TOYOTA TERCEL 1996 Service Repair Manual

AC1DU-02
N13793
Charging Cylinder High Pressure
Service Valve Low Pressure
Service ValvePush
Air
N13792
Gas Leak
Detector AC-12
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
CHARGING
1. INSTALL CHARGING CYLINDER
HINT:
When handling the charging cylinder, always follow the direc-
tions given in the instruction manual.
(a) Charge the proper amount of refrigerant into the charging
cylinder.
(b) Connect the center hose to the charging cylinder.
CAUTION:
Do not open both high and low hand valves of manifold
gauge set.
(c) Open the valve of charging cylinder.
(d) Press the valve core on the side of manifold gauge and
expel the air inside of the center hose.
2. INSPECT REFRIGERATION SYSTEM FOR LEAKS
(a) Open the high pressure hand valve and charge refriger-
ant.
(b) When the low pressure gauge indicates 98 kPa
(1 kgf/cm
2, 14 psi) close the high pressure hand valve.
(c) Using a gas leak detector, check the system for leakage.
If leak is found, repair the faulty component or connection.
Add evacuate air from refrigeration system (See page
AC-1 1).
CAUTION:
Use the refrigerant recovery/ recycling machine to recover
the refrigerant whenever replacing parts.

N13790
Low Pressure
Service Valve
High Pressure
Service Valve
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-13
1996 TERCEL (RM440U)
3. CHARGE REFRIGERANT INTO REFRIGERANT SYS-
TEM
If there is no leakafter refrigerant leak check, charge the proper
amount of refrigerant intor refrigeration system.
CAUTION:

Never run the engine when charging the system
through the high pressure side.

Do not open the low pressure hand a valve when the
system is being charged with liquid refrigerant.
(a) Open the high pressure hand valve fully.
(b) Charge specified amopunt of refrigerant, then close the
high pressure hand valve.
HINT:
A fully charged system is indicated by the sight flass being free
of any bubbles.
4. SET OFF MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Disconnect the quick disconnect adapters from the ser-
vice valves.
5. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINES

AC2WB-01
AC-14
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TERCEL (RM440U)
LOCATION

AC2WC-01
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-15
1996 TERCEL (RM440U)
POSITIONING

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

CH0086
CorrectWrong
AC1C5-04
Z16157
PS Pump
Idle Pulley
Compressor
Compressor Crankshaft
PulleyCrankshaft
Pulley
I17366
Nippondenso Borroughs AC-18
- AIR CONDITIONINGDRIVE BELT
1170 Author
: Date
:
1996 TERCEL (RM440U)
DRIVE BELT
ON-VEHICLE INSPECTION
1. INSPECT DRIVE BELT'S INSTALLATION CONDITION
Check that the drive belt fits properly in the ribbed grooves.
2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20 (95506-00020) or Borroughs
No. BT-33-73F
Drive belt tension:
New belt 160 ± 25 lbf
Used belt 100 ± 20 lbf
HINT:

ºNew beltº refers to a belt which has been used less than
5 minutes on a running engine.

ºUsed beltº refers to a belt which has been used on a run-
ning engine for 5 minutes or more.

After installing the drive belt, check that it fits properly in
the ribbed grooves.

AC1C6-03
N05463
Adjusting
Bolt
Compressor
Drive Belt
Idle Pully Lock Nut
N15502
- AIR CONDITIONINGDRIVE BELT
AC-19
1996 TERCEL (RM440U)
REMOVAL
1. w/o Power Steering:
REMOVE DRIVE BELT
(a) Loosen the idle pully lock nut.
Torque: 39 N´m (400 kgf´cm, 29 ft´lbf)
(b) Loosen the adjusting bolt and remove drive belt.
2. w/ Power Steering:
REMOVE DRIVE BELT
(a) Loosen the 2 PS pump set bolts.
Torque: 43 N´m (440 kgf´cm, 32 ft´lbf)
(b) Loosen the adjusting bolt.
(c) Remove the belt.

AC2WH-02
AC-20
- AIR CONDITIONINGDRIVE BELT
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-19).

N12205
Low Pressure
Charging Hose High Pressure
Charging Hose
AC1DD-01
N04392
Sleeve
- AIR CONDITIONINGMANIFOLD GAUGE SET
AC-21
1173 Author
: Date
:
1996 TERCEL (RM440U)
MANIFOLD GAUGE SET
SET ON
1. CONNECT CHARGE HOSES TO MANIFOLD GAUGE
SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4. REMOVE CAPS FROM SERVICE VALVE ON REFRIG-
ERANT LINES
5. CONNECT QUICK DISCONNECT ADAPTER TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then
slide, the sleeve of the quick disconnect adapter downward to
lock it.