1996 TOYOTA TERCEL Service Repair Manual

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.

- MFIFUEL PUMP
MF-7
531 Author
: Date
:
1996 TERCEL (RM440U)
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf)
(v) Check for fuel leakage (See page MF-1).
3. REMOVE REAR SEAT CUSHION
4. DISCONNECT FUEL PUMP AND SENDER GAUGE
CONNECTOR
5. INSPECT FUEL PUMP RESISTANCE
Using an ohmmeter, measure the resistance between terminals
2 and 6.
Resistance: 0.2 - 3.0 W at 20°C (68°F)
If the resistance is not as specified, replace the fuel pump.
6. INSPECT FUEL PUMP OPERATION
Connect the positive (+) lead from the battery to terminal 2 of
the connector, and the negative (-) lead to terminal 6. Check
that the fuel pump operates.
NOTICE:

These tests must be performed quickly (within 10 se-
conds) to prevent the coil from burning out.

Keep the fuel pump as far away from the battery as
possible.

Always perform switching at the battery side.
If operation is not as specified, replace the fuel pump or lead
wire.
7. RECONNECT FUEL PUMP AND SENDER GAUGE
CONNECTOR
8. REINSTALL REAR SEAT CUSHION

SF0WS-04
MF-8
- MFIFUEL PUMP
1996 TERCEL (RM440U)
COMPONENTS

SF1PS-02
- MFIFUEL PUMP
MF-9
1996 TERCEL (RM440U)
REMOVAL
CAUTION:
Do not smoke or work near an open flame when working on
the fuel pump.
1. REMOVE REAR SEAT CUSHION
2. REMOVE FLOOR SERVICE HOLE COVER
3. DISCONNECT FUEL PUMP AND SENDER GAUGE
CONNECTOR
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page MF-1).
4. REMOVE FUEL PUMP BRACKET ASSEMBLY FROM
FUEL TANK
CAUTION:
Remove the fuel filler cap to prevent the fuel from flowing
out.
(a) Using SST, disconnect the outlet pipe from the pump
bracket.
HINT:
At the time of installation, plaese refer to the following items. Us-
ing SST.
SST 09631-22020
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf) for use with SST
(See page MF-1)
(b) Remove the 8 bolts.
Torque: 3.4 N´m (35 kgf´cm, 31 in.´lbf)
HINT:
At the time of installation, plaese refer to the following items.
Check for fuel leakage (See page MF-1).
(c) Disconnect the return hoses from the pump bracket.
(d) Pull out the pump bracket assembly.
NOTICE:

Do not damage the fuel pump filter.

Be careful that the arm of the sender gauge should
not bent.

SF1PT-01
MF-10
- MFIFUEL PUMP
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE FUEL CUTOFF VALVE FROM FUEL PUMP
BRACKET
Remove the 2 screws, retainer, fuel cut-off valve and gasket.
HINT:
At the time of installation, plaese refer to the following items.
Install a new gaskt.
Torque: 1.5 N´m (15 kgf´cm, 13 )in.´lbf
2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP
BRACKET
(a) Remove the screw and disconnect the lead wire from the
pump bracket.
(b) Disconnect the 3 lead wires.
(c) Remove the 2 screws and sender gauge.
3. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Pull out the lower side of the fuel pump from the pump
bracket.
(b) Disconnect the connector from the fuel pump.
(c) Disconnect the fuel hose from the fuel pump, and remove
the fuel pump.
(d) Remove the rubber cushion from the fuel pump.
4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Using a small screwdriver, remove the clip.
HINT:
At the time of installation, plaese refer to the following items.
Install the pump filter with a new clip.
(b) Pull out the pump filter.

SF0WV-04
- MFIFUEL PUMP
MF-1 1
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page MF-10).