1996 TOYOTA TERCEL fuel injector

SS0N7-04
- SERVICE SPECIFICATIONSMFI
SS-1 1
141 Author
: Date
:
1996 TERCEL (RM440U)
MFI
SERVICE DATA
Fuel pressure
regulatorFuel pressure at no vacuum281 - 287 kPa (2.87 - 2.93 kgf/cm2, 40.8 - 41.7 psi)
Fuel pumpResistance at 20°C (68°F)0.2 - 3.0 W
InjectorResistance at 20°C (68°F)
Injection volume
Difference between each cylinder
Fuel leakage13.4 - 14.2 W
39 - 49 cm3 (2.4 - 3.0 cu in.) per 15 sec.
5 cm3 (0.31 cu in.) or less
1 drop or less per 3 min.
Throttle bodyThrottle body fully closed angle6°
Throttle position
sensorResistance
0 mm (0 in.) VTA - E2
0.50 mm (0.020 in.)IDL - E2
0.70 mm (0.028 in.)IDL - E2
Throttle valve fully open VTA - E2
- VC - E2
0.2 - 5.7 kW
2.3 kW or less
Infinity
2.0 - 10.2 kW
2.5 - 5.9 kW
IAC valveResistance +B - RSO (or RSC)
Cold (-10°C (14°F) to 50°C (122°F))
Hot (50°C (122°F) to 100°C (212°F))
17.0 - 24.5 W
21.5 - 28.5 W
VSV for EGRResistance at 20°C (68°F)33 - 39 W
ECT sensor and
IAT sensorResistance at -20°C (-4°F)
at 0°C (32°F)
at 20°C (68°F)
at 40°C (104°F)
at 60°C (140°F)
at 80°C (176°F)10 - 20 kW
4 - 7 kW
2 - 3 kW
0.9 - 1.3 kW
0.4 - 0.7 kW
0.2 - 0.4 kW
MAP sensorPower source voltage4.5 - 5.5 V
Main heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Sub heated
oxygen sensorHeater coil resistance at 20°C (68°F)11 - 16 W
Fuel cut rpmFuel return rpm900 rpm

P25916
S00553
DI-10
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
7 Check fuel pressure.
PREPARATION:
(a) Be sure that enough fuel is in the tank.
(b) Turn ignition switch ON.
(c) Remove the fuse cover on the instrument panel.
(d) Connect the TOYOTA hand-held tester to DLC3 on the
vehicle.
(e) Use ACTIVE TEST mode to operate the fuel pump.
(f) 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-1).
CHECK:
Check for fuel pressure in the inlet hose when it is pinched off.
HINT:
At this time, you will hear a fuel flowing noise.
NG Proceed to page MF-1 and continue to trouble-
shoot.
OK
8 Check for spark.
PREPARATION:
(a) Disconnect the high-tension cord from spark plug or re-
move the ignition coil.
(b) Remove spark plug.
(c) Install the spark plug to high-tension cord or ignition coil.
(d) Disconnect injector connector.
(e) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cranked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
NG Proceed to page IG-1 and continue to trouble-
shoot.
OK

DI-12
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
TOYOTA Enhanced Signals:
TOYOTA hand-held tester displayMeasurement ItemNormal Condition*
MISFIRE RPMEngine RPM for first misfire rangeMisfire 0: 0 rpm
MISFIRE LOADEngine load for first misfire rangeMisfire 0: 0 g/r
INJECTORFuel injection time for cylinder No.1Idling: 2.66 - 3.9 ms
IAC DUTY RATIOIntake Air Control Valve Duty Ratio
Opening ratio rotary solenoid type IAC valveIdling: 25.5 - 43 %
STARTER SIGStarter SignalCranking: ON
CTP SIGClosed Throttle Position SignalThrottle Fully Closed: ON
A/C SIGA/C Switch SignalA/C ON: ON
PNP SWPark/Neutral Position Switch SignalP or N position: ON
FC IDLFuel Cut Idle: Fuel cut when throttle valve fully
closed, during decelerationFuel cut operating: ON
FC TAUFuel Cut TAU: Fuel cut during very light loadFuel cut operating: ON
CYL#1, CYL#2, CYL#3, CYL#4Abnormal revolution variation for each cylinder0%
IGNITIONTotal number of ignition for every 1,000 revolu-
tions0 - 2,000 rpm
FUEL PUMPFuel Pump SignalIdling: ON
TOTAL FT B1Total Fuel Trim Bank 1: Average value for fuel
trim system of bank 1Idling: 0.8 - 1.2 V
O2 LR B1, S1
Oxygen Sensor Lean Rich Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from lean to rich.
Idling after warmed up: 0 - 1,000 msec.
O2 RL B1, S1
Oxygen Sensor Rich Lean Bank 1, Sensor 1 Re-
sponse time for oxygen sensor output to switch
from rich to lean.
Idling after warmed up: 0 - 1,000 msec.
*: If no conditions are specifically stated for ºldlingº, it means the shift lever is at N or P position, the A/C switch
is OFF and all accessory switches are OFF.

DI-14
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)DTC No.
(See Page)
Detection ItemTrouble AreaMIL*Memory
P0171
(DI-49)System too Lean
(Fuel Trim)
Air intake (hose loose)
Fuel line pressure
Injector blockage
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0172
(DI-49)System too Rich
(Fuel Trim)
Fuel line pressure
Injector blockage, leak
Oxygen sensor malfunction
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0300
(DI-52)Random/Multiple Cylinder
Misfire DetectedIgnition system
Injector
FlliP0301
P0302
P0303
P0304
(DI-52)Misfire Detected
- Cylinder 1
- Cylinder 2
- Cylinder 3
- Cylinder 4Fuel line pressure
Compression pressure
Valve clearance not to specification
Valve timing
Manifold absolute pressure sensor
Engine coolant temp. sensor

P0325
(DI-57)Knock Sensor 1 Circuit
MalfunctionOpen or short in knock sensor 1 circuit
Knock sensor 1 (looseness)
ECM

P0335
(DI-60)Crankshaft Position Sensor
Circuit ºAº Malfunction
Open or short in crankshaft position sensor circuit
Crankshaft position sensor
Starter
ECM

P0340
(DI-63)Camshaft Position Sensor
Circuit Malfunction
Open or short in camshaft position sensor circuit
Camshaft position sensor
Starter
ECM

P0420
(DI-73)Catalyst System Efficiency
Below ThresholdThree-way catalytic converter
Open or short in (heated) oxygen sensor circuit
(Heated) oxygen sensor

P0500
(DI-76)Vehicle Speed Sensor
Malfunction
Open or short in vehicle speed sensor circuit
Vehicle speed sensor
Speedometer cable
ECM

P0505
(DI-78)Idle Control System
Malfunction
IAC valve is stuck or closed
Open or short in IAC valve circuit
Open or short in AC1 switch circuit
Air intake (hose loose)

*: 


MIL lights up

- DIAGNOSTICSENGINE
DI-49
1996 TERCEL (RM440U)
DTC P0171 System too Lean (Fuel Trim)
DTC P0172 System too Rich (Fuel Trim)
CIRCUIT DESCRIPTION
ºFuelº trim refers to the feedback compensation value compared against the basic injection time. Fuel trim
includes short-term fuel trim and long-term fuel trim.
ºShort-term fuel trimº is the short-term fuel compensation used to maintain the air-fuel ratio at its ideal
theoretical value. The signal from the oxygen sensor indicates whether the air-fuel ratio is RICH or LEAN
compared to the ideal theoretical value, triggering a reduction in fuel volume if the air-fuel ratio is rich, and
an increase in fuel volume if it is lean.
ºLong-term fuel trimº is overall fuel compensation carried out long-term to compensate for continual devi-
ation of the short-term fuel trim form the central value due to individual engine differences, wear over time
and changes in the usage environment.
If both the short-term fuel trim and long-term fuel trim are LEAN or RICH beyond a certain value, it is de-
tected as a malfunction and the MIL lights up.
DTC No.DTC Detection ConditionTrouble Area
P0171
When the air-fuel ratio feedback is stable after engine warming
up, the fuel trim is considerably in error on the RICH side
(2 trip detection logic)

Air intake (hose loose)

Fuel line pressure

Injector blockage

Heated oxygen sensor malfunction

Manifold absolute pressure sensor

Engine coolant temp. sensor
P0172
When the air-fuel ratio feedback is stable after engine warming
up, the fuel trim is considerably in error on the LEAN side.
(2 trip detection logic)

Fuel line pressure

Injector blockage, leak

Heated oxygen sensor malfunction

Manifold absolute pressure sensor

Engine coolant temp. sensor
HINT:

When DTC P0171 is recorded, the actual air-fuel ratio is on the LEAN side. When DTC P0172 is re-
corded, the actual air-fuel ratio is on the RICH side.

If the total of the short-term fuel trim value and long-term fuel trim value is within + 25 %, the system
is functioning normally.

If the vehicle runs out of fuel, the air-fuel ratio is LEAN and DTC P0171 is recorded. The MIL then
comes on.
DI052-09

DI-52
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P0300 Random/Multiple Cylinder Misfire Detected
DTC P0301 Cylinder 1 Misfire Detected
DTC P0302 Cylinder 2 Misfire Detected
DTC P0303 Cylinder 3 Misfire Detected
DTC P0304 Cylinder 4 Misfire Detected
CIRCUIT DESCRIPTION
Misfire: The ECM uses the crankshaft position sensor and camshaft position sensor to monitor changes in
the crankshaft rotation for each cylinder.
The ECM counts the number of times the engine speed change rate indicates that misfire has occurred. And
when the misfire rate equals or exceeds the count indicating that the engine condition has deteriorated, the
MIL lights up.
If the misfire rate is high enough and the driving conditions will cause catalyst overheating, the MIL blinks
when misfiring occurs.
DTC No.DTC Detection ConditionTrouble Area
P0300Misfiring of random cylinders is detected during any particular
200 or 1,000 revolutions
Ignition system


Injector
P0301
P0302
For any particular 200 revolutions of the engine, misfiring is
detected which can cause catalyst overheating
(This causes MIL to blink)

Injector

Fuel line pressure

Compression pressure

Valve clearance not to specification
P0302
P0303
P0304For any particular 1,000 revolutions of the engine, misfiring is
detected which causes a deterioration in emissions
(2 trip detection logic)
Valve clearance not to s ecification

Valve timing

Manifold absolute pressure sensor

Engine coolant temp. sensor
HINT:
When the 2 or more codes for a misfiring cylinder are recorded repeatedly but no Random Misfire code is
recorded, it indicates that the misfires were detected and recorded at different times.
DI39Y-04

P25779S00553A05593
DI-54
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
INSPECTION PROCEDURE
1 Check spark plug and spark of misfiring cylinder.
PREPARATION:
(a) Disconnect the high-tension cord or ignition coil.
(b) Remove the spark plug.
CHECK:
(a) Check plug type.
(b) Check for carbon deposits on electrode.
(c) Check electrode gap.
OK:
(1) Twin ground electrodes type.
Recommended spark plug:
ND: K16TR11
NGK: BKR5EKB-11
(2) No large carbon deposit present.
Not wet with gasoline or oil.
(3) Electrode gap: 1.0 - 1.1 mm (0.039 - 0.043 in.)
PREPARATION:
(a) Install the spark plug to the high-tension cord or ignition
coil.
(b) Disconnect the injector connector.
(c) Ground the spark plug.
CHECK:
Check if spark occurs while engine is being cracked.
NOTICE:
To prevent excess fuel being injected from the injectors
during this test, do not crank the engine for more than 5 -
10 seconds at a time.
OK:
Spark jumps across electrode gap.
NG Replace or check ignition system (See page
IG-1).
OK

A15699
- DIAGNOSTICSENGINE
DI-55
1996 TERCEL (RM440U)
2 Check voltage of ECM terminals for injector of failed cylinder.
PREPARATION:
(a) Remove the lower finish panel.
(b) Turn the ignition switch ON.
CHECK:
Measure the voltage between applicable terminals of the ECM
connector and the body ground.
OK:
Voltage: 9 - 14 V
OK Go to step 4.
NG
3 Check injector resistance of misfiring cylinder (See page MF-16).
NG Replace injector.
OK
Check for open and short in harness and con-
nector between injector and ECM (See page
IN-26).
4 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
5 Check injector injection (See page MF-16).
NG Replace injector.