TOYOTA TERCEL 1996 Service Repair Manual

AC3IQ-01
AC1849
AC1850
SST
AC1849
SST
AC0946
Shim
Pressure Plate
AC1403
SST
AC-42
- AIR CONDITIONINGMAGNETIC CLUTCH
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE COMPRESSOR
(See page AC-38)
2. REMOVE PRESSURE PLATE
(a) USING SST and socket wrench, remove the shaft bolt.
SST 07112-76050
Torque: 14 N´m (140 kgf´cm, 10 ft´lbf)
(b) Install SST to the pressure plate.
SST 07112-66040
(c) Using SST and a socket wrench, remove the pressure
plate.
SST 07112-76050, 07112-66040
(d) Remove the shims from the shaft.
3. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114-84020

AC1404
AC1101
AC1405
- AIR CONDITIONINGMAGNETIC CLUTCH
AC-43
1996 TERCEL (RM440U)
NOTICE:
At the time of reassembly, the snap ring should be installed
so that its beveled side faces up.
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE:
Be careful not to damage the pulley when tapping on the ro-
tor.
4. REMOVE STATOR
(a) Using a screwdriver disconnect the stator lead wires from
the compressor housing.
(b) Using SST, remove the snap ring.
SST 07114-84020
NOTICE:
At the time of reassembly, the snap ring should be installed
so that its beveled side faces up.

AC1423
AC-44
- AIR CONDITIONINGMAGNETIC CLUTCH
1996 TERCEL (RM440U)
(c) Remove the stator.

N04963
Dial Indicator
AC2WR-02
- AIR CONDITIONINGMAGNETIC CLUTCH
AC-45
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See
page AC-42).
INSPECT CLEARANCE OF MAGNETIC CLUTCH
(a) Set the dial-indicator to the pressure plate of the magnet-
ic clutch.
(b) Connect the magnetic clutch lead wire to the positive (+)
terminal of the battery.
(c) Check the clearance between the pressure plate and ro-
tor, when connect the negative (-) terminal of the battery.
Standard clearance:
0.5 ± 0.15 mm F(0.020 ± 0.0059 in.)
If the clearance is not within standard clearance adjust the
clearance using shims to obtain the standard clearance.

AC3IR-01
AC-46
- AIR CONDITIONINGRECEIVER
1198 Author
: Date
:
1996 TERCEL (RM440U)
RECEIVER
ON-VEHICLE INSPECTION
INSPECT SIGHT GLASS, FUSIBLE PLUG AND FITTINGS
FOR LEAKAGE
Use a gas leak detector. Repair as necessary.

AC2WU-02
- AIR CONDITIONINGRECEIVER
AC-47
1996 TERCEL (RM440U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
Charge system with refrigerant and inspect for leakage of refrig-
erant.
HINT:
At the time of installation, evacuate air from refrigeration sys-
tem.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. REMOVE FRONT GRILLE
3. DISCONNECT 2 LIQUID TUBES FROM RECEIVER
Remove the 2 bolts and both tubes.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap the open fittings immediately to keep moisture dirt out
of the system.
HINT:
At the time of installation, lubricate 2 new O-rings with com-
pressor oil and install the tubes.
4. REMOVE RECEIVER FROM RECEIVER HOLDER
Remove the holder bolts and pull the receiver up ward from the
receiver holder.
HINT:
If receiver was replaced, add compressor oil to compressor.
Add 10 cc (0.4 fl.oz.)
Compressor oil: ND-OIL 9 or equivalent
5. REMOVE RECEIVER HOLDER
Remove the bolt and holder.

AC2WV-01
AC-48
- AIR CONDITIONINGRECEIVER
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-47).

AC1CX-02
- AIR CONDITIONINGCONDENSER
AC-49
1201 Author
: Date
:
1996 TERCEL (RM440U)
CONDENSER
ON-VEHICLE INSPECTION
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air.
NOTICE:
Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers.
2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE
Repair as necessary.

AC1CY-04
N12238
N12241
AC-50
- AIR CONDITIONINGCONDENSER
1996 TERCEL (RM440U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
Charge system with refrigerant and inspect for leakage of refrig-
erant.
HINT:
At the time of installation, evacuate air from refrigeration sys-
tem.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. REMOVE RECEIVER (See page AC-47)
3. DISCONNECT LIQUID TUBE AND DISCHARGE TUBE
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
Lubricate 2 new O-rings with compressor oil and install them
to the tubes.
4. REMOVE CONDENSER
(a) Remove the 2 radiator upper mountings.
(b) Remove the 2 bolts from condenser upper mountings.
(c) Push the radiator toward the engine.
(d) Push the condenser toward radiator and pull it upward.
HINT:
If condenser was replaced, add compressor oil to compressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND-OIL 9 or equivalent

AC1CZ-02
- AIR CONDITIONINGCONDENSER
AC-51
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-50).