1996 TOYOTA TERCEL spark plugs

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)

S00591
From Battery
Ignition Coil
Spark Plug
IGC1
IGC2
GND TA C IGT1
IGT2
To Tachometer ECM G
NE
No.1 Cylinder
No.4 Cylinder
Various
Sensor
IGF
No.2 Cylinder
No.3 Cylinder Camshaft
Position
Sensor
Crankshaft
Position
SensorIgniter
DI-84
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
DTC P1300 Ignition Circuit Malfunction
CIRCUIT DESCRIPTION
A DIS (Direct Ignition System) has been adopted. The DIS improves the ignition timing accuracy, reduces
high-voltage loss, and enhances the overall reliability of the ignition system by eliminating the distributor.
The DIS is a 2-cylinder simultaneous ignition system which ignites 2 cylinders simultaneously with one igni-
tion coil. In the 2-cylinder simultaneous ignition system, each of the 2 spark plugs is connected to the end
of the secondary winding. High voltage generated in the secondary winding is applied directly to the 2 spark
plugs. The sparks of the 2 spark plugs pass simultaneously from the center electrode to the ground elec-
trode.
The ECM determines ignition timing end outputs the ignition signals (IGT) for each cylinder. Based on IGT
signals, the igniter controls the primary ignition signals (IGC) for all ignition coils. At the same time, the igniter
also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM.
DTC No.DTC Detection ConditionTrouble Area
P1300No IGF signal to ECM while engine is running

Open or short in IGF or IGT circuit from igniter to ECM

Igniter

ECM
DI3A0-04

EM0KB-06
- ENGINE MECHANICALCOMPRESSION
EM-3
424 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSION
INSPECTION
HINT:
If there is lack of power, excessive oil consumption or poor fuel
economy, measure the compression pressure.
1. WARM UP AND STOP ENGINE
Allow the engine to warm up to normal operating temperature.
2. REMOVE SPARK PLUGS (See page IG-1)
3. CHECK CYLINDER COMPRESSION PRESSURE
(a) Insert a compression gauge into the spark plug hole.
(b) Fully open the throttle.
(c) While cranking the engine, measure the compression
pressure.
HINT:
Always use a fully charged battery to obtain engine revolutions
of 250 rpm or more.
(d) Repeat steps (a) through (c) for each cylinder.
NOTICE:
This measurement must be done in as short a time as pos-
sible.
Compression pressure:
1,275 kPa (13.0 kgf/cm
2, 185 psi) or more
Minimum pressure:
980 kPa (10.0 kgf/cm
2, 142 psi)
Difference between each cylinder:
100 kPa (1.0 kgf/cm
2, 14 psi) or less
(e) If the cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into the cylinder through
the spark plug hole and repeat steps (a) through (c) for
cylinders with low compression.

If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or damage.

If pressure stays low, a valve may be sticking or
seating is improper, or there may be leakage past
the gasket.
4. REINSTALL SPARK PLUGS

EM0KA-05
P20168
EM-4
- ENGINE MECHANICALVALVE CLEARANCE
425 Author
: Date
:
1996 TERCEL (RM440U)
VALVE CLEARANCE
INSPECTION
HINT:
Inspect and adjust the valve clearance when the engine is cold.
1. DISCONNECT PCV HOSES FROM CYLINDER HEAD
COVER
2. REMOVE HIGH- TENSION CORDS AND IGNITION
COILS FROM SPARK PLUGS
3. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.
4. SET NO.1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley, and align its groove with the
timing mark º0º of the No.1 timing belt cover.
(b) Check that the valve lifters on the No.1 cylinder are loose
and valve lifters on the No.4 cylinder are tight.
If not, turn the crankshaft 1 complete revolution (360°) and align
the marks as above.
5. INSPECT VALVE CLEARANCE
(a) Check only the valves indicated.
(1) Using a feeler gauge, measure the clearance be-
tween the valve lifter and camshaft.
(2) Record the out-of-specification valve clearance
measurements. They will be used later to determine
the required replacement adjusting shim.
Valve clearance (Cold):
Intake0.15 - 0.25 mm (0.006 - 0.010 in.)
Exhaust0.31 - 0.41 mm (0.012 - 0.016 in.)

EG0023
EM-24
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
9. w/ A/C and w/o PS:
REMOVE IDLER PULLEY BRACKET
(a) Loosen the idler pulley mounting nut and adjusting bolt,
and remove the drive belt.
(b) Remove the 3 bolts and idler pulley bracket.
10. REMOVE IGNITION COILS AND SPARK PLUGS
11. DISCONNECT VACUUM HASES
(a) Disconnect the vacuum hose from the EGR valve.
(b) Disconnect the 3 vacuum hoses from the throttle body.
(c) Disconnect the vacuum hose from the TVV (to charcoal
canister).
(d) Disconnect the vacuum hose from the TVV (to throttle
body).
(e) Disconnect the vacuum hose from the EGR VSV.
12. REMOVE THROTTLE BODY (See page MF-28)
13. REMOVE EGR PIIPE
Loosen the union nut, and remove the 2 nuts, EGR pipe and
gasket.
14. REMOVE EGR VALVE AND VACUUM MODULATOR
(a) Remove the bolt and disconnect the vacuum modulator.
(b) Remove the 2 nuts, EGR valve, EGR vacuum modulator
with the bracket and gasket.
15. REMOVE EGR VSV AND CAMSHAFT POSITION SEN-
SOR
(a) Disconnect the EGR VSV and camshaft position sensor
connector.
(b) Remove the bbolt and EGR VSV.
(c) Remove the bolt, camshaft position sensor and O-ring.

EG0023
P20290
- ENGINE MECHANICALCYLINDER HEAD
EM-53
1996 TERCEL (RM440U)
22. INSTALL EGR PIPE
Install a new gasket, sleeve ball and the EGR pipe with the
union nut and 2 nuts.
Torque:
Union nut
40 N´m (400 kgf´cm, 29 in.´lbf)
Nut
30 N´m (300 kgf´cm, 22 in.´lbf)
23. INSTALL THROTTLE BODY (See page MF-32)
24. CONNECT VACUUM HOSES
(a) Connect the vacuum hose from the EGR valve.
(b) Connect the 3 vacuum hoses from the throttle body.
(c) Connect the vacuum hose from TVV (to charcoal canis-
ter).
(d) Connect the vacuum hose from the TVV (to throttle body).
(e) Connect the vacuum hose from the EGR VSV.
25. INSTALL IGNITION COILS AND SPARK PLUGS
26. w/ A/C and w/o PS:
INSTALL IDLER PULLEY BRACKET
(a) Install the idler pulley bracket with the 3 bolts.
Torque:
12 mm head bolt
27 N´m (275 kgf´cm, 20 ft´lbf)
14 mm head bolt
37 N´m (375 kgf´cm, 27 ft´lbf)
(b) Install and adjust the drive belt (See page AC-18).
27. w/ PS:
INSTALL PS PUMP BRACKET AND PS PUMP
(a) Install the PS pump bracket with the 3 bolts.
Torque: 44 N´m (440 kgf´cm, 32 ft´lbf)
(b) Temporarily install the PS pump and drive belt with the 2
bolts (See page SR-33).
(c) Adjust the belt tension (See page SR-3).
28. CONNECT FUEL HOSE
Connect the fuel inlet hose with the union bolt and 2 new gas-
kets.
Torque: 29 N´m (300 kgf´cm, 22 ft´lbf)
29. INSTALL AIR CLEANER ASSEMBLY WITH AIR IN-
TAKE CONNECTOR
30. INSTALL ACCELERATOR CABLE, AND ADJUST IT
31. A/T:
CONNECT THROTTLE CABLE, AND ADJUST IT

IG08E-06
CHECK POWER SUPPLY TO IGNITION COIL
AND IGNITER
SPARK TEST
Replace the camshaft position sensor.
CHECK RESISTANCE OF HIGH-TENSION
CORD (See step 2)
Maximum resistance: 25 kW per cord
CHECK RESISTANCE OF IGNITION COIL
(See step 4) 1. Turn ignition switch to ON.
2. Check that there is battery voltage at
ignition coil positive (+) terminal.
CHECK CONNECTION OF IGNITION COIL IGNITER
Resistance: Cold Hot
Secondary
9.3 - 16.0 kW
11.7 - 18.8 kW
CHECK RESISTANCE OF CAMSHAFT POSITION SENSOR
(See step 5)
Resistance:Cold Hot
985 - 1,600 W1,265 - 1,890 W
CHECK IGT SIGNAL FROM ECM
(See page
DI-84)
CHECK RESISTANCE OF CRANKSHAFT POSITION SENSOR
(See step 6)
Resistance:Cold
Hot
TRY ANOTHER IGNITERReplace the crankshaft position sensor. Replace the ignition coil. Connect securely.
Replace the cord(s).
Check wiring between ignition switch
to ignition coil and igniter.
Check wiring between ECM, distributor
and igniter, and then try another ECM.
NO
OK OK
OK
OK
OK
OKBAD
BAD
BAD
BAD
BAD
BAD
BAD
Primary
0.67 - 1.05 kW0.85 - 1.23 kW
985 - 1,600 W1,265 - 1,890 W
- IGNITIONIGNITION SYSTEM
IG-1
632 Author
: Date
:
1996 TERCEL (RM440U)
IGNITION SYSTEM
ON-VEHICLE INSPECTION
NOTICE:
ºColdº and ºHotº in following sentences express the tem-
perature of the coils themselves. ºColdº is from -10°C
(14°F) to 50°C (122°F) and ºHotº is from 50°C (122°F) to
100°C (212°F).
1. INSPECT SPARK TEST
Check that the spark occurs.
(1) Disconnect the high-tension cord from the spark
plug.
(2) Remove the spark plugs.
(3) Install the spark plugs to the high-tension cord.
(4) Ground the spark plug.
(5) See if spark occurs while engine is being cranked.
NOTICE:
To prevent gasoline from being injected from injectors dur-
ing this test, crank the engine for no more than 5 - 10 se-
conds at time. If the spark done not occur, do the test as fol-
lows:

P20908
CORRECT
WRONG
S06255
P21178
Ohmmeter
S06256
Push
P04690
CORRECT
WRONG IG-2
- IGNITIONIGNITION SYSTEM
633 Author
: Date
:
1996 TERCEL (RM440U)
2. INSPECT HIGH-TENSION CORDS
(a) Disconnect the high-tension cords from the spark plugs.
(1) Disconnect the high-tension cords at the rubber
boot. Do not pull on the cords.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside.
(2) Disconnect the high-tension cords from the clamp.
(b) Disconnect the high-tension cords from the ignition coils.
(1) Using a screwdriver, lift up the lock claw and discon-
nect the holder from the ignition coils.
(2) Disconnect the high-tension cord at the grommet.
(3) Do not pull on the cord.
NOTICE:
Pulling on or bending the cords may damage the conductor
inside. Do not wipe any of the oil from the grommet after the
high-tension cord is disconnected.
(c) Reconnect the high-tension cords to the ignition coils.
Maximum resistance: 25 kW per cord
If the resistance is greater than maximum, check the terminals.
If necessary, replace the high-tension cord.
(d) Reinstall the high-tension cords.
(1) Assemble the holder and grommet.
(2) Align the spline of the ignition coil with the spline of
the holder, and push in the cord.
NOTICE:
Check that the holder is correctly installed to the grommet
and distributor cap as shown in the illustration.
(3) Check that the lock claw of the holder is engaged by
lightly pulling the holder.
(4) Connect the high-tension cords to the clamp.
(e) Reconnect high-tension cords to spark plugs.