1996 TOYOTA TERCEL ECU

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.

- MFITHROTTLE BODY
MF-31
1996 TERCEL (RM440U)
4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-
SOR
(a) Loosen the 2 set screws of the sensor.
(b) Insert a 0.60 mm (0.024 in.) feeler gauge between the
throttle stop screw and stop lever.
(c) Connect the tester probe of an ohmmeter to the terminals
IDL and E2 of the sensor.
(d) Gradually turn the sensor clockwise until the ohmmeter
deflects, and secure it with the 2 set screws.
(e) Recheck the continuity between terminals IDL and E2.
Clearance between
lever and stop screwContinuity (IDL - E2)
0.50 mm (0.020 in.)Continuity
0.70 mm (0.028 in.)No continuity

IG08E-06
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
SPARK TEST
Replace the camshaft position sensor.
CHECK RESISTANCE OF HIGH-TENSION
CORD (See step 2)
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL
(See step 4) 1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL IGNITER
Resistance: Cold Hot
Secondary
9.3 - 16.0 kW
11.7 - 18.8 kW
CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
(See step 5)
Resistance:Cold Hot
985 - 1,600 W1,265 - 1,890 W
CHECK IGT SIGNAL FROM ECM
(See page
DI-84)
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
(See step 6)
Resistance:Cold
Hot
TRY ANOTHER IGNITERReplace the crankshaft position sensor. Replace the ignition coil. Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
NO
OK OK
OK
OK
OK
OKBAD
BAD
BAD
BAD
BAD
BAD
BAD
Primary
0.67 - 1.05 kW0.85 - 1.23 kW
985 - 1,600 W1,265 - 1,890 W
- IGNITIONIGNITION SYSTEM
IG-1
632 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in following sentences express the tem-
perature of the coils themselves. ºColdº is from -10°C
(14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to
100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high-tension cord from the spark
plug.
(2) Remove the spark plugs.
(3) Install the spark plugs to the high-tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time. If the spark done not occur, do the test as fol-
lows:

Z19162
Type A
Z14812
Type B
P04209
SST(A)
Turn SST(B)
P04210
SST (C)
CH-8
- CHARGINGGENERATOR
1996 TERCEL (RM440U)
3. Type A
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws and rectifier holder.
(b) Remove the 4 rubber insulators.
4. Type B:
REMOVE RECTIFIER HOLDER
(a) Remove the 4 screws.
(b) Using needle-nose pliers, straighten the stator lead wire.
(c) Remove the rectifier holder.
5. REMOVE PULLEY
(a) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Check that SST (A) is secured to the rotor shaft.
(c) Mount SST (C) in a vise.
(d) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

CH0HC-01
P04218
P13695
29 mm
Socket
Wrench
P04209
SST (A)
Turn SST (B)
P04210
SST (C)
- CHARGINGGENERATOR
CH-15
1996 TERCEL (RM440U)
REASSEMBLY
1. PLACE RECTIFIER END FRAME ON PULLEY
2. INSTALL ROTOR TO DRIVE END FRAME
3. INSTALL RECTIFIER END FRAME
(a) Install the generator washer to the rectifier end frame.
NOTICE:
Be careful of the generator washer installation direction.
(b) Using a 29 mm socket wrench and press, slowly press in
the rectifier end frame.
(c) Type A
Install the 4 nuts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
(d) Type B:
Install the 2 nuts and 2 bolts.
Torque: 4.5 N´m (46 kgf´cm, 40 in.´lbf)
4. INSTALL PULLEY
(a) Install the pulley to the rotor shaft by tightening the pulley
nut by hand.
(b) Hold SST (A) with a torque wrench, and tighten SST (B)
clockwise to the specified torque.
SST 09820-63010
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(c) Check that SST (A) is secured to the pulley shaft.
(d) Mount SST (C) in a vise.
(e) Insert SST (B) into SST (C), and attach the pulley nut to
SST (C).

MX07F-04
Q06439
Z1891017 mm Head
Starter Set Bolt
Q06443
Q09187
Filler Plug
Oil Level
0 - 5 mm
Drain Plug MX-4
- MANUAL TRANSAXLEMANUAL TRANSAXLE UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE BATTERY AND AIR CLEANER CASE AS-
SEMBLY WITH AIR HOSE
2. REMOVE CLUTCH RELEASE CYLINDER AND LINE
CLAMP
(a) Remove the 2 bolts and release cylinder.
(b) Remove the 2 bolts and release cylinder line clamp.
Torque: 12 N´m (120 kgf´cm, 9 ft´lbf)
3. DISCONNECT GROUND CABLE
Remove the 2 bolts and disconnect the 2 ground cables from
the transaxle side and engine left mounting bracket side.
4. DISCONNECT BACK-UP LIGHT SWITCH CONNEC-
TOR
5. DISCONNECT CONTROL CABLE
(a) Remove the 2 clips and washers.
(b) Remove the 2 clips from the cables.
6. REMOVE STARTER SET BOLT
Remove the 2 set bolts of the starter from the transaxle upper
side.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
7. REMOVE TRANSAXLE MOUNTING BOLT
Remove the 3 bolts of transaxle case upper side.
Torque:
17 mm head: 64 N´m (650 kgf´cm, 47 ft´lbf)
8. INSTALL ENGINE SUPPORT FIXTURE
9. REMOVE FRONT WHEEL
Torque: 103 N´m (1,050 kgf´cm, 76 ft´lbf)
10. RAISE VEHICLE
NOTICE:
Make sure that the vehicle is securely supported.
11. REMOVE LH AND RH ENGINE UNDER COVERS
12. DRAIN TRANSAXLE OIL
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.9 liters (2.0 US qts, 1.7 Imp. qts)
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
13. REMOVE LH AND RH DRIVE SHAFTS
(See page SA-17)

MX07S-03
CM0009
Engine Side
N00077
N00078
N00079
MX-32
- MANUAL TRANSAXLEOUTPUT SHAFT
1996 TERCEL (RM440U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
assembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the No.1 clutch hub and shifting keys to the No.1
hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE:
Position the key springs so that their end gaps are not in
line.
2. INSTALL BALL, THRUST WASHER, 1ST GEAR,
NEEDLE ROLLER BEARING, SYNCHRONIZER RING
AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT
SHAFT
(a) Install the ball to the shaft.
(b) Fit the thrust washer groove securely over the locking ball
when installing the thrust on the shaft.
(c) Apply gear oil to the needle roller bearing.
(d) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(e) Using a press, install the 1st gear and No.1 hub sleeve.