TOYOTA TERCEL 1996 Service Repair Manual

Z06166
12 34
5
12 345
AC2X8-02
AC-62
- AIR CONDITIONINGHEATER MAIN RELAY
1214 Author
: Date
:
1996 TERCEL (RM440U)
HEATER MAIN RELAY
INSPECTION
INSPECT HEATER MAIN RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 3
2 - 4Continuity
Apply B+ between
terminals 3 and 5.4 - 5Continuity
If continuity is not as specified, replace the relay.

Z06346
1
2
3 41 2
3 4
AC2X9-01
- AIR CONDITIONINGMAGNETIC CLUTCH RELAY
AC-63
1215 Author
: Date
:
1996 TERCEL (RM440U)
MAGNETIC CLUTCH RELAY
INSPECTION
INSPECT MAGNETIC CLUTCH RELAY CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 3Continuity
Apply B+ between
terminals 3 and 5.2 - 4Continuity
If continuity is not as specified, replace the relay.

Z12319
1
2 34
12 34AC2XA-01
N02832
1
2 345
1
23
45
I07286
1
2 3
51
2
3
5 AC-64
- AIR CONDITIONINGCOOLING FAN RELAY
1216 Author
: Date
:
1996 TERCEL (RM440U)
COOLING FAN RELAY
INSPECTION
1. INSPECT COOLING FAN RELAY No. 1 (Marking: FAN)
CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2
3 - 4Continuity
Apply B+ between
terminals 1 and 2.3 - 4No continuity
If continuity is not as specified, replace the relay.
2. INSPECT COOLING FAN RELAY No. 2 (Marking: A.C
FAN No. 2) CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2
3 - 4Continuity
Apply B+ between
terminals 1 and 2.3 - 5Continuity
If continuity is not as specified, replace the relay.
3. INSPECT COOLING FAN RELAY No. 3 (Marking: A.C
FAN No. 3) CONTINUITY
ConditionTester connectionSpecified condition
Constant1 - 2Continuity
Apply B+ between
terminals 1 and 2.3 - 5Continuity
If continuity is not as specified, replace the relay.

N12550
AC3IU-01
- AIR CONDITIONINGCONDENSER FAN
AC-65
1217 Author
: Date
:
1996 TERCEL (RM440U)
CONDENSER FAN
ON-VEHICLE INSPECTION
INSPECT COOLING FAN MOTORS OPERATION
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter.
(c) Check that the cooling fan rotates smoothly, and then
check that the reading on the ammeter.
Specified amperage: 6.9 ± 0.5 A
(d) Connect the fan connector.

AC1D0-04
Z14427
Wire harness side
1
23
4
5
10 9 8 6
71112
Z14428
1 2 3 4 5
1098
6 7 11 12 From back side AC-66
- AIR CONDITIONINGAIR CONDITIONING AMPLIFIER
1218 Author
: Date
:
1996 TERCEL (RM440U)
AIR CONDITIONING AMPLIFIER
ON-VEHICLE INSPECTION
1. w/ Power Steering:
INSPECT A/C AMPLIFIER CIRCUIT
(a) Disconnect the connector from amplifier and inspect the
connector on wire harness side, as shown in the chart.
Test conditions:

Turn ignition switch to ON

Blower speed control switch at ºHIº position

A/C switch ON

Temperature control lever at MAX COOL
Tester connectionConditionSpecified condition
5 - GroundConstantContinuity
1 - GroundConstantContinuity
6 - GroundConstantContinuity
1 - ECM terminal AC1ConstantContinuity
6 - ECM terminal ACTConstantContinuity
8 - 12ConstantApprox. 1.5 kW at 25°C (77°F)
7 - GroundA/C switch ONBattery positive voltage
7 - GroundA/C switch OFFNo voltage
9 - GroundA/C switch ONBattery positive voltage
9 - GroundA/C switch OFFNo voltage
11 - GroundConstantBattery positive voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
(b) Connect the connector to A/C amplifier and inspect the
wire harness connector from the back side, as shown in
the chart below.
Tester conditions:

Running engine at idle speed

Blower speed control switch at HI position

Temperature control lever at MAX COOL
position

A/C switch ON

Set manifold gauge set

Z11344
1234
5
10 9 8 6
7 Wire harness side
N10516
1 2 3 4
5 10 9 8
6 7
From back side
- AIR CONDITIONINGAIR CONDITIONING AMPLIFIER
AC-67
1219 Author
: Date
:
1996 TERCEL (RM440U)Tester connection
ConditionSpecified condition
2 - GroundRefrigerant pressure 196 - 3,140 kPaBattery positive voltage
2 - GroundRefrigerant pressure less than
196 kPa or more than 3,140No voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
2. w/o Power steering:
INSPECT A/C AMPLIFIER
(a) Disconnect the connector from amplifier and inspect the
connector on wire harness side, as shown in the chart.
Test conditions:

Turn ignition switch to ON

Blower speed control switch at HI position

A/C switch ON

Temperature control lever at MAX COOL
Test connectionConditionSpeed condition
4 - GroundConstantContinuity
6 - ECM terminal ACTConstantContinuity
8 - ECM terminal AC1ConstantContinuity
6 - 10ConstantApprox. 1.5 kW at 25°C (77°F)
5 - GroundA/C switch ONBattery positive voltage
5 - GroundA/C switch OFFNo voltage
9 - GroundIgnition switch ONBattery positive voltage
9 - GroundIgnition switch ONNo voltage
7 - GroundA/C switch ONBattery positive voltage
7 - GroundA/C switch OFFNo voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.
(b) Connect the connector to amplifier and inspect the wire
harness connector from back side, as shown in the chart
below.
Test conditions:

Running engine at idle speed

Blower speed control switch at HI position

Temperature control lever at MAX COOL
position

A/C switch ON

Set manifold gauge set

AC-68
- AIR CONDITIONINGAIR CONDITIONING AMPLIFIER
1220 Author
: Date
:
1996 TERCEL (RM440U)Tester connection
ConditionSpecified condition
1 -GroundRefrigeration pressure 196 - 3,140 kPaBattery positive voltage
1 - GroundRefrigeration pressure
less than 196 or more than 3,140 kPaNo voltage
If circuit is as specified, try replacing the amplifier with a new
one. If the circuit is not as specified, inspect the circuits con-
nected to other parts.

AC3IV-01
- AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC-69
1221 Author
: Date
:
1996 TERCEL (RM440U)
HEATER CONTROL ASSEMBLY
ON-VEHICLE INSPECTION
INSPECT A/C CONTROL LEVERS OPERATION
Move the control dials and lever left and right and check for stiffness and binding through the full range of
the levers.

AC3IW-01
AC-70
- AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TERCEL (RM440U)
REMOVAL
1. REMOVE GLOVE COMPARTMENT PARTS
(See page BO-45).
2. REMOVE INSTRUMENT LOWER FINISH PANEL
(See page BO-45).
3. REMOVE CENTER CLUSTER FINISH PANEL
(See page BO-45).
4. DISCONNECT A/C CONTROL CABLES
5. REMOVE A/C CONTROL ASSEMBLY
(a) Remove the heater control knobs.
(b) Remove the A/C switch.
(c) Remove the heater control panel.
(d) Remove the 4 screws and A/C control assembly.

AC1DO-04
Z16144
Z07777
1
3
4 5 6
- AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC-71
1996 TERCEL (RM440U)
INSPECTION
1. INSPECT BLOWER SWITCH CONTINUTY
Position / CircuitTester connectionSpecified condition
OFF-No continuity
LO5 - 6Continuity
M11 - 5 - 6Continuity
M22 - 5 - 8Continuity
HI5 - 6 - 8Continuity
Illumination circuit3 - 4Continuity
If continuity is not as specified, replace the A/C control assem-
bly.
2. INSPECT A/C SWITCH CONTINUITY
Condition/ CircuitTester connectionSpecified condition
OFF-No continuity
ON4 - 5
4 - 6Continuity
Illumination circuit1 - 3Continuity
Switch continuity:
If continuity is not as specified, replace the switch.
Illumination circuit:
If continuity is not as specified, test the bulb.