fuel cap TOYOTA TERCEL 1996 Service Repair Manual

MA00R-19
MA0659
Upper Lower
- MAINTENANCEENGINE
MA-5
43 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. REPLACE TIMING BELT (See pages EM-12 and
EM-17)
2. INSPECT DRIVE BELTS (See pages CH-2, SR-3 and
AC-18)
3. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty,
damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
First blow from the upper side thoroughly, then blow off
the lower side of the air filter.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE SPARK PLUGS (See page IG-1)
6. REPLACE ENGINE OIL AND OIL FILTER (See page
LU-3)
7. REPLACE ENGINE COOLANT (See page CO-2)
8. INSPECT CHARCOAL CANISTER (See page EC-5)
9. REPLACE GASKET IN FUEL TANK CAP (See page
EC-5)
10. INSPECT FUEL LINES AND CONNECTIONS (See
page EC-5)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for severe
corrosion, leaks or damage.
12. ADJUST VALVE CLEARANCE (See page EM-4)

SS0N6-04
SS-8
- SERVICE SPECIFICATIONSENGINE MECHANICAL
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Cylinder head cover x Cylinder head7.07061 in.´lbf
No. 2 idler pulley x Cylinder head2828020
Camshaft timing pulley x Camshaft5151037
No. 1 idler pulley x Cylinder block18.518513
Crankshaft pulley x Crankshaft1551,55011 2
No. 2 crankshaft pulley x Crankshaft pulley1919514
RH engine mounting insulator x RH engine mounting bracket6465047
RH engine mounting insulator x Body7374054
No. 1 engine hanger x Cylinder head2121015
No. 2 engine hanger x Cylinder head5353038
Cylinder head x Cylinder block 1st
2nd45
Turn 90°450
Turn 90°33
Turn 90°
Camshaft bearing cap x Cylinder head131309
Intake manifold x Cylinder head19.519514
Intake manifold stay x Intake manifold2020015
Intake manifold stay x Cylinder block2020015
Exhaust manifold x Cylinder head4848035
Exhaust manifold stay x Cylinder block4040029
Exhaust manifold stay x Exhaust manifold4040029
Exhaust manifold heat insulator x Exhaust manifold8.08069 in.´lbf
Water outlet housing x Cylinder head3030022
Camshaft position sensor x Cylinder head8.08069 in.´lbf
EGR VSV x Cylinder head17.517513
EGR valve x Cylinder head17.517513
EGR pipe x EGR valve4040029
EGR pipe x Intake manifold3030022
PS ump bracket x Cylinder head4344032
Fuel inlet hose x Fuel filter2930022
Front exhaust pipe x Exhaust manifold6263049
Connecting rod cap x Connecting rod4040029
Crankshaft bearing cap x Cylinder block5858042
Rear oil seal retainer x Cylinder block7.57565 in.´lbf
Oil filter union x Cylinder block2525018
Oil pressure switch x Cylinder block131309
RH engine mounting bracket x Cylinder block5959043
Knock sensor x Cylinder block4545033
Generator bracket x Cylinder block2424018
Rear end plate x Cylinder block101007
Flywheel x Crankshaft9090065
Drive plate x Crankshaft9090065
Drive plate x Torque converter clutch2525018
A/C compressor bracket x Cylinder block2728020
PS pump adjusting strut x Cylinder block2121015

- SERVICE SPECIFICATIONSBODY ELECTRICAL
SS-41
171 Author
: Date
:
1996 TERCEL (RM440U) FUEL RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 115.8
A - CApprox. 177.2
B - CApprox. 61.4
w/o Tachometer:Resistance (W)
A - BApprox. 171.2
A - CApprox. 272.8
B - CApprox. 101.6
FUEL SENDER GAUGE
Float position: mm (in.)Resistance (W)
F: Approx. 13.0 ± 3 (0.512 ± 0.118)Approx. 3 ± 1.0
1/2: Approx. 61.0 (2.402)Approx. 29 ± 4.8
E: Approx. 124.0 ± 3 (4.882 ± 0.118)Approx. 110 ± 7.7
ENGINE COOLANT TEMPERATURE RECEIVER GAUGE
w/ Tachometer:Resistance (W)
A - BApprox. 51.0
A - CApprox. 148.6
B - CApprox. 199.6
w/o Tachometer:Resistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
DEFOGGER SWITCH
Timer Circuit:
2 - Ground (Ignition switch LOCK or ACC)No voltage
2 - Ground (Ignition switch ON)Battery positive voltage
6 - Ground (Ignition switch LOCK or ACC)No voltage
6 - Ground (Ignition switch ON)Battery positive voltage

FI4741 (-4) 0.1 0.2
0 -20 0.3 0.51 2 35 10 20 30
20 40 60 80 100
(32) (68) (104) (140) (212)(176)
Resistance kW
Acceptable
Temp.°C (°F) (fig.1)
DI-24
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0110 Intake Air Temp. Circuit Malfunction
CIRCUIT DESCRIPTION
The intake air temperature sensor is built into the air cleaner
cap and senses the intake air temperature. A thermistor built in
the sensor changes the resistance value according to the in-
take air temperature. The lower the intake air temperature, the
greater the thermistor resistance value, and the higher the in-
take air temperature, the lower the thermistor resistance value
(See Fig. 1). The intake air temperature sensor is connected to
the ECM (See next page). The 5 V power source voltage in the
ECM is applied to the intake air temperature sensor from the ter-
minal THA via a resistor R. That is, the resistor R and the intake
air temp. sensor are connected in series. When the resistance
value of the intake air temperature sensor changes in accor-
dance with changes in the intake air temperature, the potential
at terminal THA also changes. Based on this signal, the ECM
increases the fuel injection volume to improve driveability dur-
ing cold engine operation.
If the ECM detects the DTC ºP0110º, it operates the fail-safe
function in which the intake air temperature is assumed to be
20° (68°F).
Reference
Intake air temp.
°C (°F)Resistance
(kW)Voltage
(V)
-20 (-4)16.24.3
0 (32)5.93.4
20 (68)2.52.4
40 (104)1.11.5
60 (140)0.60.9
80 (176)0.30.5
100 (212)0.20.3
DTC No.DTC Detecting ConditionTrouble Area
P0110Open or short in intake air temp. sensor circuit

Open or short in intake air temp. sensor circuit

Intake air temp. sensor

ECM
HINT:
After confirming DTC P0110, use the OBD II scan tool or TOYOTA hand-held tester to confirm the intake
air temperature from the CURRENT DATA.
Temperature DisplayedMalfunction
-40°C (-40°F)Open circuit
140°C (284°F) or moreShort circuit
DI1E5-08

EC0JN-01
EC3070
Gasket
Check Valve
(Vacuum Valve)
- EMISSION CONTROLEVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM
EC-5
518 Author
: Date
:
1996 TERCEL (RM440U)
EVAPORATIVE EMISSION (EVAP)
CONTROL SYSTEM
INSPECTION
1. VISUALLY INSPECT LINES AND CONNECTIONS
Look for loosen connections, sharp bends or damage.
2. VISUALLY INSPECT FUEL TANK
Look for deformation, cracks or fuel leakage.
3. VISUALLY INSPECT FUEL TANK CAP
Check if the cap and or gasket are deformed or damaged.
If necessary, repair or replace the cap.
4. REMOVE CHARCOAL CANISTER
5. REMOVE CAP FROM CHARCOAL CANISTER
6. VISUALLY INSPECT CHARCOAL CANISTER
Look for cracks or damage.
7. INSPECT FOR CLOGGED FILTER AND STUCK
CHECK VALVE
(a) Using low pressure compressed air4.71 kPa (48 gf/cm
2,
0.68 psi), blow into port A and check that air flows from the
other ports.
If operation is not as specified, replace the charcoal canister.
(b) Blow air 4.71 kPa (48 gf/cm
2, 0.68 psi) into port B and
check that air does not flow from the other ports.

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.

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.

BE26Q-01
N12803N12541I22670
w/ Tachometer
A
B
w/o Tachometer
A
B
N13601
Ignition
Switch
BatteryFuel
Receiver
Gauge
Z08460
N12804
A
BC
DE F BE-38
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT VEHICLE SPEED SENSOR OPERATION
Check that there is continuity between terminals A and B four
times for every revolution of the speedometer shaft.
If operation is not as specified, replace the speedometer.
2. INSPECT FUEL RECEIVER GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON, check that the receiver gauge
needle indicates EMPTY.
(c) Connect terminals 5 and 6 on the wire harness side con-
nector through a 3.4 W test bulb.
(d) Turn the ignition switch ON, check that the bulb lights up
and the receiver gauge needle moves towards the full
side.
HINT:
Because of the silicon oil in the gauge, it will take a short time
for needle to stabilize.
If operation is not as specified, inspect the receiver gauge resis-
tance.
3. INSPECT FUEL RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer:
Between terminalsResistance (W)
A - BApprox. 115.8
A - CApprox. 177.2
B - CApprox. 61.4

N12805
A
BC
N15789
EF
1/256
Z08044
Ignition
Switch
BatteryWarning Light
N13602
1
4
- BODY ELECTRICALCOMBINATION METER
BE-39
1996 TERCEL (RM440U)
w/o Tachometer:
Between terminalsResistance (W)
A - BApprox. 171.2
A - CApprox. 272.8
B - CApprox. 101.6
If resistance value is not as specified, replace the receiver
gauge.
4. INSPECT FUEL SENDER GAUGE RESISTANCE
Measure the resistance between Red Cable and Black Cable.
Float position : mm (in.)Resistance (W)
F : Approx. 13.0 ± 3
(0.512 ± 0.118)3 ± 1.0
1/2 : Approx. 61.0 (2.402)29 ± 4.8
E : Approx. 124.0 ± 3
(4.882 ± 0.118)110 ± 7.7
If resistance value is not as specified, replace the sender
gauge.
5. INSPECT FUEL LEVEL WARNING LIGHT
(a) Disconnect the connector from the sender gauge.
(b) Connect terminals 1 and 3 on the wire harness side con-
nector.
(c) Turn the ignition switch ON, check that the warning light
lights up.
If the warning light does no light up, test the bulb.
6. INSPECT FUEL LEVEL WARNING SWITCH
OPERATION
(a) Apply battery positive voltage between terminals and
through a 3.4 W test bulb, check that the bulb lights up.
HINT:
It will take a short time for bulb to light up.

N13603
1
4
Z08045
Engine Coolant Temperature Gauge
Ignition
Switch
BatterySender
Gauge
Z07424
Engine Coolant Temperature Gauge
BatteryTest Bulb
(3.4 W)
N12804
A
BC
DE F
N12806
A B
C BE-40
- BODY ELECTRICALCOMBINATION METER
1996 TERCEL (RM440U)
(b) Submerge the switch in fuel, and check that the bulb goes
out.
If operation is not as specified, replace the sender gauge.
7. INSPECT RECEIVER ENGINE COOLANT
TEMPERATURE GAUGE OPERATION
(a) Disconnect the connector from the sender gauge.
(b) Turn the ignition switch ON, and check that the receiver
gauge needle indicates COOL.
(c) Ground terminal on the wire harness side connecter
through a 3.4 W test bulb.
(d) Turn the ignition switch ON, check that the bulb lights up
and the receiver gauge needle moves to the hot side.
If operation is as specified, replace the sender gauge. Then, re-
check the system.
If operation is not as specified, measure the receiver gauge re-
sistance.
8. INSPECT ENGINE COOLANT TEMPERATURE
RECEIVER GAUGE RESISTANCE
Measure the resistance between terminals.
w/ Tachometer:
Between terminalsResistance (W)
D - EApprox. 51.0
D - FApprox. 148.6
E - FApprox. 199.6
w/o Tachometer:
Between terminalsResistance (W)
A - BApprox. 54.0
A - CApprox. 175.7
B - CApprox. 229.7
HINT:
Connect the test leads so that the current from the ohmmeter
can flow according to the above order. This circuit includes the
diode.