check engine TOYOTA TERCEL 1996 Service Repair Manual

BE0044
Ignition
Switch
BatteryWarning Light
BE0146
BE1217
Ignition
Switch
BatteryWarning Light
BE1601
ON OFF
- BODY ELECTRICALCOMBINATION METER
BE-41
1996 TERCEL (RM440U)
If resistance value is not as specified, replace the receiver
gauge.
9. INSPECT LOW OIL PRESSURE WARNING LIGHT
(a) Disconnect the connector from the warning switch and
ground terminal on the wire harness side connector.
(b) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
10. INSPECT LOW OIL PRESSURE SWITCH CONTINUITY
(a) Disconnect the connector from the switch.
(b) Check that there is continuity between terminal and
ground with the engine stopped.
(c) Check that there is no continuity between terminal and
ground with the engine running.
HINT:
Oil pressure should be over 49 kPa (0.5 kgf/cm
2, 7.1 psi).
If operation is not as specified, replace the switch.
11. INSPECT BRAKE SYSTEM WARNING LIGHT
(a) Disconnect the connectors from the level warning switch
and parking brake switch.
(b) Connect terminals on the wire harness side connector of
the level warning switch connector.
(c) Turn the ignition switch ON, and check that the warning
light lights up.
If the warning light does not light up, test the bulb.
12. INSPECT BRAKE FLUID LEVEL WARNING SWITCH
CONTINUITY
(a) Check that there is no continuity between terminals with
the switch OFF (float up).
(b) Check that there is continuity between terminals with the
switch ON (float down).
If operation is not as specified, replace the switch.

AC2WA-02
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-3
1996 TERCEL (RM440U)
ON-VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control set at ºMAX COOLº
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to item 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sigh glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
of purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect-
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.

I01390
Condition: Insufficient cooling
I01392
Condition: Insufficient cooling
NOTE : These gauge indica-
tions are shown when the
refrigeration system has
been opened and the refrig-
erant charged without vacu-
um purging.
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-7
1996 TERCEL (RM440U)
(6) Refrigerant overcharged or insufficient cooling of
condenser
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 No air bubbles seen through the
sight glass even when the engine
rpm is lowered Unable to develop sufficient per-
formance due to excessive refrig-
erant in system
 Insufficient cooling of condenserExcessive refrigerant in
cycle " refrigerant overcharged
 Condenser cooling "condenser
fins clogged of condenser fan
faulty.(1) Clean condenser
(2) If (1) is normal, check amount
of refrigerant
Charge proper amount or refriger-
ant
(7) Air present in refrigeration system
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 The low pressure piping hot to
the touch
 Bubbles seen in sight glass
Air entered in refrigeration system
 AIr present in refrigeration sys-
tem
 Insufficient vacuum purging
(1) Check compressor oil to see if
it is dirty or insufficient
(2) Evacuate air and charge new
refrigerant

N14519
Drain Hose
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-9
1996 TERCEL (RM440U)
3. INSPECT IDLE-UP SPEED
(a) Warm up engine.
(b) Inspect idle-up speed when the these conditions are es-
tablished.
Test conditions:
Blower speed control switch HI
Electrical lood OFF
A/C switch ON
Put gear shift in neutral
Standard idle-up speed: 800 - 900 rpm
If idle speed is not as specified, check the IAC valve and air in-
take system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:
Stop engine.
Secure good ventilation (If the gas leak detector
may not react to volatile gases which are not refrig-
erant, such as evaporated gasoline and exhaust
gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approx. 392 - 588 kPa
(4 - 6 kgf/ cm
2, 57 - 85 psi)
(b) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:
After the blower motor has stopped, leave the cooling unit
for more than 15 minutes.
Expose the gas leak detector sensor under the drain
hose.
When bring the gas leak detector close to the drain hose,
make sure that the gas leak detector does not react to the
volatile gases.
If such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected on the drain hose, remove the
power transistor from the cooling unit. Then insert the gas
leak detector sensor into the unit and perform the test.
(d) Disconnect the connector and leave the pressure switch
for approx. 20 minutes. Then bring the gas leak detector
close to the pressure switch and perform the test.
(e) Bring the gas leak detector close to the refrigerant lines
and perform the test.

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

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
-

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.

AC3IO-01
AC-36
- AIR CONDITIONINGCOMPRESSOR
1188 Author
: Date
:
1996 TERCEL (RM440U)
COMPRESSOR
ON-VEHICLE INSPECTION
1. INSTALL MANIFOLD GAUGE SET
2. RUN ENGINE AT APPROX. 2,000 RPM
3. INSPECT COMPRESSOR
(a) High pressure gauge reading is not lower and low pressure gauge reading is not higher than normal.
(b) Check that the metallic sound.
(c) Check that the leakage from shaft seal.

AC2XI-01
AC-54
- AIR CONDITIONINGEXPANSION VALVE
1206 Author
: Date
:
1996 TERCEL (RM440U)
EXPANSION VALVE
ON-VEHICLE INSPECTION
1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE
2. INSTALL MANIFOLD GAUGE SET
3. RUN ENGINE
Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is 1.37 - 1.57
MPa (14 - 16 kgf/cm
2, 199 - 228 psi).
4. CHECK EXPANSION VALVE
If the expansion valve is faulty, the low pressure reading will drop to 0 kgf/cm
2, 0 psi), otherwise it is OK.
HINT:
When the low pressure drops to 0 kPa (0 kgf/cm
2, 0 psi), feel the receiver's IN and OUT sides for 0 tempera-
ture difference.

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