engine TOYOTA TERCEL 1996 Service Repair Manual

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

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

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