1996 TOYOTA TERCEL air conditioning

MA0659
Outside
Inside
DI-8
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
YES
2 Is engine cranked ?
NO Proceed to ST-13, ST-28, ST-31 and continue
to troubleshoot.
YES
3 Does engine start ?
NO Go to step 7.
YES
4 Check air filter.
PREPARATION:
Remove the air filter.
CHECK:
Visual check that the air cleaner element is not excessively dirty
or oily.
HINT:
If necessary, clean the filter with compressed air. First blow from
inside thoroughly, then blow from outside of filter.
NG Repair or replace.
OK
5 Check engine idle speed.
PREPARATION:
(a) Warm up engine to normal operating temperature.
(b) Switch off all accessories.
(c) Switch off air conditioning.
(d) Shift transmission into ºNº position.

A15740
DI-106
- DIAGNOSTICSENGINE
1996 TERCEL (RM440U)
A/C Cut Control Circuit
CIRCUIT DESCRIPTION
This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration per-
formance. During acceleration with the vehicle speed at 25 km/h (16 mph) or less, engine speed at 1,200
rpm or less and throttle valve opening angle at 50° or more, the A/C magnet switch is turned OFF for several
seconds.
WIRING DIAGRAM
INSPECTION PROCEDURE
TOYOTA hand-held tester:
1 Connect TOYOTA hand-held tester and check operation of air conditioning cut
control.
PREPARATION:
(a) Remove the fuse cover on the instrument panel.
(b) Connect the TOYOTA hand-held tester to the DLC3.
(c) Turn ignition switch ON and TOYOTA hand-held tester main switch ON.
(d) Start the engine and air conditioning switch ON.
HINT:
A/C magnet clutch is turned ON.
(e) Select the ACTIVE TEST mode on the TOYOTA hand-held tester.
CHECK:
Check operation of A/C magnet clutch cut when air conditioning cut control is operated by the TOYOTA
hand-held tester.
OK:
A/C magnet clutch is turned OFF
OK Proceed to next circuit inspection shown on
matrix chart (See page DI-19).
DI1EK-09

SR0KE-01
R14423
Vacuum Hose
- STEERINGAIR CONTROL VALVE
SR-9
929 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONTROL VALVE
INSPECTION
1. TURN AIR CONDITIONING SWITCH OFF
2. CHECK IDLE-UP
(a) Start the engine and run it at idle.
(b) Fully turn the steering wheel.
(c) Check that the engine rpm decreases when the vacuum
hose is pinched.
(d) Check that the engine rpm increases when the hose is re-
leased.

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