1996 TOYOTA TERCEL fan switch

EM18V-02
EM-10
- ENGINE MECHANICALIDLE SPEED
431 Author
: Date
:
1996 TERCEL (RM440U)
IDLE SPEED
INSPECTION
1. INITIAL CONDITIONS
(a) Engine coolant at normal operating temperature.
(b) Air cleaner installed.
(c) All pipes and hoses of air induction system connected.
(d) All accessories switched OFF.
(e) All vacuum lines properly connected.
HINT:
All vacuum hoses for EGR system, etc. should be properly connected.
(f) SFI system wiring connectors fully plugged.
(g) Ignition timing set correctly.
(h) Transmission in neutral position.
2. CONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL (See page EM-9)
3. INSPECT IDLE SPEED
(a) Race the engine speed at 2,500 rpm for approx. 90 seconds.
(b) Check the idle speed.
Idle speed:
750 ± 50 rpm
(w/ Cooling fan OFF and transmission in neutral position)
If the idle speed is not as specified, check the IAC valve and air intake system.
4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBDII SCAN TOOL

P20496
P20406
- ENGINE MECHANICALCYLINDER HEAD
EM-25
1996 TERCEL (RM440U)
16. REMOVE WATER INLET AND OUTLET HOUSING
(a) Disconnect the engine coolant temperature sender
gauge connector.
(b) Disconnect the engine coolant temperature sensor con-
nector.
(c) Disconnect the fan engine coolant temperature switch
connector.
(d) Disconnect the 2 radiator hoses.
(e) Disconnect the water inlet hose.
(f) Disconnect the heater outlet hose.
(g) Remove the bolt, 2 nuts, the water inlet and outlet hous-
ing.
17. REMOVE EXHAUST MANIFOLD
(a) Remove the 3 bolts and heat insulator.
(b) Remove the bolt, 2 nuts and exhaust manifold stay.
(c) Remote the 6 nuts, exhaust manifold and gasket.
18. REMOVE DELIVERY PIPE AND INJECTORS (See
page MF-18)
19. DISCONNECT BRAKE BOOSTER AND MAP VACUUM
HOSES
20. REMOVE INTAKE MANIFOLD
(a) Disconnect the engine wire clamps from the intake man-
ifold stay.
(b) Remove the bolt, nut and intake manifold stay.
(c) Remove the 2 bolts, 3 nuts, intake manifold and gasket
with air pipe.
21. REMOVE CYLINDER HEAD COVER
(a) Remove the oil filler cap.
(b) Remove the 5 cap nuts and seal washers.
(c) Pry out the cylinder head cover, and remove the cover
and gasket.

EM-52
- ENGINE MECHANICALCYLINDER HEAD
1996 TERCEL (RM440U)
HINT:
Avoid applying an excess amount to the surface. Be especially
careful near oil passages.

Parts must be assembled within 15 minutes of ap-
plication. Otherwise, the material must be removed
and reapplied.

Immediately remove nozzle from tube and reinstall
cap.

Do not pour in any coolant until at least 2 hours after
installation is completed.
(c) Install the water outlet housing with the bolt and 2 nuts.
Torque: 17.5 N´m (175 kgf´cm, 13 ft´lbf)
(d) Connect the 2 radiator hoses.
(e) Connect the water inlet hose.
(f) Connect the heater outlet hose.
(g) Connect the engine coolant temperature sensor connec-
tor.
(h) Connect the engine coolant temperature sender gauge
connector.
(i) Connect the fan engine coolant temperature switch con-
nector.
20. INSTALL CAMSHAFT POSITION SENSOR AND EGR
VSV
(a) Install a new O-ring to the position sensor.
(b) Install the position sensor with the bolt.
Torque: 8.0 N´m (80 kgf´cm, 69 in.´lbf)
(c) Install the EGR VSV with the bolt.
Torque: 17.5 N´m (175 kgf´cm, 13 in.´lbf)
(d) Connect the position sensor and EGR VSV connectors.
21. INSTALL EGR VALVE AND VACUUM MODULATOR
(a) Install a new gasket and the EGR valve with the 2 nuts.
Torque: 30 N´m (300 kgf´cm, 22 in.´lbf)
(b) Install the EGR vacuum modulator and bracket with the
bolt.

P20565
M/T EM-58
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)

Engine coolant temperature sender gauge connec-
tor

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
15. M/T only:
REMOVE CLUTCH RELEASE CYLINDER WITHOUT
DISCONNECTING TUBE
(a) Remove the 3 bolts, release cylinder and tube from the
transaxle.
(b) Disconnect the ground strap.
16. M/T:
DISCONNECT CONTROL CABLE(S) FROM TRANS-
AXLE
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.

EM-66
- ENGINE MECHANICALENGINE UNIT
1996 TERCEL (RM440U)
15. CONNECT ENGINE WIRE HARNESS
Connect these connectors and wires:

Main heated oxygen sensor connector

Oil pressure switch connector

Engine coolant temperature sender gauge
connector

Engine coolant temperature sensor connector

Camshaft position sensor connector

EGR VSV

Fan engine coolant temperature switch connector

A/T only:
Lock-up solenoid connector

A/T only:
Park/Neutral position switch connector

M/T only:
Backup light switch connector

A/T only:
No.2 vehicle speed sensor connector

Ground strap

Throttle position sensor connector

IAC valve connector

Injector connectors

Crankshaft position sensor connector

Knock sensor connector

Starter connector and wire

Generator connector and wire
16. w/ PS:
CONNECT IDLE-UP AIR HOSES TO AIR CONTROL
VA LV E
17. CONNECT SPEEDOMETER CABLE
18. CONNECT HOSES
(a) Connect the brake booster vacuum hose.
(b) Connect the MAP sensor hose.
(c) Connect the heater hoses.

CO0Y5-02
P20875
Above 94°C
P20883
Ammeter
Battery
- COOLINGELECTRIC COOLING FAN
CO-23
603 Author
: Date
:
1996 TERCEL (RM440U)
ELECTRIC COOLING FAN
ON-VEHICLE INSPECTION
1. CHECK COOLING FAN OPERATION WITH LOW TEM-
PERATURE (Below 83°C (181°F))
(a) Turn the ignition switch ON.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and ECT switch, and check
for a separated connector or severed wire between the cooling
fan relay and ECT switch.
(c) Disconnect the ECT switch connector.
(d) Check that the cooling fan rotates.
If not, check the engine main relay, cooling fan relay, cooling
fan, fuses, and check for short circuit between the cooling fan
relay and ECT switch.
(e) Reconnect the ECT switch connector.
2. CHECK COOLING FAN OPERATION WITH HIGH TEM-
PERATURE (Above 94°C (201°F))
(a) Start the engine, and raise coolant temperature to above
94°C (201°F).
(b) Check that the cooling fan rotates.
If not, replace the ECT switch.
3. INSPECT NO.1 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage:
M/T5.7 - 7.7 A
A/T8.6 - 11.6 A
(d) Reconnect the cooling fan connector.
4. INSPECT NO.2 COOLING FAN
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and check
the reading on the ammeter.
Standard amperage: 6.4 - 7.4 A
(d) Reconnect the cooling fan connector.

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
-

AC1D2-02
Z13470
Magnetic Clutch Control
Low Pressure Side High Pressure Side
ON (Continuity)
196 kPa
(2.0 kgf´cm
2, 28 psi)
OFF (No Continuity)3, 140 kPa
(32.0 kgf´cm2, 455 psi)
OFF (No Continuity)
Z13471
1, 520 kPa
(15.5 kgf´cm2, 220psi)
ON
(Continuity)
OFF
(No Continity)
1, 226 kPa
(12.5 kgf´cm
2, 178psi) Condenser Fan Control
- AIR CONDITIONINGPRESSURE SWITCH
AC-59
1211 Author
: Date
:
1996 TERCEL (RM440U)
PRESSURE SWITCH
ON-VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
(See page AC-21)
2. DISCONNECT CONNECTOR FROM PRESSURE
SWITCH
3. RUN ENGINE AT APPROX. 2,000 RPM
4. Magnetic Clutch Control:
INSPECT PRESSURE SWITCH OPERATION
(a) Connect the positive (+) lead from the ohmmeter to termi-
nal 4 and the negative (-) lead to terminal 1.
(b) Check continuity between terminals when refrigerant
pressure is charged, as shown in the illustration.
If operation is not as specified, replace the pressure switch.
5. Condenser Fan Control:
INSPECT PRESSURE SWITCH OPERATION
(a) Connect the positive (+) lead from the ohmmeter to termi-
nal 2 and the negative (-) lead to terminal 3.
(b) Check continuity between terminals when refrigerant
pressure is changed, as shown in the illustration.
If operation is not as specified, replace the pressure switch.
6. STOP ENGINE AND SET OFF MANIFOLD GAUGE SET
7. CONNECT CONNECTOR TO PRESSURE SWITCH