Page 206 of 1202
DI-32
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0116 Engine Coolant Temp. Circuit Range/
Performance Problem
CIRCUIT DESCRIPTION
Refer to Engine Coolant Temp. Circuit Malfunction on page DI-28.
DTC No.DTC Detection ConditionTrouble Area
P0116
20 min. or more after the engine starts, engine coolant
temp. sensor value is 40°C (104°F) or less (2 trip detection
logic)Engine coolant temp. sensor
Cooling system
INSPECTION PROCEDURE
HINT:
If DTC P0115 and P0116 are output Simultaneously, engine coolant temperature sensor circuit may be open.
Perform troubleshooting of DTC P0115 first.
1 Are there any other codes (besides DTC P0116) being output?
YES Go to relevant DTC chart.
NO
2 Check thermostat (See page CO-10).
NG Replace thermostat.
OK
Replace engine coolant temp. sensor.
DI1E7-08
Page 248 of 1202
FI7132
Engine Speed
2,500 - 3,000 rpm
Idling
IG SW OFF
Warmed up3 min. or soCheckTime (a)(c)
(d)
(b)
FI6514
OX Signal Waveform (Oscilloscope)
1.0 V
0 V
200 m sec. /Division
DI-74
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
CONFIRMATION ENGINE RACING PATTERN
(a) Connect the TOYOTA hand-held tester to the DLC3, or connect the probe of the oscilloscope between
terminals OX1, OX2 and E1 of ECM.
(b) Start engine and warm it up with all accessories switched OFF until engine coolant temperature is
stable.
(c) Race the engine at 2,500 - 3,000 rpm for about 3 minutes.
(d) After confirming that the waveform of the oxygen sensor, bank 1 sensor 1 (OX1), oscillate around 0.5
V during feedback to the ECM, check the waveform of the heated oxygen sensor, bank 1 sensor 2
(OX2).
HINT:
If there is a malfunction in the system, the waveform of the
heated oxygen sensor, bank 1 sensor 2 (OX2), is almost the
same as that of the oxygen sensor, bank 1 sensor 1 (OX1), on
the left.
There are some cases where, even though a malfunction ex-
ists, the MIL may either light up or not light up.
INSPECTION PROCEDURE
1 Are there any other codes (besides DTC P0420) being output?
YES Go to relevant DTC chart.
NO
2 Check heated oxygen sensor (bank 1 sensor 2) (See page DI-44).
Page 423 of 1202
EM18U-02
P19776
CO/HC Meter
- ENGINE MECHANICALCO/HC
EM-1
422 Author: Date:
1996 TERCEL (RM440U)
CO/HC
INSPECTION
HINT:
This check is used only to determine whether or not the idle CO/
HC complies with regulations.
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR systems, etc. should be properly
connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
(i) CO/HC meter calibrated by hand.
2. START ENGINE
3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SE-
CONDS
4. INSERT CO/HC METER TESTING PROBE AT LEAST
40 cm (1.3 ft) INTO TAILPIPE DURING IDLING
5. IMMEDIATELY CHECK CO/HC CONCENTRATION AT
IDLE AND/OR 2,500 RPM
HINT:
When doing the 2 mode (2,500 rpm and idle) test, follow the
measurement order prescribed by the applicable local regula-
tions.
Page 432 of 1202
EM18V-02
EM-10
- ENGINE MECHANICALIDLE SPEED
431 Author: Date:
1996 TERCEL (RM440U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed:
750 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral position)
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL
Page 447 of 1202
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.
Page 474 of 1202
EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.
Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.
Immediately remove nozzle from tube and reinstall
cap.
Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.
Page 480 of 1202
P20565
M/T EM-58
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
Engine coolant temperature sender gauge connec-
tor
Engine coolant temperature sensor connector
Camshaft position sensor connector
EGR VSV
Fan engine coolant temperature switch connector
A/T only:
Lock-up solenoid connector
A/T only:
Park/Neutral position switch connector
M/T only:
Backup light switch connector
A/T only:
No.2 vehicle speed sensor connector
Ground strap
Throttle position sensor connector
IAC valve connector
Injector connectors
Crankshaft position sensor connector
Knock sensor connector
Starter connector and wire
Generator connector and wire
15. M/T only:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
(a) Remove the 3 bolts, release cylinder and tube from the
transaxle.
(b) Disconnect the ground strap.
16. M/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.
Page 488 of 1202
EM-66
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
15. CONNECT ENGINE WIRE HARNESS
Connect these connectors and wires:
Main heated oxygen sensor connector
Oil pressure switch connector
Engine coolant temperature sender gauge
connector
Engine coolant temperature sensor connector
Camshaft position sensor connector
EGR VSV
Fan engine coolant temperature switch connector
A/T only:
Lock-up solenoid connector
A/T only:
Park/Neutral position switch connector
M/T only:
Backup light switch connector
A/T only:
No.2 vehicle speed sensor connector
Ground strap
Throttle position sensor connector
IAC valve connector
Injector connectors
Crankshaft position sensor connector
Knock sensor connector
Starter connector and wire
Generator connector and wire
16. w/ PS:
CONNECT IDLE-UP AIR HOSES TO AIR CONTROL
VA LV E
17. CONNECT SPEEDOMETER CABLE
18. CONNECT HOSES
(a) Connect the brake booster vacuum hose.
(b) Connect the MAP sensor hose.
(c) Connect the heater hoses.
