1996 TOYOTA TERCEL Service Repair Manual

Z14695
SST (Hose)
SST (Union)
O-Ring
SST
(Clamp)
Vinyl Tube
P19552
TOYOTA Hand-Held Tester
DLC3
FI3211
SST
(Wire)
Connect
FI1676
MF-20
- MFIINJECTOR
1996 TERCEL (RM440U)
(h) Install the grommet and a O-ring to the injector.
(i) Connect SST (union and hose) to the injector, and hold
the injector and union with SST (clamp).
SST 09368-41046
(j) Put the injector into the graduated cylinder.
CAUTION:
Install a suitable vinyl hose onto the injector to prevent
gasoline from splashing out.
(k) Remove the fuse cover on the instrument panel.
(l) Connect the TOYOTA hand-held tester to the DLC3.
(m) Turn the ignition switch ON and TOYOTA hand-held tes-
ter main switch ON.
NOTICE:
Do not start the engine.
(n) Select the active test mode on the TOYOTA hand-held
tester.
(o) Please refer to the TOYOTA hand-held tester operator's
manual for further details.
(p) If you have no TOYOTA hand-held tester, connect the
positive (+) and negative (-) leads from the battery to the
fuel pump connector (See page MF-5).
(q) Connect SST (wire) to the injector and battery for 15 se-
conds, and measure the injection volume with a gra-
duated cylinder. Test each injector 2 or 3 times.
SST 09842-30070
Volume:
39 - 49 cm
3 (2.4 - 3.0 cu in.) per 15 sec.
Difference between each injector:
5 cm
3 (0.3 cu in.) or less
If the injection volume is not as specified, replace the injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the tester probes of
SST (wire) from the battery and check the fuel leakage
from the injector.
SST 09842-30070
Fuel drop:
1 drop or less per 3 minutes
(b) Disconnect the negative (-) terminal cable from the bat-
tery.
(c) Remove the SST.

- MFIINJECTOR
MF-21
1996 TERCEL (RM440U)
SST 09268-41046, 09842-30070, 09843-18020
(d) Reinstall the pressure regulator to the delivery pipe (See
page MF-15).
(e) Reconnect the fuel inlet hose to the fuel filter outlet with
2 new gaskets and the union bolt.
Torque: 29 N´m (290 kgf´cm, 22 ft´lbf)
(f) Turn the ignition switch OFF.
(g) Disconnect the TOYOTA hand- held tester from the
DLC3.
(h) Reinstall the fuse cover on the instrument panel.

SF0X4-05
FI3271
New
O-Ring
New Grommet
P00159
CORRECT
WRONG
InjectorDelivery Pipe GrommetO-Ring
WRONG
P20295
Spacer
Insulator
Connector MF-22
- MFIINJECTOR
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL INJECTORS AND DELIVERY PIPE
(a) Install a new grommet to the injector.
(b) Apply a light coat of gasoline to an O-ring, and install it
to the injector.
(c) While turning the injector left and right, install it to the de-
livery pipe. Install the 4 injectors.
(d) Place the 2 spacers and 4 insulators in position on the cyl-
inder head.
(e) Place the injectors together with the delivery pipe on the
cylinder head.
(f) Check that the injectors rotate smoothly.
HINT:
If the injectors do not rotate smoothly, the probable cause is in-
correct installation of O-rings. Replace the O-rings.
(g) Position the injector connector upward.
(h) Install the 2 bolts.
Torque: 19 N´m (190 kgf´cm, 14 ft´lbf)
2. CONNECT ENGINE WIRE
(a) Connect the 4 injector connectors.
(b) Connect the engine wire to the surge tank stay.
3. CONNECT FUEL INLET HOSE TO DELIVERY PIPE
(a) Install 2 new gaskets and the inlet hose with the union
bolt.
Torque: 30 N´m (300 kgf´cm, 23 ft´lbf)
(b) Connect the engine wire clamp to the No.2 engine hang-
er.
4. CONNECT FUEL RETURN HOSE TO FUEL RETURN
PIPE
5. CONNECT VACUUM SENSING HOSE TO FUEL PRES-
SURE REGULATOR

- MFIINJECTOR
MF-23
1996 TERCEL (RM440U)
6. CHECK FOR FUEL LEAKS (See page MF-1)

SF0X5-04
MF-24
- MFIFUEL TANK AND LINE
548 Author
: Date
:
1996 TERCEL (RM440U)
FUEL TANK AND LINE
COMPONENTS
CAUTION:

Always use new gaskets when replacing the fuel tank or components parts.

Apply the proper torque to all parts tightened.

SF0X7-03
BO0919
CrackLeakage
Defomation
Z00085
Fulcrum
Length
30 cm
(11.81 in.) Use SST
30 N´m
(310 kgf´cm, 22 ft´lbf)
SST: 09631-22020SST
FU0041
2 - 7 mm (0.08 - 0.28 in.)
Pipe Hose
0 - 3 mm (0 - 0.12 in.)
FI6138
Fuel Inlet Hose
2.5 mm (0.1 in.) or less
- MFIFUEL TANK AND LINE
MF-25
1996 TERCEL (RM440U)
INSPECTION
INSPECT FUEL TANK AND LINE
(a) Check the fuel lines for cracks or leakage, and all connec-
tions for deformation.
(b) Check the fuel tank vapor vent system hoses and connec-
tions for looseness, sharp bends or damage.
(c) Check the fuel tank for deformation, cracks, fuel leakage
or tank band looseness.
(d) Check the filler neck for damage or fuel leakage.
(e) Hose and the tube connections are as shown in the il-
lustration.
(f) Make sure the hose clamps do not interfere with the tank,
tubes, hoses and other parts.
If a problem is found, repair or replace the parts as necessary.

SF1PW-01
MF-26
- MFITHROTTLE BODY
550 Author
: Date
:
1996 TERCEL (RM440U)
THROTTLE BODY
ON-VEHICLE INSPECTION
1. INSPECT THROTTLE BODY
(a) Check that the throttle linkage moves smoothly.
(b) Check the vacuum at port.
(1) Start the engine.
(2) Check the vacuum with your finger.
Port nameAt idleOther than idle
PNo vacuumVacuum
ENo vacuumVacuum
RNo vacuumNo vacuum
2. INSPECT THROTTLE POSITION SENSOR
(a) A/T:
Disconnect the throttle cable from the linkage.
(b) Disconnect the sensor connector.
(c) Insert feeler gauge between the throttle stop screw and
stop lever.
(d) Using an ohmmeter, measure the resistance between
each terminal.
Clearance between
lever and stop screwBetween
terminalsResistance
0 mm (0 in.)VTA - E20.2 - 5.7 kW
0.50 mm (0.020 in.)IDL - E22.3 kW or less
0.70 mm (0.028 in.)IDL - E2Infinity
Throttle valve
fully openedVTA - E22.0 - 10.2 kW
-VC - E22.5 - 5.9 kW
(e) Reconnect the sensor connector.
(f) A/T:
Reconnect the throttle cable.

SF0X9-05
Air Cleaner Cap
- MFITHROTTLE BODY
MF-27
1996 TERCEL (RM440U)
COMPONENTS