1996 TOYOTA TERCEL lock

(a)
(b)
- EMISSION CONTROLEXHAUST GAS RECIRCULATION (EGR) SYSTEM
EC-9
1996 TERCEL (RM440U)
7. INSPECT EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Apply vacuum directly to the EGR valve with the engine
idling.
(c) Check that the engine runs rough or dies.
(d) Reconnect the vacuum hoses to the proper locations.
HINT:
As exhaust gas is increasingly recirculated, the engine will start
to misfire.
8. VSV ISPECTION (See page MF-42)
9. CHECK EGR VACUUM MODULATOR OPERATION
(a) Disconnect the vacuum hoses from ports P, Q and R of
the EGR vacuum modulator.
(b) Block ports P and R with your finger.
(c) Bllow air into port Q, and check that the air passes through
to the air filter freely.
(d) Start the engine and maintain speed at 2,500 rpm.
(e) Repeat the above test. Check that there is a strong resis-
tans to air flow.
If operation is not as specified, replace the EGR vacuum modu-
lator.
(f) Reconnect the vacuum hoses to the proper locations.
10. REMOVE AIR CLEANER CAP
11. REMOVE EGR VALVE
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the EGR hose from the vacuum modulator.
(c) Loosen the union nut.
(d) Remove the 4 nuts, EGR valve, pipe sleeve ball and the
2 gaskets.
12. INSPECT EGR VALVE
Check for sticking and heavy carbon deposits.
If a problem is found, replace the valve.
13. REINSTALL EGR VALVE
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300kgf´cm, 22ft´lbf)
(b) Install anew gasket, the EGR pipe, new sleeve ball with
the 2 nuts and union nut.
Torque:
Nut: 30 N´m (300kgf´cm, 22ft´lbf)
Union nut: 40 N´m (400kgf´cm, 30ft´lbf)
(c) Connect the vacuum hoses to the EGR valve.
(d) Connect the EGR hose to the vacuum modulator.
14. REINSTALL AIR CLEANER CAP

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.

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.

- 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

SF0WP-03
Z19295
Voltmeter
ECMVacuum
PIM
E2
Voltage Drop:
Applied
Vacuum
kPa
mmHg
in.Hg
Vo l t a ge
drop V13.3
100
3.94
0.3 - 0.5
26.7 40.0 53.5 66.7
200
7.87
300
11.81400
15.75500
19.69
0.7 - 0.9 1.1 - 1.3 1.5 - 1.7 1.9 - 2.1 MF-48
- MFIMANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF MAP SEN-
SOR
(a) Disconnect the MAP sensor connector.
(b) Turn the ignition switch ON.
(c) Using a voltmeter, measure the voltage between connec-
tor terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
(d) Turn the ignition switch to LOCK.
(e) Reconnect the MAP sensor connector.
2. INSPECT POWER OUTPUT OF MAP SENSOR
(a) Turn the ignition switch ON.
(b) Disconnect the vacuum hose from the MAP sensor.
(c) Connect a voltmeter to terminals PIM and E2 of the ECM,
and measure the output voltage under ambient atmo-
spheric pressure.
(d) Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg,
3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69
in.Hg).
(e) Measure the voltage drop from step (c) above for each
segment.
(f) Reconnect the vacuum hose to the MAP sensor.

CO0HR-04
P20196
Drain Plug
Drain Plug
CO-2
- COOLINGCOOLANT
1996 TERCEL (RM440U)
REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the right side of the ra-
diator lower tank) and engine drain plug (on the left front
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use a good brand of ethylene-glycol base coolant
and mix it according to the manufacturer's direc-
tions.

Using coolant which includes more than 50 % ethyl-
ene-glycol (but not more than 70 %) is recom-
mended.
NOTICE:

Do not use an alcohol type coolant.

The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T4.9 liters (5.2 US qts, 4.3 lmp. qts)
A/T5.3 liters (5.6 US qts, 4.7 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
ºFULLº line.
3. CHECK ENGINE COOLANT FOR LEAKS

CO0Y1-02
P21031
CO1231 CORRECT WRONG
Seal Diameter
2 - 3 mm
(0.08 - 0.12 in.)
Seal Packing
P21131
New
O-Ring CO-6
- COOLINGWATER PUMP
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL WATER PUMP
(a) Remove any old packing (FIPG) material and be careful
not to drop any oil on the contact surfaces of the water
pump and cylinder block.

Using a razor blade and gasket scraper, remove all
the old packing (FIPG) material from the contact
surfaces and sealing groove.

Thoroughly clean all components to remove all the
loose material.

Using a non-residue solvent, clean both sealing
surfaces.
(b) Apply seal packing to the water pump groove.
Seal packing:
Part No. 08826-00100, THREE BOND 1282B or
equivalent

Install a nozzle that has been cut to a 2 - 3 mm (0.08
- 0.12 in.) opening.
HINT:
Avoid applying an excessive amount to the surface.

Parts must be assembled within 5 minutes of ap-
plication. Otherwise the material must be removed
and reapplied.

Immediately remove nozzle from the tube and rein-
stall cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water pump with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 14 ft´lbf)
2. INSTALL OIL DIPSTICK GUIDE AND GENERATOR AD-
JUSTING BAR
(a) Install a new O-ring to the dipstick guide.
(b) Apply soapy water to the O-ring.
(c) Push in the dipstick guide, and install it with the mounting
bolt of the generator adjusting bar and dipstick guide
clamp.
Torque: 18.5 N´m (185 kgf´cm, 14 ft´lbf)
(d) Install the oil dipstick.