect the vacuum hose from port R of the EGR vac-
uum modulator and connect port R directley to the intake
manifold with another hose.
(e) Check that the vacuum gauge indicates high vacuum at
2,500 rpm.
HINT:
As a large amount of exhaust gas enters, the will misfire slghtly.
6. REMOVE VACUUM GAUGE
Remove the vacuum gauge and reconnect the vacuum hoses
to the proper locations.

(a)
(b)
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC-9
1996 TERCEL (RM440U)
7. INSPECT EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Apply vacuum directly to the EGR valve with the engine
idling.
(c) Check that the engine runs rough or dies.
(d) Reconnect the vacuum hoses to the proper locations.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
8. VSV ISPECTION (See page MF-42)
9. CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
(b) Block ports P and R with your finger.
(c) Bllow air into port Q, and check that the air passes through
to the air filter freely.
(d) Start the engine and maintain speed at 2,500 rpm.
(e) Repeat the above test. Check that there is a strong resis-
tans to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
(f) Reconnect the vacuum hoses to the proper locations.
10. REMOVE AIR CLEANER CAP
11. REMOVE EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the EGR hose from the vacuum modulator.
(c) Loosen the union nut.
(d) Remove the 4 nuts, EGR valve, pipe sleeve ball and the
2 gaskets.
12. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.
13. REINSTALL EGR VALVE
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300kgf´cm, 22ft´lbf)
(b) Install anew gasket, the EGR pipe, new sleeve ball with
the 2 nuts and union nut.
Torque:
Nut: 30 N´m (300kgf´cm, 22ft´lbf)
Union nut: 40 N´m (400kgf´cm, 30ft´lbf)
(c) Connect the vacuum hoses to the EGR valve.
(d) Connect the EGR hose to the vacuum modulator.
14. REINSTALL AIR CLEANER CAP

EC07B-04
EC-10- EMISSION CONTROLTHREE-W AY CATALYTIC CONVERTER (TWC)
SYSTEM
523 Author
: Date
:
1996 TERCEL (RM440U)
THREE-W AY CATALYTIC CONVERTER (TWC) SYSTEM
INSPECTION
1. CHECK CONNECTION FOR LOOSENESS OR DAMAGE
2. CHECK CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE
3. CHECK FOR DENTS OR DAMAGE
If any part of the protector is damaged or dented to the extent that it touches the TWC, repair or replace it.
4. CHECK HEAT INSULATOR FOR DAMAGE
5. CHECK FOR ADEQUATE CLEARANCE BETWEEN TWC AND HEAT INSULATOR

EC07C-01
- EMISSION CONTROLTHREE-W AY CATALYTIC CONVERTER (TWC)
SYSTEMEC-1 1
1996 TERCEL (RM440U)
REPLACEMENT
REMOVE FRONT EXHAUST PIPE (See page EM-92)

SF1PQ-02
- MFIMFI SYSTEM
MF-1
525 Author
: Date
:
1996 TERCEL (RM440U)
MFI SYSTEM
PRECAUTION
1. BEFORE WORKING ON FUEL SYSTEM, DISCON-
NECT NEGATIVE (-) TERMINAL CABLE FROM BAT-
TERY
HINT:
Any diagnostic trouble code retained by the computer will be
erased when the negative (-) terminal cable is disconnected.
Therefore, if necessary, read the diagnosis before disconnect-
ing the negative (-) terminal cable from the battery.
2. DO NOT SMOKE OR WORK NEAR AN OPEN FLAME
WHEN WORKING ON THE FUEL SYSTEM
3. KEEP GASOLINE AWAY FROM RUBBER OR LEATH-
ER PARTS
4. MAINTENANCE PRECAUTIONS
(a) In event of engine misfire, the following precautions
should be taken.
(1) Check proper connection to battery terminals, etc.
(2) Handle higt-tension cords carefully.
(3) After repair work, check that the ignition coil termi-
nals and all other ignition system lines are recon-
nected securely.
(4) When cleaning the engine compartment, be espe-
cially careful to protect the electrical system from
water.
(b) Precautions when handling the oxygen sensor.
(1) Do not allow the oxygen sensor to drop or hit
against an object.
(2) Do not allow the sensor to come into contact with
water.
5. IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYS-
TEM (HAM, CB, ETC.)
If the vehicle is equipped with a mobile communication system,
refer to the precaution in the IN section.
6. AIR INDUCTION SYSTEM
(a) Separation of the engine oil dipstick, oil filler cap, PCV
hose, etc. may cause the engine out of tune.
(b) Disconnection, looseness or cracks in the parts of the air
induction system between the throttle body and cylinder
head will cause air suction and cause the engine out of
tune.
7. ELECTRONIC CONTROL SYSTEM
(a) Before removing MFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch to LOCK or disconnecting the negative (-) terminal
cable from the battery.

FI2553
SST
FI4429
Plug MF-2
- MFIMFI SYSTEM
526 Author
: Date
:
1996 TERCEL (RM440U)
(b) When installing the battery, be especially careful not to in-
correctly connect the positive (+) and negative (-) cables.
(c) Do not permit parts to receive a severe impact during re-
moval or installation. Handle all MFI parts carefully, espe-
cially the ECM.
(d) Do not be careless during troubleshooting as there are
numerous transistor circuits and contact with terminals
can cause further trouble.
(e) Do not open the ECM cover.
(f) When inspecting during rainy weather, take care to pre-
vent the entry of water. Also, when washing the engine
compartment, prevent water from getting on the MFI parts
and wiring connectors.
(g) Parts should be replaced as an assembly.
(h) Care is required when pulling out and inserting wiring con-
nectors.
(i) Release the lock and pull out the connector, pulling on the
connectors.
(j) Fully insert the connector and check that it is locked.
(k) When inspecting a connector with a volt/ohmmeter.
(l) Carefully take off the water-proofing rubber if it is a wa-
ter-proof type connector.
(m) Insert the tester probe into the connector from the wiring
side when checking the continuity, amperage or voltage.
(n) Do not apply unnecessary force to the terminal.
(o) After checking, install the water-proofing rubber securely
on the connector.
(p) Use SST for inspecting or testing the injector or its wiring
connector.
SST 09842-30070
8. FUEL SYSTEM
(a) When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe these proce-
dures:
(1) Disconnect the fuel pump connector.
(2) Start the engine. After the engine has stopped on
its own, turn the ignition switch.
(3) Put a container under the connection.
(4) Slowly loosen the connection.
(5) Disconnect the connection.
(6) Plug the connection with a rubber plug.
(7) Reconnect the fuel pump connector.

P20175
New
Gasket
FI1654
Fulcrum Length
SST
30 cm
FI4295
CORRECT
WRONG
WRONG Delivery Pipe O-Ring
Grommet
Injector
FI4296
Delivery
Pipe
O-Ring
Grommet
InjectorCylinder Head
- MFIMFI SYSTEM
MF-3
527 Author
: Date
:
1996 TERCEL (RM440U)
(b) When connecting the union bolt on the high pressure pipe
union, observe these procedures:
(1) Always use 2 new gaskets.
(2) Tighten the union bolt by hand.
(3) Tighten the union bolt to the specified torque.
Torque: 29.0 N´m (290 kgf´cm, 22 ft´lbf)
(c) When connecting the flare nut on the high pressure pipe
union, observe these procedures:
(1) Apply a light coat of engine oil to the flare nut, and
tighten the flare nut by hand.
(2) Using SST, tighten the flare nut to specified torque.
SST 09631-22020
NOTICE:
Do not rotate the fuel pipe, when tightening the flare nut.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
HINT:
Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).
(d) Observe these precautions when removing and installing
the injectors.
(1) Never reuse the O-ring.
(2) When placing a new O-ring on the injector, take
care not to damage it in any way.
(3) Coat a new O-ring with spindle oil or gasoline be-
fore installing-never use engine, gear or brake oil.
(e) Install the injector in the delivery pipe and cylinder head
as shown in the illustration.

P19552
TOYOTA Hand-Held Tester
DLC3
MF-4
- MFIMFI SYSTEM
528 Author
: Date
:
1996 TERCEL (RM440U)
(f) Check that there are no fuel leaks after performing main-
tenance anywhere on the fuel system.
(1) Remove the fuse cover on the instrument panel.
(2) Connect the TOYOTA hand- held tester to the
DLC3.
(3) Turn the ignition switch ON and TOYOTA hand-
held tester main switch ON.
NOTICE:
Do not start the engine.
(4) Select the active test mode on the TOYOTA hand-
held tester.
(5) Please refer to the TOYOTA hand-held tester oper-
ator 's manual for further details.
If you have no TOYOTA hand-held tester, connect the positive
(+) and negative (-) leads from the battery to the fuel pump con-
nector (See page MF-5).
(6) Pinch the fuel return hose.
(7) The pressure in the high pressure line will rise to
approx. 392 kPa (4 kgf/cm
2, 57 psi). In this state.
Check to see that there are no leaks from any part
of the fuel system.
NOTICE:
Always pinch the hose. Avoid bending as it may cause the
hose to crack.
(8) Turn the ignition switch to LOCK.
(9) Disconnct the TOYOTA hand-held tester from the
DLC3.
(10) Install the fuse cover on the instrument panel.

P19552
TOYOTA Hand-Held Tester
DLC3
P20392
SF1PR-02
P20176
P20391
- MFIFUEL PUMP
MF-5
529 Author
: Date
:
1996 TERCEL (RM440U)
FUEL PUMP
ON-VEHICLE INSPECTION
1. CHECK FUEL PUMP OPERATION
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn the ignition switch ON and TOYOTA hand-held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(d) Select the active test mode on the TOYOTA hand-held
tester.
(e) Please refer to the TOYOTA hand-held tester operator's
manual for further details.
If you have no TOYOTA hand-held tester, connect the positive
(+) and negative (-) leads from the battery to the fuel pump con-
nector (See step 6).
(f) Check that there is pressure in the fuel inlet hose from the
fuel filter.
HINT:
If there is fuel pressure, you will hear the sound of fuel flowing.
If there is no pressure, check the fusible link, H-fuse, fuses, EFI
main relay, circuit opening relay, fuel pump, ECM and wiring
connections.
2. CHECK FUEL PRESSURE
(a) Check the battery positive voltage is above 11 V.
(b) Disconnect the negative (-) terminal cable from the bat-
tery.
(c) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
CAUTION:
Put a shop towel under the fuel filter.Slowly loosen the
union bolt.