1996 TOYOTA TERCEL fuel line

IN-14
- INTRODUCTIONFOR ALL OF VEHICLES
14 Author
: Date
:
1996 TERCEL (RM440U)
2. FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER
CAUTION:
If large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz-
ard. To prevent this, observe the following precautions and explain them to your customer.
(a) Use only unleaded gasoline.
(b) Avoid prolonged idling.
Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid spark jump test.
(1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never race the engine.
(d) Avoid prolonged engine compression measurement.
Engine compression tests must be done as rapidly as possible.
(e) Do not run engine when fuel tank is nearly empty.
This may cause the engine to misfire and create an extra load on the converter.
(f) Avoid coasting with ignition turned off.
(g) Do not dispose of used catalyst along with parts contaminated with gasoline or oil.
3. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM
For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe
the following precautions.
(1) Install the antenna as far as possible away from the ECU and sensors of the vehicle's electronic
system.
(2) Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve-
hicle's electronic systems. For details about ECU and sensors locations, refer to the section on
the applicable component.
(3) Avoid winding the antenna feeder together with other wiring as much as possible, and also avoid
running the antenna feeder parallel with other wire harnesses.
(4) Check that the antenna and feeder are correctly adjusted.
(5) Do not install powerful mobile communications system.
4. FOR USING OBD II SCAN TOOL OR TOYOTA HAND-HELD TESTER
CAUTION:
Observe the following items for safety reasons:

Before using the OBD II scan tool or TOYOTA hand-held tester, the OBD II scan tool's instruc-
tion book or TOYOTA hand-held tester's operator manual should be read thoroughly.

Be sure to route all cables securely when driving with the OBD II scan tool or TOYOTA hand-
held tester connected to the vehicle. (i.e. Keep cables away from feet, pedals, steering wheel
and shift lever.)

Two persons are required when test driving with the OBD II scan tool or TOYOTA hand-held
tester, one person to drive the vehicle and the other person to operate the OBD II scan tool or
TOYOTA hand-held tester.

IN-32
- INTRODUCTIONTERMS
32 Author
: Date
:
1996 TERCEL (RM440U) CW
Curb Weight
DCDirect Current
DEFDefogger
DFLDeflector
DIFF.Differential
DIFF. LOCKDifferential Lock
D/INJDirect Injection
DLIDistributorless Ignition
DOHCDouble Over Head Cam
DPDash Pot
DSDead Soak
DSPDigital Signal Processor
EBDElectronic Brake Force Distribution
ECAMEngine Control And Measurement System
ECDElectronic Controlled Diesel
ECDYEddy Current Dynamometer
ECUElectronic Control Unit
EDElectro-Deposited Coating
EDICElectric Diesel Injection Control
EDUElectronic Driving Unit
EFIElectronic Fuel Injection
E/GEngine
EGR-VMExhaust Gas Recirculation-Vacuum Modulator
ELREmergency Locking Retractor
ENGEngine
ESAElectronic Spark Advance
ETCSElectronic Throttle Control System
EVPEvaporator
E-VR VElectric Vacuum Regulating Valve
EXHExhaust
FEFuel Economy
FFFront-Engine Front-Wheel-Drive
F/GFuel Gage
FIPGFormed In Place Gasket
FLFusible Link
F/PFuel Pump
FPUFuel Pressure Up
FrFront
FRFront-Engine Rear-Wheel-Drive
F/WFlywheel
FW/DFlywheel Damper
FWDFront-Wheel-Drive
GASGasoline
GSAGear Shift Actuator
GNDGround
HACHigh Altitude Compensator

MA001-24
- MAINTENANCEOUTSIDE VEHICLE
MA-1
39 Author
: Date
:
1996 TERCEL (RM440U)
OUTSIDE VEHICLE
GENERAL MAINTENANCE
The owners are responsible for these maintenance and inspection items.
They can be done by the owner or they can have them done at a service shop.
These items include those which should be checked on a daily basis, those which, in most cases, do not
require (special) tools and those which are considered to be reasonable for the owner to do.
Items and procedures for general maintenance are as follows.
1. GENERAL NOTES

Maintenance items may vary from country to country. Check the owner's manual supplement in which
the maintenance schedule is shown.

Every service item in the periodic maintenance schedule must be performed.

Periodic maintenance service must be performed according to whichever interval in the periodic main-
tenance schedule occurs first, the odometer reading (miles) or the time interval (months).

Maintenance service after the last period should be performed at the same interval as before unless
otherwise noted.

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.
2. TIRES
(a) Check the pressure with a gauge.
If necessary, adjust.
(b) Check for cuts, damage or excessive wear.
3. WHEEL NUTS
When checking the tires, check the nuts for looseness or for missing nuts.
If necessary, tighten them.
4. TIRE ROTATION
Check the owner's manual supplement in which the maintenance schedule is shown.
5. WINDSHIELD WIPER BLADES
Check for wear or cracks whenever they do not wipe clean.
If necessary, replace.
6. FLUID LEAKS
(a) Check underneath for leaking fuel, oil, water or other fluid.
(b) If you smell gasoline fumes or notice any leak, have the cause found and corrected.
7. DOORS AND ENGINE HOOD
(a) Check that all doors and includiing the trunk lid operate smoothly, and that all latches lock securely.
(b) Check that the engine hood secondary latch secures the hood from opening when the primary latch
is released.

MA00R-19
MA0659
Upper Lower
- MAINTENANCEENGINE
MA-5
43 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE
INSPECTION
HINT:
Inspect these items when the engine is cold.
1. REPLACE TIMING BELT (See pages EM-12 and
EM-17)
2. INSPECT DRIVE BELTS (See pages CH-2, SR-3 and
AC-18)
3. INSPECT AIR FILTER
(a) Visually check that the air filter is not excessively dirty,
damaged or oily.
If necessary, replace the air filter.
(b) Clean the air filter with compressed air.
First blow from the upper side thoroughly, then blow off
the lower side of the air filter.
4. REPLACE AIR FILTER
Replace the air filter with a new one.
5. REPLACE SPARK PLUGS (See page IG-1)
6. REPLACE ENGINE OIL AND OIL FILTER (See page
LU-3)
7. REPLACE ENGINE COOLANT (See page CO-2)
8. INSPECT CHARCOAL CANISTER (See page EC-5)
9. REPLACE GASKET IN FUEL TANK CAP (See page
EC-5)
10. INSPECT FUEL LINES AND CONNECTIONS (See
page EC-5)
11. INSPECT EXHAUST PIPES AND MOUNTINGS
Visually check the pipes, hangers and connections for severe
corrosion, leaks or damage.
12. ADJUST VALVE CLEARANCE (See page EM-4)

PP3IT-01
- PREPARATIONMFI
PP-1 1
58 Author
: Date
:
1996 TERCEL (RM440U)
MFI
SST (Special Service Tools)
09268-41046Injection Measuring Tool Set
(09268-41091)NO.7 Union
(90405-09015)No.1 Union
09268-45012EFI Fuel Pressure Gauge
09631-22020Power Steering Hose Nut
14 x 17 mm Wrench SetFuel line flare nut
09816-30010Oil Pressure Switch SocketKnock sensor
09842-30070Wiring ºFº EFI Inspection
09843-18020Diagnosis Check Wire

SS0N8-03
SS-12
- SERVICE SPECIFICATIONSMFI
1996 TERCEL (RM440U)
TORQUE SPECIFICATION
Part tightenedN´mkgf´cmft´lbf
Fuel line Union bolt type
Flare nut type29
30290
30022
23
Fuel inlet hose x Fuel filter2929022
Fuel outlet pipe x Fuel pump bracket2929022
Fuel tank x Fuel pump set bolt3.43530 in.´lbf
Fuel pressure regulator x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Delivery pipe8.08069 in.´lbf
Fuel return pipe x Fuel pressure regulator2020014
Delivery pipe x Cylinder head1919014
Fuel inlet hose x Delivery pipe3030023
Fuel pump bracket x Fuel cut-off valve1.51513 in.´lbf
Fuel tank x Fuel tank filler pipe3.43530 in.´lbf
Fuel tank x Body3334025
Throttle body x Intake manifold19.519514
Main heated oxygen sensor x Exhaust manifold4444032
Sub heated oxygen sensor x Exhaust pipe4444032
Knock sensor x Cylinder block4545033

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

P24296
Throttle Position
Sensor
E2 VTAECM
VC
- DIAGNOSTICSENGINE
DI-33
1996 TERCEL (RM440U)
DTC P0120 Throttle/Pedal Position Sensor/Switch ºAº
Circuit Malfunction
CIRCUIT DESCRIPTION
The throttle position sensor is mounted in the throttle body and
detects the throttle valve opening angle. When the throttle valve
is fully closed, a voltage of approximately 0.3 - 0.8 V is applied
to terminal VTA of the ECM. The voltage applied to the terminal
VTA of the ECM increases in proportion to the opening angle
of the throttle valve and becomes approximately 3.2 - 4.9 V
when the throttle valve is fully opened. The ECM judges the ve-
hicle driving conditions from these signals input from terminal
VTA and uses them as one of the conditions for deciding the
air-fuel ratio correction, power increases correction and fuel-
cut control etc.
DTC No.DTC Detection ConditionTrouble Area
P0120
Condition (a) or (b) continues:
(a) VTA < 0.1 V
(b) VTA > 4.9 V
Open or short in throttle position sensor circuit

Throttle position sensor

ECM
HINT:
After confirming DTC P0120, use the OBD II scan tool or TOYOTA hand-held tester to confirm the throttle
valve opening percentage.
Throttle valve opening position expressed as percentageTblAThrottle valve fully closedThrottle valve fully openTrouble Area
0 %0 %VC line open
VTA line open or short
100 %100 %E2 line open
DI1E8-08