TOYOTA TERCEL 1996 Service Repair Manual

AC1CG-04
AC2884
Hose Clip
Heater Radiator
Pipe
Water Hose
InsulatorLeft Side
of Vehicle
N12242
AC-32
- AIR CONDITIONINGHEATER UNIT
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE COOLING UNIT
(See page AC-27)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all the coolant.
3. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
HINT:

Push the water hose onto the heater radiator pipe as far
as the ridge on the pipe.

Install the hose clip in a position, as shown in the illustra-
tion.
4. REMOVE PIPE GROMMETS
5. REMOVE INSTRUMENT PANEL SAFETY PAD AND
REINFORCEMENT (See page BO-48)
6. REMOVE HEATER UNIT
Remove the 2 nuts and the heater unit.
7. REMOVE HEATER RADIATOR
(a) Remove the screw and clamp.
(b) Pull out the heater radiator.

AC1CK-02
- AIR CONDITIONINGHEATER UNIT
AC-33
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-32).

AC3IN-01
N12203
AC-34
- AIR CONDITIONINGBLOWER UNIT
1186 Author
: Date
:
1996 TERCEL (RM440U)
BLOWER UNIT
REMOVAL
1. REMOVE COOLING UNIT (See page AC-27)
2. REMOVE BLOWER UNIT
(a) Disconnect the connector from the blower motor.
(b) Disconnect the air inlet damper control cable.
(c) Remove the 2 nut, bolt and the blower unit.
3. REMOVE BLOWER MOTOR
Remove the 3 screws and blower motor.

AC1CO-02
- AIR CONDITIONINGBLOWER UNIT
AC-35
1996 TERCEL (RM440U)
INSTALLATION
Installation is in the reverse order of removal procedure (See page AC-34).

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.

AC2WL-02
- AIR CONDITIONINGCOMPRESSOR
AC-37
1996 TERCEL (RM440U)
COMPONENTS

AC3IP-01
AC-38
- AIR CONDITIONINGCOMPRESSOR
1996 TERCEL (RM440U)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. DISCONNECT CONNECTOR FROM MAGNETIC CLUTCH
7. DISCONNECT 2 HOSES FROM COMPRESSOR SERVICE VALVE
NOTICE:
Cap the open fitting immediately to keep moisture or dirt out of the system
8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the compressor.

AC2WN-02
- AIR CONDITIONINGCOMPRESSOR
AC-39
1996 TERCEL (RM440U)
INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING BOLTS
Torque: 25 N´m (250 kgf´cm, 18 ft´lbf)
2. INSTALL DRIVE BELT (See page AC-20)
3. CONNECT 2 HOSES TO COMPRESSOR SERVICE VALVES
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
HINT:
Lubricate 2 new O-rings with compressor oil and install the tubes.
4. CONNECT MAGNETIC CLUTCH LEAD WIRE TO WIRING HARNESS
5. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT
Specified amount:
600 ± 50 g (21.73 ± 1.76 oz.)
7. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
8. INSPECT A/C OPERATION

AC2WO-02
AC-40
- AIR CONDITIONINGMAGNETIC CLUTCH
1192 Author
: Date
:
1996 TERCEL (RM440U)
MAGNETIC CLUTCH
ON-VEHICLE INSPECTION
INSPECT MAGNETIC CLUTCH
(a) Inspect the pressure plate and the rotor for signs of oil.
(b) Check the clutch bearings for noise and grease leakage.
(c) Connect the positive (+) lead from the battery to the termi-
nal on 4 and the negative (-) lead to the body ground.
(d) Check that the magnetic clutch is energized.
If the magnetic clutch is not energized, replace the magnetic
clutch.

AC2WP-02
N12676
Pressure Plate

Snap RingCompressor
Stator Rotor

Snap Ring

Non-reusable part
Shim
- AIR CONDITIONINGMAGNETIC CLUTCH
AC-41
1996 TERCEL (RM440U)
COMPONENTS