MF-1 TOYOTA TERCEL 1996 Service Repair Manual

P25916
S00553
DI-10
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Remove the fuse cover on the instrument panel.
(d) Connect the TOYOTA hand-held tester to DLC3 on the
vehicle.
(e) Use ACTIVE TEST mode to operate the fuel pump.
(f) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page MF-1).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page MF-1 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high-tension cord from spark plug or re-
move the ignition coil.
(b) Remove spark plug.
(c) Install the spark plug to high-tension cord or ignition coil.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
NG Proceed to page IG-1 and continue to trouble-
shoot.
OK

DI-50
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check air induction system (See page MF-1).
NG Repair or replace.
OK
2 Check for heated oxygen sensor data.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the OBD II scan tool or TOYOTA hand-held tester to the DLC3.
(c) Warm up engine to normal operating temperature.
CHECK:
Read the oxygen sensor output voltage and short-term fuel trim.
RESULT:
PatternOxygen sensor output voltageShort-term fuel trim
1Lean condition (Changes at 0.55 V or less)Changes at about + 20 %
2RIch condition (Changes at 0.4 V or more)Changes at about - 20 %
3Except 1 and 2
3 Check for oxygen sensor
(See page DI-41).
1, 2
3 Check fuel pressure (See page MF-1).
NG Check and repair fuel pump, pressure regulator,
fuel pipe line and filter. (See page MF-5)
OK

- DIAGNOSTICSENGINE
DI-51
1996 TERCEL (RM440U)
4 Check injector injection (See page MF-19).
NG Replace injector.
OK
5 Check manifold absolute pressure sensor and engine coolant temp. sensor
(See page DI-20, DI-28).
NG Repair or replace.
OK
6 Check for spark and ignition (See page IG-1).
NG Repair or replace.
OK
Check and replace ECM (See page IN-26).

A15699
- DIAGNOSTICSENGINE
DI-55
1996 TERCEL (RM440U)
2 Check voltage of ECM terminals for injector of failed cylinder.
PREPARATION:
(a) Remove the lower finish panel.
(b) Turn the ignition switch ON.
CHECK:
Measure the voltage between applicable terminals of the ECM
connector and the body ground.
OK:
Voltage: 9 - 14 V
OK Go to step 4.
NG
3 Check injector resistance of misfiring cylinder (See page MF-16).
NG Replace injector.
OK
Check for open and short in harness and con-
nector between injector and ECM (See page
IN-26).
4 Check fuel pressure (See page MF-1).
NG Check and repair fuel pump, pressure regulator,
fuel pipe line and filter (See page MF-5).
OK
5 Check injector injection (See page MF-16).
NG Replace injector.

A15716
- DIAGNOSTICSENGINE
DI-79
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check air induction system (See page MF-1).
NG Repair or replace.
OK
2 Check A/C signal circuit (See page AC-66).
NG Repair or replace.
OK
3 Check voltage between terminals RSO, RSC of ECM connector and body ground.
PREPARATION:
(a) Remove the lower finish panel.
(b) Disconnect the E7connector of ECM.
(c) Turn the ignition switch ON.
CHECK:
Measure the voltage between terminal RSO and RSC of the
ECM connector and the body ground.
OK:
Voltage: 9 - 14 V
OK Go to step 5.
NG
4 Check IAC valve (See page MF-33).
NG Replace IAC valve.
OK

A15737
DI-102
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
TOYOTA hand-held tester:
1 Connect TOYOTA hand-held tester and check operation of fuel pump
(See page MF-1).
OK Check for starter signal circuit.
NG
2 Check for ECM power source circuit (See page DI-97).
NG Repair or replace.
OK
3 Check circuit opening relay (See page MF-40).
NG Replace circuit opening relay.
OK
4 Check voltage between terminal FC of ECM and body ground.
PREPARATION:
(a) Remove the lower finish panel.
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminal FC of ECM and body
ground.
OK:
Voltage: 9 - 14 V
NG Check for open in harness and connector be-
tween EFI main relay and circuit opening relay,
circuit opening relay and ECM.
OK

A15739
- DIAGNOSTICSENGINE
DI-103
1996 TERCEL (RM440U)
5 Check fuel pump (See page MF-1).
NG Repair or replace fuel pump.
OK
6 Check for open in harness and connector between circuit opening relay and fuel
pump, fuel pump and body ground (See page IN-26).
NG Repair or replace harness or connector.
OK
Check and replace ECM (See page IN-26).
OBD II scan tool (excluding TOYOTA hand-held tester):
1 Check fuel pump operation.
PREPARATION:
(a) Remove the lower finish panel.
(b) Turn the ignition switch ON.
CHECK:
(a) Connect terminal FC of the ECM and the body ground to-
gether.
(b) Check for fuel pressure in the fuel inlet hose when it is
pinched off.
OK:
There is pressure in the inlet hose
HINT:
At this time, you will hear a fuel flowing noise.
OK Check for starter signal circuit.

DI-104
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
NG
2 Check for ECM power source circuit (See page DI-97).
NG Repair or replace.
OK
3 Check circuit opening relay (See page MF-40).
NG Replace circuit opening relay.
OK
4 Check voltage between terminal FC of ECM connector and body ground.
(See page DI-100)
NG Check for open in harness and connector be-
tween EFI main relay and circuit opening relay,
circuit opening relay and ECM.
OK
5 Check fuel pump (See page MF-1).
NG Repair or replace fuel pump.
OK
6 Check for open in harness and connector between circuit opening relay and fuel
pump, fuel pump and body ground (See page IN-26).

P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.

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.