1996 TOYOTA TERCEL heater

BO1IC-04
N15778
No.2 Heater to
Register Duct
Center Heater to
Register Duct
Instrument Panel Reinforcement
AG
AA
G
G
G
G
G
G
A
A Instrument Panel
Brace No.1
Instrument Panel
Brace No.2
Clock Hole Cover
C
CInstrument Panel
Heater
Control
B
B
B
B
DDD
Lower Center Finish Panel
Center Upper
Cluster Finish Panel
Combination
Mater
Steering Column Cover
Front Pillar Garnish
Combination Switch
Cowl Side
Trim
Front Door
Scuff Plate
Instrument Panel
Lower Pad
Lower Center Finish Panel
Steering Wheel
Center Cluster
Finish Panel
Shifting Hole
Bezel
F
F
Ash Receptacle BoxD
D
D
D
Console Box
Lower Instrument Cover
BB
BBHeater Control Panel
Knob
- BODYINSTRUMENT PANEL
BO-45
1139 Author
: Date
:
1996 TERCEL (RM440U)
INSTRUMENT PANEL
COMPONENTS

N15580
Defroster Nozzle
E
EE
E
E
No.1 Heater to
Register Duct
E
E
E
No.3 Heater to Register Duct
Instrument Panel Wire
Airbag Door
No.1 RegisterE
E
No.2 RegisterEE
E
ED
DDD
Center Bracket
Lower RH Panel
Lower LH Panel
Front Passenger Airbag Assembly
No.3 Register
E
E BO-46
- BODYINSTRUMENT PANEL
1140 Author
: Date
:
1996 TERCEL (RM440U)

BO347-01
N12292
N12291
N12055
BO-48
- BODYINSTRUMENT PANEL
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE FRONT PILLAR GARNISHES
2. REMOVE COWL SIDE TRIMS
3. REMOVE FRONT DOOR SCUFF PLATES
4. REMOVE STEERING WHEEL (See page SR-13)
5. REMOVE LOWER INSTRUMENT COVER
(a) Remove the 2 screws and the hood lock release lever.
(b) Remove the 2 hole covers.
(c) Remove the 4 bolts and the lower cover.
6. REMOVE INSTRUMENT PANEL LOWER PAD
7. REMOVE CENTER UPPER CLUSTER FINISH PANEL
8. REMOVE STEERING COLUMN COVERS
9. REMOVE COMBINATION SWITCH
10. REMOVE COMBINATION METER
11. REMOVE LOWER CENTER FINISH PANEL
(a) Remove the 4 bolts and 3 screws.
(b) Remove the instrument finish panel by pulling.
12. DISCONNECT FRONT PASSENGER AIRBAG CON-
NECTOR (See page RS-21)
13. REMOVE SHIFTING HOLE BEZEL
14. REMOVE CONSOLE BOX
15. REMOVE LOWER CENTER FINISH PANEL
16. REMOVE CENTER CLUSTER FINISH PANEL
17. REMOVE ASH RECEPTACLE BOX
18. REMOVE RADIO ASSEMBLY
19. REMOVE HEATER CONTROL PANEL (See page
AC-70)
20. REMOVE JUNCTION BLOCK NO. 1
Remove the 3 screws and J/B No. 1.

N12054
N12053
- BODYINSTRUMENT PANEL
BO-49
1996 TERCEL (RM440U)
21. REMOVE NO. 2 HEATER TO REGISTER DUCT
Remove the clip and the duct.
22. REMOVE CLOCK HOLE COVER
Using a screwdriver, remove the clock then disconnect the con-
nector.
HINT:
Tape the screwdriver tip before use.
23. REMOVE INSTRUMENT PANEL
Remove the 4 bolts, nuts and the instrument panel.
24. CENTER HEATER TO REGISTER DUCT
25. INSTRUMENT PANEL BRACE NO. 1
26. INSTRUMENT PANEL BRACE NO. 2
27. INSTRUMENT PANEL REINFORCEMENT

BO348-01
N12255
Front BO-50
- BODYINSTRUMENT PANEL
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE DEFROSTER NOZZLE
2. REMOVE NO. 3 HEATER TO REGISTER DUCT
3. REMOVE NO. 1 HEATER TO REGISTER DUCT
4. REMOVE NO. 1 REGISTER
5. REMOVE NO. 3 REGISTER
6. REMOVE NO. 2 REGISTER
7. REMOVE FRONT PASSENGER AIRBAG ASSEMBLY
(a) Remove the 2 bolts, 2 nuts and the front passenger airbag
assembly.
(b) Remove the airbag door.
CAUTION:

Do not store the front passenger airbag assembly
with the airbag deployment direction facing down.

Never disassemble the front passenger airbag as-
sembly.
NOTICE:

When installing the instrument panel, take care that
the airbag wire harness does not interfere with other
parts and is not pinched between other parts.

When installing the instrument panel box, carefully
pull out the airbag wire harness from the glove
compartment upper hole.
8. REMOVE CENTER BRACKET
9. REMOVE LOWER RH PANEL
10. REMOVE LOWER LH PANEL
11. REMOVE INSTRUMENT PANEL WIRE HARNESS

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

AC1CF-04
- AIR CONDITIONINGHEATER UNIT
AC-31
1183 Author
: Date
:
1996 TERCEL (RM440U)
HEATER UNIT
COMPONENTS