MF-30

MFI - THROTTLE BODY

SF1PY-01

INSPECTION
1. CLEAN THROTTLE BODY
(a) Wash and clean the cast part with a soft brush and carbu-
retor cleaner.
(b) Using compressed air, blow all passages and apertures
in the throttle body.
NOTICE:
To prevent deterioration, do not clean the throttle position
senser.

2. INSPECT THROTTLE VALVE

Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully closed.

3. INSPECT THROTTLE POSITION SENSOR

(a) Insert a 0.050 mm (0.020 in.) or 0.70 mm (0.028 in.) feeler
gauge between the throttle stop screw and stop lever.

(b) Using an ohmmeter, measure the resistance between

each terminal.
Clearance between
Between terminals Resistance
lever and stop screw
0 mm (0 in.) VTA - E2 0.2 - 5.7 kΩ
0.50 mm (0.020 in.) IDL - E2 2.3 kΩ or less
0.70 mm (0.028 in.) IDL - E2 Infinity
Throttle valve fully
VTA - E2 2.0 - 10.2 kΩ
open
- VC - E2 2.5 - 5.9 kΩ

1996 TERCEL (RM440U)

 MF-31
MFI - THROTTLE BODY

4. IF NECESSARY, ADJUST THROTTLE POSITION SEN-

SOR
(a) Loosen the 2 set screws of the sensor.

(b) Insert a 0.60 mm (0.024 in.) feeler gauge between the

throttle stop screw and stop lever.

(c) Connect the tester probe of an ohmmeter to the terminals

IDL and E2 of the sensor.

(d) Gradually turn the sensor clockwise until the ohmmeter

deflects, and secure it with the 2 set screws.

(e) Recheck the continuity between terminals IDL and E2.

Clearance between
Continuity (IDL - E2)
lever and stop screw
0.50 mm (0.020 in.) Continuity
0.70 mm (0.028 in.) No continuity

1996 TERCEL (RM440U)

MF-32
MFI - THROTTLE BODY
SF0XC-05

INSTALLATION
Installation is in the reverse order of removal (See page MF-28 ).

1996 TERCEL (RM440U)

 MF-33
MFI - IDLE AIR CONTROL (IAC) VALVE

IDLE AIR CONTROL (IAC) VALVE SF199-02

ON-VEHICLE INSPECTION
1. INSPECT IAC VALVE OPERATION
(a) Initial conditions:

Engine at normal operating temperature

Idle speed set correctly

Transmission in neutral position

(b) Using SST, connect terminals TE1 and E1 of the DLC1.

SST 09843-18020
(c) After engine rpm is kept at 900 - 1,300 rpm for 5 seconds,
check that it returns to idle speed.
If the rpm operation is not as specified, check the IAC valve, wir-
ing and ECM.
(d) Remove the SST from the DLC1.
SST 09843-18020

2. INSPECT IAC VALVE RESISTANCE

NOTICE:
”Cold” and ”Hot” in the following sentences express the temper-
ature of the coils themselves. ”Cold” is from -10°C (14°F) to 50°C
(122°F) and ”Hot” is from 50°C (122°F) to 100°C (212°F).
(a) Disconnect the IAC valve connector.
(b) Using an ohmmeter, measure the resistance between ter-
minal +B and other terminals (RSC, RSO).
Resistance:
Cold 17.0 - 24.5 Ω
Hot 21.5 - 28.5 Ω
If resistance is not as specified, replace the IAC valve.
(c) Reconnect the IAC valve connector.

1996 TERCEL (RM440U)

Author
: Date
: 557

MF-34
MFI - IDLE AIR CONTROL (IAC) VALVE
SF0XE-05

COMPONENTS

1996 TERCEL (RM440U)

 MF-35
MFI - IDLE AIR CONTROL (IAC) VALVE
SF0XF-07

REMOVAL
1. REMOVAL THROTTLE BODY (See page MF-28 )
2. REMOVE IAC VALVE
Remove the 4 screws, IAC valve and gasket.
HINT:
At the time of installation, plaese refer to the following items.
Use a new gasket.

1996 TERCEL (RM440U)

MF-36
MFI - IDLE AIR CONTROL (IAC) VALVE
SF19A-01

RSC INSPECTION
+B
INSPECT IAC VALVE OPERATION
Battery
(a) Connect the positive (+) lead form the battery to terminal
+B and negative (-) lead to terminal RSC, and check that
the valve is closed.

Closed

Z14697

(b) Connect the positive (+) lead from the battery to terminal
+B +B and negative (-) lead to terminal RSO, and check that
RSO Battery the valve is open.
If operation is not as specified, replace the IAC valve.

Open

Z14698

1996 TERCEL (RM440U)

 MF-37
MFI - IDLE AIR CONTROL (IAC) VALVE
SF0XH-03

INSTALLATION
Installation is in reverse order of removal (See page MF-35 ).

1996 TERCEL (RM440U)

MF-38
MFI - EFI MAIN RELAY

EFI MAIN RELAY SF0XI-04

INSPECTION
1. REMOVE EFI MAIN RELAY (Marking: EFI MAIN)
LOCATION: In the engine compartment relay box.

EFI Main
Relay
P20320

Continuity
2. INSPECT EFI MAIN RELAY CONTINUITY
No (a) Using an ohmmeter, check that there is continuity be-
Continuity 86 tween terminals 86 and 85.
87 If there is no continuity, replace the relay.
(b) Check that there is no continuity between terminals 87
Ohmmeter Ohmmeter and 30.
30 If there is continuity, replace the relay.
85
Z13175

3. INSPECT EFI MAIN RELAY OPERATION

Continuity (a) Apply battery voltage across terminals 86 and 85.
86 (b) Using an ohmmeter, check that there is continuity be-
87 tween terminals 87 and 30.
Ohmmeter If there is no continuity, replace the relay.
4. REINSTALL EFI MAIN RELAY
30
85 Battery
Z13176

1996 TERCEL (RM440U)

Author
: Date
: 562

 MF-39
MFI - CIRCUIT OPENING RELAY

CIRCUIT OPENING RELAY

SF0XJ-01

COMPONENTS
Circuit Opening Relay

Cowl Side Trim

Door Scuff Plate Lower No.1 Finish Panel

P20940

1996 TERCEL (RM440U)

Author
: Date
: 563

MF-40
MFI - CIRCUIT OPENING RELAY
SF0XK-05

INSPECTION
No 1. REMOVE CIRCUIT OPENING RELAY
Continuity 86
2. INSPECT CIRCUIT OPENING RELAY CONTINUITY
87
(a) Using an ohmmeter, check that there is continuity be-
Ohmmeter tween terminals 86 and 85.
If there is no continuity, replace the relay.
30
(b) Check that there is no continuity between terminals 87
85
and 30.
Z13175
If there is continuity, replace the relay.

3. INSPECT CIRCUIT OPENING RELAY OPERATION

(a) Apply battery voltage across terminals 86 and 85.
Continuity 86 (b) Using an ohmmeter, check that there is continuity be-
87 tween terminals 87 and 30.
Ohmmeter
If there is no continuity, replace the relay.
4. REINSTALL CIRCUIT OPENING RELAY
30
85
Z13176

1996 TERCEL (RM440U)

 MFI - VSV FOR EXHAUST GAS RECIRCULATION (EGR) MF-41
SYSTEM

VSV FOR EVAPORATIVE EMISSION (EVAP)

SF0XL-03

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 565

MF-42 MFI - VSV FOR EXHAUST GAS RECIRCULATION (EGR)
SYSTEM
SF0XM-05

INSPECTION
1. REMOVE VSV
2. INSPECT VSV FOR OPEN CIRCUIT
Using an ohmmeter, check that there is continuity between the
terminals.
Resistance: 33 - 39 Ω at 20°C (68°F)
If there is no continuity, replace the VSV.

3. INSPECT VSV FOR GROUND

Using an ohmmeter, check that there is no continuity between
each terminal and the body.
If there is continuity, replace the VSV.

4. INSPECT VSV OPERATION

(a) Check that air does not flow from ports E to F.
NOTICE:
Never apply more than 60 kPa (0.61 kgf/cm2, 8.7 psi) of
E pressure compressed air to the VSV.

(b) Apply battery positive voltage across the terminals.

(c) Check that air flows from ports E to F.
If operation is not as specified, replace the VSV.
5. REINSTALL VSV
E

1996 TERCEL (RM440U)

 MF-43
MFI - ENGINE COOLANT TEMPERATURE (ECT) SENSOR

ENGINE COOLANT TEMPERATURE (ECT) SENSOR

SF0XP-05

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 567

MF-44
MFI - ENGINE COOLANT TEMPERATURE (ECT) SENSOR
SF0XQ-05

INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SENSOR
3. INSPECT ECT SENSOR
Ohmmeter Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the ECT sensor.
4. REINSTALL ECT SENSOR
5. REFILL WITH ENGINE COOLANT

Acceptable
Resistance kΩ

Temperature °C (°F)

Z02917

1996 TERCEL (RM440U)

 MF-45
MFI - INTAKE AIR TEMPERATURE (IAT) SENSOR

INTAKE AIR TEMPERATURE (IAT) SENSOR

SF0XR-03

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 569

MF-46
MFI - INTAKE AIR TEMPERATURE (IAT) SENSOR
SF0XS-04

INSPECTION
1. REMOVE IAT SENSOR
2. INSPECT IAT SENSOR
Using an ohmmeter, measure the resistance between the ter-
Ohmmeter minals.
Resistance: Refer to the graph
If the resistance is not as specified, replace the sensor.
3. REINSTALL IAT SENSOR

30
20
10
Acceptable
5
Resistance kΩ

3
2
1

0.5
0.3
0.2
0.1

-20 0 20 40 60 80 100
(-4) (32) (68) (104) (140) (176) (212)
Temperature °C (°F)

Z02772

1996 TERCEL (RM440U)

 MF-47
MFI - MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

SF0WO-03

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 571

MF-48
MFI - MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
SF0WP-03

INSPECTION
1. INSPECT POWER SOURCE VOLTAGE OF MAP SEN-
SOR
(a) Disconnect the MAP sensor connector.
(b) Turn the ignition switch ON.

(c) Using a voltmeter, measure the voltage between connec-

tor terminals VC and E2 of the wiring harness side.
Voltage: 4.5 - 5.5 V
(d) Turn the ignition switch to LOCK.
(e) Reconnect the MAP sensor connector.
2. INSPECT POWER OUTPUT OF MAP SENSOR
(a) Turn the ignition switch ON.

(b) Disconnect the vacuum hose from the MAP sensor.

(c) Connect a voltmeter to terminals PIM and E2 of the ECM,

and measure the output voltage under ambient atmo-
spheric pressure.
(d) Apply vacuum to the MAP sensor in 13.3 kPa (100 mmHg,
3.94 in.Hg) segments to 66.7 kPa (500 mmHg, 19.69
in.Hg).
(e) Measure the voltage drop from step (c) above for each
segment.
Voltage Drop:
Vacuum Applied
Vacuum 13.3 26.7 40.0 53.5 66.7
Voltmeter kPa
ECM
mmHg 100 200 300 400 500
in.Hg 3.94 7.87 11.81 15.75 19.69
Voltage
0.3 - 0.5 0.7 - 0.9 1.1 - 1.3 1.5 - 1.7 1.9 - 2.1
drop V
PIM E2
(f) Reconnect the vacuum hose to the MAP sensor.
Z19295

1996 TERCEL (RM440U)

 MF-49
MFI - KNOCK SENSOR

KNOCK SENSOR
SF0WM-03

COMPONENTS

Knock Sensor

Knock Sensor
Connector

P20326

1996 TERCEL (RM440U)

Author
: Date
: 573

MF-50
MFI - KNOCK SENSOR
SF0WN-01

INSPECTION
SST 1. REMOVE KNOCK SENSOR
(a) Disconnect the knock sensor connector.
(b) Using SST, remove the knock sensor.
SST 09816-30010

P20327

2. INSPECT KNOCK SENSOR

Using an ohmmeter, check that there is no continuity between
Ohmmeter
the terminal and body.
If there is continuity, replace the sensor.
3. REINSTALL KNOCK SENSOR
Torque: 45 N·m (450 kgf·cm, 33 ft·lbf)

P01630

1996 TERCEL (RM440U)

 MF-51
MFI - HEATED OXYGEN SENSOR

HEATED OXYGEN SENSOR

SF0WK-03

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 575

MF-52
MFI - HEATED OXYGEN SENSOR

1996 TERCEL (RM440U)

Author
: Date
: 576

 MF-53
MFI - HEATED OXYGEN SENSOR
SF1PZ-01

INSPECTION
1. INSPECT HEATER RESISTANCE OF MAIN HEATED
OXYGEN SENSOR (BANK 1 SENSOR 1)
(a) Disconnect the oxygen sensor connectors.
(b) Using an ohmmeter, measure the resistance between the
terminals +B and HT.
Resistance: 11 - 16 Ω at 20°C (68°F)
If the resistance is not as specified, replace the sensor.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(c) Reconnect the oxygen sensor connectors.

Ohmmeter 2. INSPECT HEATER RESISTANCE OF SUB HEATED

OXYGEN SENSOR (BANK 1 SENSOR 2)
(a) Remove the passenger’s seat.
(b) Take out the console box side of the floor carpet.
(c) Disconnect the oxygen sensor connector.
(d) Using an ohmmeter, measure the resistance between the
terminals +B and HT.
+B HT Resistance: 11 - 16 Ω at 20°C (68°F)
P20873 If the resistance is not as specified, replace the sensor.
Torque: 44 N·m (440 kgf·cm, 32 ft·lbf)
(e) Reconnect the oxygen sensor connectors.
(f) Reinstall the floor carpet.
(g) Reinstall the passenger’s seat.

1996 TERCEL (RM440U)

MF-54
MFI - ENGINE CONTROL MODULE (ECM)

ENGINE CONTROL MODULE (ECM)

SF0WI-05

COMPONENTS

1996 TERCEL (RM440U)

Author
: Date
: 578

 MF-55
MFI - ENGINE CONTROL MODULE (ECM)
SF0WJ-01

INSPECTION
1. REMOVE ECM
2. INSPECT ECM (See page DI-17 )
3. REINSTALL ECM

1996 TERCEL (RM440U)

MF-56
MFI - FUEL CUT RPM

TOYOTA Hand-Held Tester FUEL CUT RPM SF0WH-03

INSPECTION
1. WARM UP ENGINE
Allow the engine to warm up to normal operating temperature.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII
SCAN TOOL
(a) Remove the fuse cover on the instrument panel.
DLC3 P19552
(b) Connect the TOYOTA hand-held tester or OBDII scan
tool to the DLC3.
(c) Please refer to the TOYOTA hand-held tester or OBDII
scan tool operator’s manual for futher details.

3. INSPECT FUEL CUT OFF PRM

(a) Increase the engine speed to at least 2,500 rpm.
(b) Use a sound scope to check for injector operating noise.
(c) Check that when the throttle lever is released, injector op-
eration noise stops momentarily and then resumes.
HINT:
Measure with the A/C OFF.
Fuel return rpm: 900 rpm
4. DISCONNECT TOYOTA HAND- HELD TESTER OR
OBDII SCAN TOOL

1996 TERCEL (RM440U)

Author
: Date
: 580

 CO-1
COOLING - COOLANT

COOLANT
CO0HQ-03

INSPECTION
1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR
The engine coolant level should be between the ”LOW” and ”FULL” lines.
If low, check for leaks and add engine coolant up to the ”FULL” line, ”when the engine is cold.”
2. CHECK ENGINE COOLANT QUALITY
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator
are still hot, as fluid and steam can be blown out under pressure.
(b) There should not be any excessive deposits of rust or scale around the radiator cap or radiator filler
hole, and the coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator cap.

1996 TERCEL (RM440U)

Author
: Date
: 581

CO-2
COOLING - COOLANT
CO0HR-04

REPLACEMENT
1. DRAIN ENGINE COOLANT
(a) Remove the radiator cap.
CAUTION:
To avoid the danger of being burned, do not remove the ra-
Drain Plug
diator cap while the engine and radiator are still hot, as fluid
and steam can be blown out under pressure.
(b) Loosen the radiator drain plug (on the right side of the ra-
Drain Plug P20196
diator lower tank) and engine drain plug (on the left front
of the cylinder block), and drain the coolant.
(c) Close the drain plugs.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
2. FILL ENGINE COOLANT
(a) Slowly fill the system with coolant.

Use a good brand of ethylene-glycol base coolant
and mix it according to the manufacturer’s direc-
tions.

Using coolant which includes more than 50 % ethyl-
ene-glycol (but not more than 70 %) is recom-
mended.
NOTICE:

Do not use an alcohol type coolant.

The coolant should be mixed with demineralized wa-
ter or distilled water.
Capacity (w/ Heater):
M/T 4.9 liters (5.2 US qts, 4.3 lmp. qts)
A/T 5.3 liters (5.6 US qts, 4.7 lmp. qts)
(b) Install the radiator cap.
(c) Start the engine, and bleed the cooling system.
(d) Refill the radiator reservoir with coolant until it reaches the
”FULL” line.
3. CHECK ENGINE COOLANT FOR LEAKS

1996 TERCEL (RM440U)