1996 TOYOTA TERCEL remove instrument panel

DI-46
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
3 Check output voltage of heated oxygen sensor (bank 1 sensor 2).
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) After warming up the engine, race the engine at 2,500 rpm for 3 minutes.
CHECK:
Read the output voltage of the heated oxygen sensor (bank 1 sensor 2) when racing the engine after 3 min-
utes have elapsed.
OK:
Heated oxygen sensor output voltage: Alternates from 0.4 V or less to 0.5 V or more.
OK Check that each connector is properly
connected.
NG
Replace heated oxygen sensor.

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

A15740
DI-106
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
A/C Cut Control Circuit
CIRCUIT DESCRIPTION
This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration per-
formance. During acceleration with the vehicle speed at 25 km/h (16 mph) or less, engine speed at 1,200
rpm or less and throttle valve opening angle at 50° or more, the A/C magnet switch is turned OFF for several
seconds.
WIRING DIAGRAM
INSPECTION PROCEDURE
TOYOTA hand-held tester:
1 Connect TOYOTA hand-held tester and check operation of air conditioning cut
control.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn ignition switch ON and TOYOTA hand-held tester main switch ON.
(d) Start the engine and air conditioning switch ON.
HINT:
A/C magnet clutch is turned ON.
(e) Select the ACTIVE TEST mode on the TOYOTA hand-held tester.
CHECK:
Check operation of A/C magnet clutch cut when air conditioning cut control is operated by the TOYOTA
hand-held tester.
OK:
A/C magnet clutch is turned OFF
OK Proceed to next circuit inspection shown on
matrix chart (See page DI-19).
DI1EK-09

N12877N14677I09780
Instrument Panel Junction Block
CIG & RAD
BE4061I05896I09781
ON
IG
(+) (-)
Disconnect
DI-238
- DIAGNOSTICSTHEFT DETERRENT SYSTEM
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check CIG / RAD fuses.
PREPARATION:
(a) Remove the fuse box cover.
(b) Remove CIG & RAD fuse from instrument panel junction
block.
CHECK:
Check continuity of CIG & RAD fuses.
OK:
Continuity
NG Check for short in all the harness and compo-
nents connected to the CIG & RAD fuse (See at-
tached wiring diagram).
OK
2 Check voltage between terminals ACC of theft deterrent ECU and body ground.
PREPARATION:
(a) Disconnect the theft deterrent ECU connectors.
(b) Turn ignition switch ON.
CHECK:
Measure voltage between terminals ACC of theft deterrent
ECU connector and body ground.
OK:
Voltage: 10 - 14 V
OK Check and replace theft deterrent ECU.
NG
Check and repair harness and connector between theft deterrent ECU and battery
(See page IN-26).

P19552
TOYOTA Hand-Held Tester
DLC3EM0K9-03
P20244
- ENGINE MECHANICALIGNITION TIMING
EM-9
430 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION TIMING
INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator's manual for further details.
3. CONNECT TIMING LIGHT
4. INSPECT IGNITION TIMING
(a) Using SST, connect terminals TE1 and E1 of the DLC1.
SST 09843-18020
(b) Using a timing light, check the ignition timing.
Ignition timing:
10° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral
position)
(c) Remove the SST from the DLC1.
SST 09843-18020
5. FURTHER CHECK IGNITION TIMING
Check that the ignition timing advances.
Ignition timing:
7 - 17° BTDC @ idle
(w/ Cooling fan OFF and transmission in neutral posi-
tion)
HINT:
The timing mark moves in a range between 7° and 17°.
6. DISCONNECT TIMING LIGHT
7. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

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.

P20392
SST
MF-6
- MFIFUEL PUMP
530 Author
: Date
:
1996 TERCEL (RM440U)
(d) Install the fuel inlet hose and SST (pressure gauge) to the
fuel filter outlet with the 3 gaskets and union bolt.
SST 09268-45012
Torque: 29.0 N´m (290 kgf´cm, 22 ft´lbf)
(e) Wipe off any splattered gasoline.
(f) Reconnect the negative (-) terminal cable to the battery.
(g) Connect the TOYOTA hand-held tester to the DLC3 (See
step 1 check fuel pump operation (a) to (f)).
(h) Turn the ignition switch ON.
(i) Measure the fuel pressure.
Fuel pressure:
281 - 287 kPa
(2.87 - 2.93 kgf/cm
2, 40.8 - 41.7 psi)
If pressure is high, replace the fuel pressure regulator.
(j) If pressure is low, check these parts:

Fuel hoses and connection

Fuel pump

Fuel filter

Fuel pressure regulator
(k) Remove the TOYOTA hand-held tester from the DLC3.
(l) Reinstall the fuse cover on instrument panel.
(m) Start the engine.
(n) Disconnect the vacuum sensing hose from the fuel pres-
sure regulator.
(o) Measure the fuel pressure at idle.
Fuel pressure:
281 - 287 kPa (2.87 - 2.93 kgf/cm
2, 40.8 - 41.7 psi)
(p) Reconnect the vaccum sensing hose to the fuel pressure
regulator plug the hose end.
(q) Measure the fuel pressure at idle.
Fuel pressure:
226 - 265 kPa (2.3 - 2.6 kgf/cm
2, 33 - 37 psi)
If pressure is not as specified, check the vacuum sensing hose
and fuel pressure regulator.
(r) Stop the engine.
(s) Check that the fuel pressure remains as specified for 5
minutes after the engine has stopped.
Fuel pressure:
147 kPa (1.5 kgf/cm
2, 21 psi) or more
If pressure is not as specified, check the fuel pump, pressure
regulator and/or injector.
(t) After checking fuel pressure, disconnect the negative (-)
terminal cable from the battery and carefully remove the
SST to prevent gasoline from splashing.
SST 09268-45012
(u) Connect the fuel inlet hose to the fuel filter with 2 new gas-
kets and the union bolt.