1996 TOYOTA TERCEL Service Repair Manual

N10070
Fall Length minus
200 mm (7.87 in.)
BO0635
BO-58
- BODYSEAT BELT
1996 TERCEL (RM440U)
(e) Retract the whole belt, then pull out the belt until 200 mm
(7.87 in.) of belt remains retracted.
(f) Tilt the retractor slowly.
(g) Make sure that the belt can be pulled out at a tilt of 15 de-
grees of tilt.
If a problem is found, replace the assembly.
4. Manual Type:
TESTING
(a) Adjust the belt to the proper length.
(b) Apply a firm load to the belt.
(c) Make sure that the belt does not extend.

AC2810
AC1DR-02
AC2811
N11084
Wrong Okay
HI LO HILO
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-1
1153 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.

AC-2
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1154 Author
: Date
:
1996 TERCEL (RM440U)
9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
The TERCEL is equipped with as SRS (Supplemental Restraint
System) such as the driver and passenger airbag. Failure to
carry out service operations the correct sequence could cause
the SRS to unexpectedly deployed during servicing, possibly
leading to a serious accident. Further, if a mistake is mode in
serving the SRS, it is possible the SRS may fail to operate when
required. Before servicing (including removal or installation of
parts, inspection or replacement), be sure to read the following
item carefully, then follow the correct procedure described in re-
pair manual.

AC2WA-02
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-3
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control set at ºMAX COOLº
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to item 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sigh glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect-
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I01386
AC-4
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
2. INSPECT REFRIGERANT PRESSURE WITH MAN-
IFOLD GAUGE SET
This is a method in which the trouble is located by using a man-
ifold gauge set. Read the manifold gauge pressure when these
conditions are established.
Test conditions:
Temperature at the air inlet with the switch set
at RECURC is 30 - 35 °C (86 - 95 °F).
Engine running at 1,500 rpm.
Blower speed control switch set at high.
Temperature control set at max. cool.
HINT:
It should be noted that the gauge indications may vary slightly
due to ambient temperature conditions.
(1) Normally functioning refrigeration system.
Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm
2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm
2)

I01387
Condition : Periodically cools and then fails to cool
I01388
Condition: Insufficient cooling
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-5
1996 TERCEL (RM440U)
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
but normal state is restored after a
time when the ice melts Drier in oversaturated state
 Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace condenser
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant
(3) Insufficient cooling
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure low on both low and
high pressure sides
 Bubbles seen in sight glass con-
tinuously
 Insufficient cooling performance
Gas leakage at some place in re-
frigeration system Insufficient refrigerant in system
 Refrigerant leaking
(1) Check for gas leakage with gas
leak detector and repair if neces-
sary
(2) Charge Proper amount of re-
frigerant
(3) If indicated pressure value is
near 0 when connected to gauge,
create the vacuum after inspecting
and repairing the location of the
leak

I01389
Condition: Insufficient cooling
I01449
Condition: Does not cool (Cools from time to time in some cases) AC-6
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
(4) Poor circulation of refrigerant
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure low in both low and
high pressure sides
 Frost on tube from receiver to
unit
Refrigerant flow obstructed by dirt
in receiverReceiver cloggedReplace receiver
(5) Refrigerant does not circulate
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Vacuum indicated on low pres-
sure side, very low pressure indi-
cated on high pressure side
 Frost or dew seen on piping be-
fore and after receiver/ drier or ex-
pansion valve Refrigerant flow obstructed by
moisture or dirt in refrigeration sys-
tem
 Refrigerant flow obstructed by
gas leakage from expansion valve
Refrigerant does not circulate
(1) Check expansion valve
(2) Clean out dirt in expansion
valve by blowing with air
If not able to remove dirt, replace
expansion valve
(3) Replace receiver
(4) Evacuate air and charge new
refrigerant to proper amount
(5) For gas leakage from expan-
sion valve, replace expansion
valve

I01390
Condition: Insufficient cooling
I01392
Condition: Insufficient cooling
NOTE : These gauge indica-
tions are shown when the
refrigeration system has
been opened and the refrig-
erant charged without vacu-
um purging.
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-7
1996 TERCEL (RM440U)
(6) Refrigerant overcharged or insufficient cooling of
condenser
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 No air bubbles seen through the
sight glass even when the engine
rpm is lowered Unable to develop sufficient per-
formance due to excessive refrig-
erant in system
 Insufficient cooling of condenserExcessive refrigerant in
cycle " refrigerant overcharged
 Condenser cooling "condenser
fins clogged of condenser fan
faulty.(1) Clean condenser
(2) If (1) is normal, check amount
of refrigerant
Charge proper amount or refriger-
ant
(7) Air present in refrigeration system
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 The low pressure piping hot to
the touch
 Bubbles seen in sight glass
Air entered in refrigeration system
 AIr present in refrigeration sys-
tem
 Insufficient vacuum purging
(1) Check compressor oil to see if
it is dirty or insufficient
(2) Evacuate air and charge new
refrigerant