Toyota Tercel 1984-1994 Repair Guide

Engine Fan

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

1984-1986 Sedans and All Wagons
  1. Disconnect the negative battery cable.
  2.  
  3. Unplug the fan electrical connection.
  4.  
  5. Remove the front grille.
  6.  
  7. Remove the fan attaching bolts and remove the fan.
  8.  
  9. Installation is the reverse of removal. Test for proper operation.
  10.  



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Fig. Fig. 1: On some models, the cooling fan is located behind the front grille



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Fig. Fig. 2: An extension is useful when removing the lower attaching bolt



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Fig. Fig. 3: Removing the upper attaching bolt



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Fig. Fig. 4: Make sure the electrical connection is unplugged when removing the cooling fan

1987-1994 Sedans

CAUTION
On models equipped with an Supplemental Restraint System (SRS) or "air bag,'' work must NOT be started until at least 90 seconds have passed from the time that both the ignition switch is turned to the LOCK position and the negative cable is disconnected from the battery.

  1. Disconnect the negative battery cable and unplug the fan electrical connection.
  2.  
  3. On fuel injected engines, remove the air intake duct.
  4.  
  5. If necessary, drain the coolant to an appropriate level and remove the upper radiator hose.
  6.  
  7. Remove the fan attaching bolts and remove the fan.
  8.  
  9. Installation is the reverse of removal. Refill the cooling system and check for leaks. Test the fan motor for proper operation.
  10.  

TESTING



See Figures 5, 6, 7, and 8

Cooling Fan Operation

CAUTION
Keep your hands and any other objects away from the fan and rotating engine parts at all times. Serious personal injury could result otherwise.

LOW TEMPERATURE TEST
  1. The engine coolant temperature must be below the following:
    1. On 1984-1986 Sedans and all Wagons-181°F (83°C)
    2.  
    3. On 1987-1990 Sedans with carbureted engines-172°F (78°C)
    4.  
    5. On 1990-1994 Sedans with fuel injected engines-181°F (83°C)
    6.  

  2.  
  3. Turn the ignition ON , the cooling fan should not be running. If it does run, check the cooling fan relay and temperature switch for proper operation. Also check for a separated connector or severed wire between the relay and temperature switch.
  4.  
  5. Unplug the temperature switch connector, the cooling fan should now run. If it does not, check for a defective fan relay or motor. Also, check for a short circuit between the fan relay and temperature switch.
  6.  
  7. Reconnect the temperature switch wire.
  8.  

HIGH TEMPERATURE TEST
  1. Start the engine and raise the coolant temperature to above the following:
    1. On 1984-1986 Sedans and all Wagons-194°F (90°C)
    2.  
    3. On 1987-1988 Sedans with carbureted engines-190°F (88°C)
    4.  
    5. On 1989-1990 Sedans with carbureted engines-192°F (89°C)
    6.  
    7. On 1990-1994 Sedans with fuel injected engines-201°F (94°C)
    8.  

  2.  
  3. Check that the cooling fan turns on at the specified temperature. If it does not, replace the temperature switch.
  4.  

CURRENT DRAW TEST
  1. Connect an ammeter in series with a battery and the fan motor connector.
  2.  
  3. Look for smooth fan rotation and check the current draw reading on the ammeter. DO NOT touch the fan!
  4.  
  5. Compare the reading with the specifications listed on the Cooling Fan specifications chart.
  6.  
  7. Replace the motor if it is out of specification.
  8.  



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Fig. Fig. 5: The ammeter should be connected as shown for the current draw test

Temperature Switch
  1. Remove the water temperature switch using the procedures outlined earlier in this section.
  2.  
  3. Submerge the sensing area of the switch in a water bath.
  4.  
  5. Using an ohmmeter, check that there is continuity between the two terminals (or between the single terminal and the switch body) when the water temperature is below the following:
    1. On 1984-1986 Sedans and all Wagons-181°F (83°C)
    2.  
    3. On 1987-1990 Sedans with carbureted engines-172°F (78°C)
    4.  
    5. On 1990-1994 Sedans with fuel injected engines-181°F (83°C)
    6.  

  6.  
  7. Using an ohmmeter, check that there is no continuity between the two terminals (or between the single terminal and the switch body) when the water temperature is above the following:
    1. On 1984-1986 Sedans and all Wagons-194°F (90°C)
    2.  
    3. On 1987-1988 Sedans with carbureted engines-190°F (88°C)
    4.  
    5. On 1989-1990 Sedans with carbureted engines-192°F (89°C)
    6.  
    7. On 1990-1994 Sedans with fuel injected engines-201°F (94°C)
    8.  

  8.  
  9. If the switch does not perform as specified, replace it.
  10.  



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Fig. Fig. 6: Checking resistance on single terminal temperature switches



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Fig. Fig. 7: Checking resistance on two terminal temperature switches

Cooling Fan Relay
CONTINUITY TEST
  1. Check for continuity between terminals 1 and 2.
  2.  
  3. Check for continuity between terminals 3 and 4.
  4.  
  5. If continuity between the terminals is not as specified, replace the relay.
  6.  

OPERATION TEST
  1. Apply battery voltage to terminals 1 and 2.
  2.  
  3. There should be no continuity between terminals 3 and 4.
  4.  
  5. If there is continuity between terminals 3 and 4, replace the relay.
  6.  



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Fig. Fig. 8: Cooling fan relay terminal identification

 
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