Page 1155 of 1202
AC1C9-03
N12246
Upper Unit Case
Magnetic Clutch
Relay
Evaporator
Expansion Valve
Grommet
Blower Resistor Lower Unit Case O-ring
O-ring
Packing Packing
Non-reusable part
Wire Harness
A/C Amplifier
AC-26
- AIR CONDITIONINGCOOLING UNIT
1178 Author: Date:
1996 TERCEL (RM440U)
COOLING UNIT
COMPONENTS
Page 1157 of 1202
AC2WI-01
AC-28
- AIR CONDITIONINGCOOLING UNIT
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE WIRE HARNESS
2. REMOVE MAGNETIC CLUTCH RELAY
3. REMOVE A/C AMPLIFIER
4. REMOVE BLOWER RESISTOR
5. SEPARATE UPPER CASE AND LOWER CASE
(a) Using a knife, cut off the each packing.
(b) Remove 2 clips and 2 screws.
(c) Separate the upper and lower unit case.
6. REMOVE EVAPORATOR
HINT:
If evaporator was replaced, add compressor oil to the compressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND-OIL 8 or equivalent
7. REMOVE THERMISTOR FROM EVAPORATOR
8. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Lubricate 4 new O-rings with compressor oil and install them to the tubes.
Page 1163 of 1202
AC3IN-01
N12203
AC-34
- AIR CONDITIONINGBLOWER UNIT
1186 Author: Date:
1996 TERCEL (RM440U)
BLOWER UNIT
REMOVAL
1. REMOVE COOLING UNIT (See page AC-27)
2. REMOVE BLOWER UNIT
(a) Disconnect the connector from the blower motor.
(b) Disconnect the air inlet damper control cable.
(c) Remove the 2 nut, bolt and the blower unit.
3. REMOVE BLOWER MOTOR
Remove the 3 screws and blower motor.
Page 1164 of 1202
AC1CO-02
- AIR CONDITIONINGBLOWER UNIT
AC-35
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-34).
Page 1184 of 1202
AC3IS-01
N12551
- AIR CONDITIONINGBLOWER MOTOR
AC-55
1207 Author: Date:
1996 TERCEL (RM440U)
BLOWER MOTOR
INSPECTION
1. REMOVE BLOWER MOTOR
(a) Remove the glove compartment parts.
(b) Remove the A/C amplifier.
(c) Disconnect the connector from the blower motor.
(d) Remove the 3 screws and the blower motor.
2. INSPECT BLOWER MOTOR OPERATION
Connect the positive (+) lead from the battery to terminal 1 and
the negative (-) lead to terminal 2, then check that the motor op-
erations smoothly.
If operation is not as specified, replace the blower motor.
3. REINSTALL BLOWER MOTOR
Install the motor in the reverse order of step1.
Page 1185 of 1202
N12245
AC3IT-01
N09039
1 2
3 4 AC-56
- AIR CONDITIONINGBLOWER RESISTOR
1208 Author: Date:
1996 TERCEL (RM440U)
BLOWER RESISTOR
INSPECTION
1. REMOVE BLOWER RESISTOR
(a) Remove the lower finish panel.
(b) Disconnect the connector from the blower resistor.
(c) Remove the 2 screws and blower resistor.
2. INSPECT BLOWER RESISTOR CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2 - 3 - 4Continuity
If continuity is not as specified, replace the blower resistor.
Page 1195 of 1202
AC1D0-04
Z14427
Wire harness side
1
23
4
5
10 9 8 6
71112
Z14428
1 2 3 4 5
1098
6 7 11 12 From back side AC-66
- AIR CONDITIONINGAIR CONDITIONING AMPLIFIER
1218 Author: Date:
1996 TERCEL (RM440U)
AIR CONDITIONING AMPLIFIER
ON-VEHICLE INSPECTION
1. w/ Power Steering:
INSPECT A/C AMPLIFIER CIRCUIT
(a) Disconnect the connector from amplifier and inspect the
connector on wire harness side, as shown in the chart.
Test conditions:
Turn ignition switch to ON
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control lever at MAX COOL
Tester connectionConditionSpecified condition
5 - GroundConstantContinuity
1 - GroundConstantContinuity
6 - GroundConstantContinuity
1 - ECM terminal AC1ConstantContinuity
6 - ECM terminal ACTConstantContinuity
8 - 12ConstantApprox. 1.5 kW at 25°C (77°F)
7 - GroundA/C switch ONBattery positive voltage
7 - GroundA/C switch OFFNo voltage
9 - GroundA/C switch ONBattery positive voltage
9 - GroundA/C switch OFFNo voltage
11 - GroundConstantBattery positive voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
(b) Connect the connector to A/C amplifier and inspect the
wire harness connector from the back side, as shown in
the chart below.
Tester conditions:
Running engine at idle speed
Blower speed control switch at HI position
Temperature control lever at MAX COOL
position
A/C switch ON
Set manifold gauge set
Page 1196 of 1202
Z11344
1234
5
10 9 8 6
7 Wire harness side
N10516
1 2 3 4
5 10 9 8
6 7
From back side
- AIR CONDITIONINGAIR CONDITIONING AMPLIFIER
AC-67
1219 Author: Date:
1996 TERCEL (RM440U)Tester connection
ConditionSpecified condition
2 - GroundRefrigerant pressure 196 - 3,140 kPaBattery positive voltage
2 - GroundRefrigerant pressure less than
196 kPa or more than 3,140No voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
2. w/o Power steering:
INSPECT A/C AMPLIFIER
(a) Disconnect the connector from amplifier and inspect the
connector on wire harness side, as shown in the chart.
Test conditions:
Turn ignition switch to ON
Blower speed control switch at HI position
A/C switch ON
Temperature control lever at MAX COOL
Test connectionConditionSpeed condition
4 - GroundConstantContinuity
6 - ECM terminal ACTConstantContinuity
8 - ECM terminal AC1ConstantContinuity
6 - 10ConstantApprox. 1.5 kW at 25°C (77°F)
5 - GroundA/C switch ONBattery positive voltage
5 - GroundA/C switch OFFNo voltage
9 - GroundIgnition switch ONBattery positive voltage
9 - GroundIgnition switch ONNo voltage
7 - GroundA/C switch ONBattery positive voltage
7 - GroundA/C switch OFFNo voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
(b) Connect the connector to amplifier and inspect the wire
harness connector from back side, as shown in the chart
below.
Test conditions:
Running engine at idle speed
Blower speed control switch at HI position
Temperature control lever at MAX COOL
position
A/C switch ON
Set manifold gauge set
