1996 TOYOTA TERCEL Service Repair Manual

AC1HH-04
AC-16
- AIR CONDITIONINGTROUBLESHOOTING
1168 Author
: Date
:
1996 TERCEL (RM440U)
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
No blower operation
2. Heater main relay
3. Blower motor
4. Blower resistor
5. Blower speed control switchAC-62
AC-55
AC-56
AC-71
No air temperature control1. Inspect engine coolant volume
2. A/C control lever-
AC-72
No compressor operation
1. Refrigerant volume
2. A/C Fuse
3. Magnetic clutch relay
4. Magnetic clutch
5. Compressor
6. Pressure switch
7. Heater main relay
8. A/C switch
9. Blower speed control switch
10.A/C amplifier
11. Thermistor
12.Wiring and wiring connectionsAC-3
-
AC-63
AC-40
AC-36
AC-59
AC-59
AC-62
AC-71
AC-66
AC-57
-
Compressor operates intermittently
1. Refrigerant volume
2. Refrigerant cooling system
3. Pressure switch
4. A/C amplifier
5. Thermistor
6. Wiring and wiring connectionsAC-3
-
AC-59
AC-66
AC-57
-
No condenser fan operation
1. Condenser fan fuse
2. Engine main relay
3. Cooling fan relay No.1
4. Cooling fan relay No.2
5. Cooling fan relay No.3
6. Magnetic clutch relay
7. Condenser fan motor
8. Pressure switch
9. Water temperature switch
10.A/C amplifier-
CO-33
AC-64
AC-64
AC-64
AC-63
AC-65
AC-59
-
AC-66
No cool air comes out
1. Refrigerant volume
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Refrigeration controlAC-3
AC-18
AC-40
AC-36
-
Cool air comes out intermittently
1. Refrigerant Volume
2. Drive belt
3. A/C amplifier
4. Expansion valve
5. Evaporator
6. Thermistor
7. Wiring and wiring connectionAC-3
AC-18
AC-66
AC-54
AC-52
AC-57
-
Cool air comes out only at high engine rpm
1. Refrigerant volume
2. Drive belt
3. Inspect refrigerant linesAC-3
AC-18
-

- AIR CONDITIONINGTROUBLESHOOTING
AC-17
1169 Author
: Date
:
1996 TERCEL (RM440U) Insufficient cooling
1. Refrigerant volume
2. Drive belt
3. Refrigerant cooling system
4. A/C amplifier
5. Refrigerant lines
6. ThermistorAC-3
AC-18
-
AC-66
-
AC-57
No engine idle up when A/C switch on
1. Idle air control (IAC) valve
2. A/C amplifier
3. Wiring and wiring connections-
AC-66
-
No warm air comes out
1. Engine coolant volume
2. A/C control lever adjustment
3. Heater radiator-
AC-73
AC-31

CH0086
CorrectWrong
AC1C5-04
Z16157
PS Pump
Idle Pulley
Compressor
Compressor Crankshaft
PulleyCrankshaft
Pulley
I17366
Nippondenso Borroughs AC-18
- AIR CONDITIONINGDRIVE BELT
1170 Author
: Date
:
1996 TERCEL (RM440U)
DRIVE BELT
ON-VEHICLE INSPECTION
1. INSPECT DRIVE BELT'S INSTALLATION CONDITION
Check that the drive belt fits properly in the ribbed grooves.
2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020) or Borroughs
No. BT-33-73F
Drive belt tension:
New belt 160 ± 25 lbf
Used belt 100 ± 20 lbf
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing the drive belt, check that it fits properly in
the ribbed grooves.

AC1C6-03
N05463
Adjusting
Bolt
Compressor
Drive Belt
Idle Pully Lock Nut
N15502
- AIR CONDITIONINGDRIVE BELT
AC-19
1996 TERCEL (RM440U)
REMOVAL
1. w/o Power Steering:
REMOVE DRIVE BELT
(a) Loosen the idle pully lock nut.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Loosen the adjusting bolt and remove drive belt.
2. w/ Power Steering:
REMOVE DRIVE BELT
(a) Loosen the 2 PS pump set bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Loosen the adjusting bolt.
(c) Remove the belt.

AC2WH-02
AC-20
- AIR CONDITIONINGDRIVE BELT
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-19).

N12205
Low Pressure
Charging Hose High Pressure
Charging Hose
AC1DD-01
N04392
Sleeve
- AIR CONDITIONINGMANIFOLD GAUGE SET
AC-21
1173 Author
: Date
:
1996 TERCEL (RM440U)
MANIFOLD GAUGE SET
SET ON
1. CONNECT CHARGE HOSES TO MANIFOLD GAUGE
SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4. REMOVE CAPS FROM SERVICE VALVE ON REFRIG-
ERANT LINES
5. CONNECT QUICK DISCONNECT ADAPTER TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then
slide, the sleeve of the quick disconnect adapter downward to
lock it.

N06553
AC1DE-01
AC-22
- AIR CONDITIONINGMANIFOLD GAUGE SET
1996 TERCEL (RM440U)
SET OFF
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to un-
lock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE

AC1DF-01
- AIR CONDITIONINGREFRIGERANT LINE
AC-23
1175 Author
: Date
:
1996 TERCEL (RM440U)
REFRIGERANT LINE
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detecter, check for leakage of refrigerant.