1996 TOYOTA TERCEL fuel pressure

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.

SF0WX-05
- MFIFUEL PRESSURE REGULATOR
MF-13
537 Author
: Date
:
1996 TERCEL (RM440U)
FUEL PRESSURE REGULATOR
COMPONENTS

SF0WY-04
MF-14
- MFIFUEL PRESSURE REGULATOR
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT VACUUM SENSING HOSE FROM FUEL
PRESSURE REGULATOR
2. DISCONNECT FUEL RETURN HOSE FROM FUEL
PRESSURE REGULATOR
3. REMOVE FUEL PRESSURE REGULATOR
(a) Remove the 3 bolts, and pull out the pressure regulator.
(b) Remove the O-ring from the pressure regulator.

SF1PU-02
- MFIFUEL PRESSURE REGULATOR
MF-15
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL FUEL PRESSURE REGULATOR
(a) Apply a light coat of gasoline to a new O-ring, and install
it to the pressure regulator.
(b) Attach the pressure regulator to the delivery pipe.
(c) Check that the pressure regulator rotates smothly.
NOTICE:
If it does not rotate smothly, the O-ring may be pinched, so
remove the pressure regulator and perform again steps (b)
and (c) above.
(d) Install the pressure regulator with the 3 bolts.
Torque:8.0 N´m (80kgf´cm, 69 in.´lbf)
2. CONNECT FUEL RETURN HOSE TO FUEL PRES-
SURE REGULATOR
3. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR
4. CHECK FOR FUEL LEAKS (See page MF-1)

SF0X2-03
MF-18
- MFIINJECTOR
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT VACUUM SEMSING HOSE FROM FUEL
PRESSURE REGULATOR
2. DISCONNECT FUEL RETURN HOSE FROM FUEL RE-
TURN PIPE
NOTICE:
Catch leaking in a container.
3. DISCONNECT FUEL INLET HOSE FROM DELIVERY
PIPE
(a) Disconnect the engine wire clamp from the No. 2 engine
hanger.
(b) Remove the union bolt, 2 gaskets and inlet hose.
4. DISCONNECT ENGINE WIRE
(a) Disconnect the engine wire from the surge tank stay.
(b) Disconnect the 4 injector connectors.
5. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the 2 bolts and delivery pipe together with the 4
injectors.
NOTICE:
Be careful not to drop the injectors when removing the de-
livery pipe.
(b) Pull out the 4 injectors from the delivery pipe.
(c) Remove the 2 spacers and 4 insulators from the cylinder
head.
(d) Remove the O-ring and grommet from each injector.

SF1PV-02
P20397
Union Bolt
Gasket
SST (Hose)
Fuel Filter
(On Vehicle) SST (Union)
- MFIINJECTOR
MF-19
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT INJECTOR INJECTION
CAUTION:
Keep injector clean of sparks during the test.
(a) Remove the union bolt and 2 gaskets, and disconnect the
fuel inlet hose from the fuel filter outlet.
(b) Connect SST (union and hose) to the fuel filter outlet with
2 gaskets and union bolts.
SST 09268-41046 (90405-09015)
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf)
(c) Remove the pressure regulator from the delivery pipe
(See page MF-14).
(d) Install a O-ring to the fuel inlet of pressure regulator.
(e) Connect SST (hose) to the fuel inlet of the pressure regu-
lator with SST (union) and the 2 bolts.
SST 09268-41046 (09268-41091)
Torque: 8.0 N´m (80 kgf´cm, 69 ft´lbf)
(f) Connect the fuel return hose to the fuel outlet of the pres-
sure regulator.
CAUTION:
Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(g) Remove the fuse cover on the instrument panel.