engine TOYOTA LAND CRUISER 1996 J80 Owner's Manual

I01390
Condition: Insufficient cooling
I01392
Condition: Insufficient coolingNOTE : These gauge indica-
tions are shown when the
refrigeration system has
been opened and the refrig-
erant charged without vacu-
um purging.
AC−8
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
1996 LAND CRUISER (RM451U)
(6) Refrigerant overcharged or insufficient cooling of
condenser
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 No air bubbles seen through the
sight glass even when the engine
rpm is lowered Unable to develop sufficient per-
formance due to excessive refrig-
eration system
 Insufficient cooling of condenser Excessive refrigerant in
cycle → refrigerant over charged
 Condenser cooling → condenser
fins clogged or cooling fan faulty
(1) Clean condenser
(2) Check cooling fan with fluid
coupling operation
(3) If (1) and (2) are in normal
state, check amount of refrigerant
Charge proper amount of refriger-
ant
(7) Air present in refrigeration system
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
 Pressure too high on both low
and high pressure sides
 The low pressure piping hot to
touch
 Bubbles seen in sight glass
Air entered in refrigeration system
 Air present in refrigeration sys-
tem
 Insufficient vacuum purging
(1) Check compressor oil to see if
it is dirty or insuf ficient
(2) Evacuate air and charge new
refrigerant
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AC−10
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
1996 LAND CRUISER (RM451U)
3. INSPECT IDLE−UP SPEED
(a) Warm up engine
(b) Inspect idle −up speed when the these conditions are es-
tablished:
Blower switch HI
Electrical load OFF
A/C switch ON
Put gear shift in neutral
Magnetic clutch conditionIdle speed
Magnetic clutch not engaged650 ± 50 rpm
Magnetic clutch engaged800 ± 50 rpm
If idle speed is not as specified, check the IAC valve and air in-
take system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:
Stop engine.
Secure good ventilation (If not, the gas leak detec-
tor may react to volatile gases which are not refrig-
erant, such as evaporated gasoline and exhaust
gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approximately 392 − 588
KPa (4 − 6 kgf/cm
2, 57 − 35 psi)
(b) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:
After the blower motor is stopped, leave the cooling unit
for more than 15 minutes.
Expose the gas leak detector sensor the under the drain
hose.
When bring the gas leak detector close to the drain hose,
make sure that the gas leak detector does not react to the
volatile gases.
If such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected on the drain hose, remove the
power transistor from the cooling unit. Then insert the gas
leak detector sensor into the unit and perform the test.
(d) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Then bring the gas leak de-
tector close to the pressure switch and perform the test.
(e) Bring the gas leak detector close to the refrigerant lines and perform the test.
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−
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC−13
1996 LAND CRUISER (RM451U)
3. CHARGE REFRIGERANT INTO REFRIGERANT SYS-
TEM
If there is no leak after refrigerant leak check charge, the proper
amount of refrigerant into refrigeration system.
CAUTION:
Never run the engine when charging the system through
the high pressure side.Do not open the low pressure hand
valve when the system is being charged with liquid refrig-
erant.
(a) Open the high pressure hand valve fully.
(b) Charge specified amount of refrigerant, then close the high pressure hand valve.
HINT:
A fully charged system is indicated by the sight glass being free
of any bubbles.
4. REMOVE MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Disconnect the quick disconnect adapters from the ser- vice valves.
5. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINES
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CH0086
CorrectWrong
AC2QG−01
N01881
DENSOBorroughs
−
AIR CONDITIONING DRIVE BELT
AC−15
1342
Author: Date:
1996 LAND CRUISER (RM451U)
DRIVE BELT
ON−VEHICLE INSPECTION
1. INSPECT DRIVE BELT’S INSTALLATION CONDITION
Check that drive belt fits properly in the ribbed groves.
2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
DENSO BTG −20 (95506−00020) or
Borroughs No. BT −33−73F
Drive belt tension:
New belt 100−150 lbf
Used belt 60−100 lbf
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been on a running
engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in
the ribbed grooves.
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AC3JL−01
−
AIR CONDITIONING COOLING UNIT
AC−23
1350
Author: Date:
1996 LAND CRUISER (RM451U)
COOLING UNIT
COMPONENTS
v
~+Packing
Engine Coolant
Temp. CutRelay
NCAmphfier------'>...,.J)
Thermistor
LowerUnitCase----"
+Non-reusable part
"JI'b,.;:y•.?~-----UpperUnitCase
c-----+Packing
Expansion Valve
~Gromet
o«'-----DrainHose
~~~paCking
A~,,~V~..~':'-'-"~--BlowerResistor'~N14361
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AC2QS−01
Z17942
Hose ”A”Hose ”B”
Z17943
Hose Clip
Heater
Radiator Pope Paint Mark
Water Hose Hose ”A”Upper
FR
RH Hose ”B”
RH
FR
Marking 45 ± 10° 45
°
10 °
N06494
AC−28
−
AIR CONDITIONING HEATER UNIT
1355
Author: Date:
1996 LAND CRUISER (RM451U)
HEATER UNIT
REMOVAL
1. REMOVE COOLING UNIT (See page AC−24)
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
(a) Grip the claws of the hose clip with pliers and slide the clip
along the hose to a place where it does not clamp the
hose to the pipe.
(b) Disconnect the water hoses.
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 (See page BO−76 )
6. REMOVE INSTRUMENT PANEL REINFORCEMENT
(See page BO−76 )
7. REMOVE HEATER UNIT
(a) Remove the 3 screws and defroster nozzle.(...~---------I I
I II II I
I II IIIv-
N02485
N18179N18181
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AC2R5−01
N06158
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−33
1360
Author: Date:
1996 LAND CRUISER (RM451U)
COMPRESSOR AND MAGNETIC
CLUTCH
ON−VEHICLE INSPECTION
1. INSTALL MANIFOLD GAUGE SET (See page AC−18 )
2. START ENGINE
Run the engine at 1,500 rpm.
3. INSPECT COMPRESSOR FOR METALLIC SOUND
Check if there is a metallic sound from the compressor when the
A/C switch is on.
If metallic sound is heard, replace the compressor assembly.
4. INSPECT REFRIGERANT PRESSURE (See page AC−5 )
5. STOP ENGINE
6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER- ANT FROM SAFETY SEAL
Using a gas leak detector, check for leakage of refrigerant.
If there is any leakage, replace the compressor assembly.
7. REMOVE MANIFOLD GAUGE SET (See page
AC−19 )
8. MAKE THESE VISUAL CHECKS:
(a) Leakage of grease from the clutch bearing.
(b) Signs of oil on the pressure plate or rotor. Repair or replace, as necessary.
9. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start engine.
(b) Check for abnormal noise from near the compressor when the A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
10. INSPECT MAGNETIC CLUTCH
(a) Disconnect the connector from the magnetic clutch.
(b) Connect the positive (+) lead from the battery to the termi-
nal on the magnetic clutch connector and the negative ( −)
lead to the body ground.
(c) Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.
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AC2R7−04
AC0943
SST
AC0944
SST
AC0945
SST
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−35
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. RUN ENGINE AT IDLE SPEED WITH A/C SWITCH ON
FOR 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE ( −) TERMINAL CABLE
FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERA TION
SYSTEM
5. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fittings immediately to keep the moisture or
dirt out of the system.
6. REMOVE ENGINE UNDER COVER
7. REMOVE DRIVE BELT (See page AC−16)
8. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 4 bolts and pull the compressor upward.
9. REMOVE COMPRESSOR (See page AC−35 )
10. REMOVE PRESSURE PLATE
(a) Using SST and a socket wrench, remove the shaft bolt. Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf)
SST 07112 −76060
(b) Install a SST on the pressure plate. SST 07112 −66040
(c) Using SST and a socket wrench, remove the pressure plate.
SST 07112 −76060
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AC2R8−01
N04963
AC−38
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. INSTALL COMPRESSOR
(a) Install the compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the connector.
2. CONNECT DISCHARGE AND SUCTION HOSES Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Hoses should be connected immediately after the caps
have been removed.
HINT:
Lubricate 2 new O −rings with compressor oil and install the
hoses.
3. INSTALL AND INSPECT DRIVE BELT (See page AC−17 )
4. INSTALL ENGINE UNDER COVER
5. CONNECT NEGATIVE ( −) TERMINAL CABLE TO BAT-
TERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM
7. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT
Specified amount:
850 ± 50 g (29.98 ± 1.76 oz.)
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
Reassembly is in the reverse order of disassembly (See
page AC−35 ).
9. CHECK CLEARANCE OF MAGNETIC CLUTCH
(a) Set the dial indicator to the pressure plate of the magnetic
clutch.
(b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery.
(c) Check the clearance between the pressure plate and ro- tor when connecting the negative ( −) terminal to the bat-
tery.
Standard clearance:
0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
If the clearance is not within the standard clearance, adjust the
clearance using shims to obtain the standard clearance. Shim Thickness:
0.1 mm (0.004 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
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AC2RR−01
−
AIR CONDITIONING EXPANSION VALVE
AC−47
1374
Author: Date:
1996 LAND CRUISER (RM451U)
EXPANSION VALVE
ON−VEHICLE INSPECTION
1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE
2. INSTALL MANIFOLD GAUGE SET
3. RUN ENGINE
(a) Run the engine at 1,500 rpm for at least 5 minutes.
(b) 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 kPa (0 kgf/cm
2, 0 psi).
HINT:
When the low pressure drops to 0 kPa (0 kgf/cm
2, 0 psi), feel the receiver’s IN and OUT sides for zero temper-
ature difference.
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