TOYOTA TERCEL 1996 Service Repair Manual

N06553
AC1DE-01
AC-22
- AIR CONDITIONINGMANIFOLD GAUGE SET
1996 TERCEL (RM440U)
SET OFF
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to un-
lock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE

AC1DF-01
- AIR CONDITIONINGREFRIGERANT LINE
AC-23
1175 Author
: Date
:
1996 TERCEL (RM440U)
REFRIGERANT LINE
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detecter, check for leakage of refrigerant.

AC1DG-03
N12553
Expansion Valve
Suction Tube
Liquid Tube Discharge Hose
Discharge HoseSuction Tube
Liquid Tube
Evaporator
Compressor
Condenser
Suction Hose
Liquid Tube AC-24
- AIR CONDITIONINGREFRIGERANT LINE
1996 TERCEL (RM440U)
LOCATION

AC1DH-03
- AIR CONDITIONINGREFRIGERANT LINE
AC-25
1996 TERCEL (RM440U)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE:
Connections should not be torqued tighter than the specified torqued.
Part tightenedN´mkgf´cmft´lbf
Compressor x Suction hose101007
Compressor x Discharge hose101007
Condenser x Discharge Hose5.45548 in.´lbf
Condenser x Liquid tube5.45548 in.´lbf
Cooling unit x Liquid tube1414010
Cooling unit x Suction tube3233024
Receiver x Liquid tube5.45548 in.´lbf
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION

AC1C9-03
N12246
Upper Unit Case
Magnetic Clutch
Relay
Evaporator
Expansion Valve
Grommet
Blower Resistor Lower Unit Case
O-ring

O-ring

Packing
Packing

Non-reusable part
Wire Harness
A/C Amplifier
AC-26
- AIR CONDITIONINGCOOLING UNIT
1178 Author
: Date
:
1996 TERCEL (RM440U)
COOLING UNIT
COMPONENTS

AC1CA-02
N12239
N12597
- AIR CONDITIONINGCOOLING UNIT
AC-27
1996 TERCEL (RM440U)
REMOVAL
1. DISCONNECT REFRIGERANT FROM REFRIGERA-
TION SYSTEM
HINT:
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.)
2. DISCONNECT LIQUID AND SUCTION TUBES
Loosen the 2 nuts and disconnect the both tubes.
Torque:
Liquid tube: 14 N´m (140 kgf´cm, 10 ft´lbf)
Suction tube: 32 N´m (330 kgf´cm, 24 ft´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 the
tubes.
3. REMOVE GLOVE COMPARTMENT PARTS
(See page BO-48)
4. REMOVE COOLING UNIT
(a) Disconnect the connector.
(b) Remove the 3 screws, 2 nuts and the cooling unit.

AC2WI-01
AC-28
- AIR CONDITIONINGCOOLING UNIT
1996 TERCEL (RM440U)
DISASSEMBLY
1. REMOVE WIRE HARNESS
2. REMOVE MAGNETIC CLUTCH RELAY
3. REMOVE A/C AMPLIFIER
4. REMOVE BLOWER RESISTOR
5. SEPARATE UPPER CASE AND LOWER CASE
(a) Using a knife, cut off the each packing.
(b) Remove 2 clips and 2 screws.
(c) Separate the upper and lower unit case.
6. REMOVE EVAPORATOR
HINT:
If evaporator was replaced, add compressor oil to the compressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND-OIL 8 or equivalent
7. REMOVE THERMISTOR FROM EVAPORATOR
8. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the expansion valve and evaporator.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
HINT:
Lubricate 4 new O-rings with compressor oil and install them to the tubes.

AC1CD-02
- AIR CONDITIONINGCOOLING UNIT
AC-29
1996 TERCEL (RM440U)
REASSEMBLY
Reassembly is in the reverse order of disassembly procedure (See page AC-28).

AC1CE-02
AC-30
- AIR CONDITIONINGCOOLING UNIT
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-27).

AC1CF-04
- AIR CONDITIONINGHEATER UNIT
AC-31
1183 Author
: Date
:
1996 TERCEL (RM440U)
HEATER UNIT
COMPONENTS