1996 TOYOTA TERCEL Service Repair Manual

CO0I9-04
P20884
CO-28
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE NO.1 COOLING FAN
(a) Remove the engine under covers.
(b) Drain the engine coolant.
(c) Remove the air cleaner inlet.
(d) Remove the reservoir tank assembly.
(e) Remove the No.1 cooling fan.
(1) Disconnect the upper radiator hose from the radia-
tor.
(2) Disconnect the cooling fan connector.
(3) Remove the 2 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)
2. REMOVE NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Remove the 3 bolts and cooling fan.
Torque: 7.0 N´m (70 kgf´cm, 61 in.´lbf)

CO0Y6-01
P20880
P20886
P20887
- COOLINGELECTRIC COOLING FAN
CO-29
1996 TERCEL (RM440U)
DISASSEMBLY
1. DISASSEMBLE NO.1 COOLING FAN
(a) Remove the nut and fan.
(b) Remove the fan motor.
(1) Disconnect the wire and connector holder from the
fan shroud.
(2) Remove the 3 screws and fan motor.
2. DISASSEMBLE NO.2 COOLING FAN
(a) Remove the 3 screws and fan.
(b) Remove the screw and fan motor cover.
(c) Remove the fan motor.
(1) Disconnect the wire and connector from the fan
shroud.
(2) Remove the 3 screws and fan motor.

CO0Y7-02
CO-30
- COOLINGELECTRIC COOLING FAN
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page CO-29).

CO0Y8-02
- COOLINGELECTRIC COOLING FAN
CO-31
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal (See page CO-28).

P21098
ECT SwitchCO0ID-04
P05962
Ohmmeter CO-32
- COOLINGENGINE COOLANT TEMPERATURE (ECT) SWITCH
612 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE COOLANT
TEMPERATURE (ECT) SWITCH
INSPECTION
1. DRAIN ENGINE COOLANT
2. REMOVE ECT SWITCH
3. INSPECT ECT SWITCH
(a) Using an ohmmeter, check that there is no continuity be-
tween the terminals when the coolant temperature is
above 94°C (201°F).
If there is continuity, replace the switch.
(b) Using an ohmmeter, check that there is continuity be-
tween the terminals when the coolant temperature is be-
low 83°C (181°F).
If there is no continuity, replace the switch.
4. REINSTALL ECT SWITCH
5. REFILL WITH ENGINE COOLANT
6. START ENGINE AND CHECK FOR COOLANT LEAKS

P20319
Engine
Main Relay
CO0IE-05
BE0075
Ohmmeter
Continuity Ohmmeter Continuity
2
1
5
4 3No
Continuity
Ohmmeter
BE0076
OhmmeterOhmmeter
2
1
5
4 3 BatteryNo
Continuity
Continuity
- COOLINGENGINE MAIN RELAY
CO-33
613 Author
: Date
:
1996 TERCEL (RM440U)
ENGINE MAIN RELAY
INSPECTION
1. REMOVE RELAY BOX COVER
2. REMOVE ENGINE MAIN RELAY (Marking: EG MAIN)
3. INSPECT ENGINE MAIN RELAY
(a) Inspect the relay continuity
(1) Using an ohmmeter, check that there is continuity
between terminals 1 and 3.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
2 and 4.
(3) Check that there is no continuity between terminals
4 and 5.
If there is continuity, replace the relay.
(b) Inspect the relay operation
(1) Apply battery positive voltage across terminals 1
and 3.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 4 and 5.
If there is no continuity, replace the relay.
(3) Check that there is no continuity between terminals
2 and 4.
If there is continuity, replace the relay.
4. REINSTALL ENGINE MAIN RELAY

P20321
No.1 Cooling
Fan Relay
CO0IF-05
Z14238
Ohmmeter
ContinuityOhmmeter
Continuity87a 86
30
85
Z14239
No
Continuity Ohmmeter
Battery 87a 86
30
85
P20322
No.2 Cooling
Fan Relay
P20030No ContinuityContinuity87 30 Ohmmeter
85Ohmmeter
86
Ohmmeter87a CO-34
- COOLINGCOOLING FAN RELAY
614 Author
: Date
:
1996 TERCEL (RM440U)
COOLING FAN RELAY
INSPECTION
1. INSPECT NO.1 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.1 cooling fan relay (Marking: FAN NO.1).
(c) Inspect the No.1 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is continuity between terminals 30
and 87a.
If there is continuity, replace the relay.
(d) Inspect the No.1 cooling fan relay operation.
(1) Apply battery voltage across terminals 85 and 86.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 30 and 87a.
If there is continuity, replace the relay.
(e) Reinstall the No.1 cooling fan relay.
2. w/ A/C:
INSPECT NO.2 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.2 cooling fan relay (Marking: FAN NO.2).
(c) Inspect the No.2 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is continuity between terminals 30
and 87a.
If there is no continuity, replace the relay.
(3) Check that there is no continuity between terminals
30 and 87.
If there is continuity, replace the relay.

P20031
Ohmmeter
Continuity85 3087a 86
Battery No
Continuity
87
P20323
No.3 Cooling
Fan Relay
Z14237
Ohmmeter No
ContinuityContinuity Ohmmeter
87 86
30
85
Z14236
Ohmmeter
Continuity
Battery 87 86
30
85
- COOLINGCOOLING FAN RELAY
CO-35
615 Author
: Date
:
1996 TERCEL (RM440U)
(d) Inspect the No.2 cooling fan relay operation.
(1) Apply battery voltage across terminals 85 and 86.
(2) Using an ohmmeter, check that there is no continu-
ity between terminals 30 and 87.
If there is continuity, replace the relay.
(3) Using an ohmmeter, check that there is continuity
between terminals 30 and 87.
If there is no continuity, replace the relay.
(e) Reinstall the No.2 cooling fan relay.
3. INSPECT NO.3 COOLING FAN RELAY
(a) Remove the relay box cover.
(b) Remove the No.3 cooling fan relay. (Marking: FAN NO.3)
(c) Inspect the No.3 cooling fan relay continuity.
(1) Using an ohmmeter, check that there is continuity
between terminals 85 and 86.
If there is no continuity, replace the relay.
(2) Check that there is no continuity between terminals
30 and 87.
If there is continuity, replace the relay.
(d) Inspect the No.3 cooling fan relay operation.
(1) Apply battery positive voltage across terminals 85
and 86.
(2) Using an ohmmeter, check that there is continuity
between terminals 30 and 87.
If there is no continuity, replace the relay.
(e) Reinstall the No.3 cooling fan relay.