TOYOTA LAND CRUISER 1996 J80 Repair Manual

N14326
Low Pressure
Charging Hose
High
Pressure
Charging
Hose
AC2QJ−01
N04392
Sleeve
AC−18
−
AIR CONDITIONING MANIFOLD GAUGE SET
1345
Author: Date:
1996 LAND CRUISER (RM451U)
MANIFOLD GAUGE SET
SET ON
1. CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4. REMOVE CAPS FROM SERVICE VALVES ON RE- FRIGERANT LINE
5. CONNECT QUICK DISCONNECT ADAPTERS TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then
slide the sleeve of the quick disconnect adapter downward to
lock it.
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AC2QK−01
N06553
−
AIR CONDITIONING MANIFOLD GAUGE SET
AC−19
1996 LAND CRUISER (RM451U)
SET OFF
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to un-
lock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE
t
=
QJL
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AC2QM−01
AC−20
−
AIR CONDITIONING REFRIGERANT LINE
1347
Author: Date:
1996 LAND CRUISER (RM451U)
REFRIGERANT LINE
ON−VEHICLE INSPECTION
1. INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
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AC2QL−01
Z17947
Liquid TubePressure Switch
Suction Tube
Discharge Hose CondenserReceiver
Suction Hose
10 (100, 7)
N·m (kgf·cm, ft·lbf) : Specified torque
 Non− reusable part
5.4 (55, 48 in.·lbf)
10 (100, 7)
14 (140, 10)
10 (100, 7)
10 (100, 7)10 (100, 7)
−
AIR CONDITIONING REFRIGERANT LINE
AC−21
1996 LAND CRUISER (RM451U)
LOCATION
N14066
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AC2QN−01
AC−22
−
AIR CONDITIONING REFRIGERANT LINE
1996 LAND CRUISER (RM451U)
REPLACEMENT
1. DISCHARGE REFRIGERANT IN REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the sy\
stem.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE:
Connections should not be torqued tighter than the specified torque.
Part tightenedN·mkgf·cmft·lbf
Compressor x Discharge hose101007
Compressor x Suction hose101007
Condenser x Discharge hose101007
Condenser x Liquid tube101007
Reciever x Liquid tube5.45548 in.·lbf
Pressure switch x Liquid tube101007
Cooling unit x Liquid tube101007
Expansion valve x Evaporator5.45548 in.·lbf
Cooling unit x Suction tube101007
Liquid tube (Piping joint)1414010
Suction line (Block joint)101007
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
Specified amount: 850 ± 50 g (29.98 ± 1.76 oz.)
5. 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.
6. INSPECT AIR CONDITIONING OPERATION
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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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AC2QO−03
N06172
N14293
AC−24
−
AIR CONDITIONING COOLING UNIT
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERA TION
SYSTEM
HINT:
At the time of installation, refer to the following procedure.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of
refrigerant.
Specified amount:
850 ± 50 g (29.98 ± 1.76 oz.)
2. DISCONNECT SUCTION TUBE AND LIQUID TUBE
FROM COOLING UNIT FITTING
Remove the 2 bolts and both tubes. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of indtallation, lubricate 2 new O −rings with com-
pressor oil and install the tubes.
3. REMOVE THESE PARTS:
(a) Glove compratment door (See page BO−76)
(b) Glove compratment door reinforcement (See page BO−76 )
4. REMOVE COOLING UNIT
(a) Disconnect the connectors.
(b) Remove the 4 screws, 2 nuts and cooling unit.
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AC2QP−01
N06174
Hexagonal WrenchExpansion Valve
−
AIR CONDITIONING COOLING UNIT
AC−25
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE A/C AMPLIFIER
2. REMOVE RELAY
3. REMOVE WIRE HARNESS
4. REMOVE BLOWER RESISTOR
Remove the 2 screws and blower resistor.
5. SEPARATE UPPER AND LOWER UNIT CASES
(a) Using a knife, cut off the each packing.
(b) Remove 3 clips and 4 screws.
(c) Separate the upper and lower unit cases.
6. REMOVE EVAPORATOR FROM LOWER UNIT CASE
HINT:
If the evaporator was replaced, add compressor oil to the com-
pressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil:
ND−OIL 8 or equivalent
7. REMOVE THERMISTOR
Pull out the thermistor from the evaporator.
8. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the
expansion valve and evaporator. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of reassembly, lubricate 4 new O−rings with com-
pressor oil and install the tubes.
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AC2QQ−01
AC−26
−
AIR CONDITIONING COOLING UNIT
1996 LAND CRUISER (RM451U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC−25 ).
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AC2QR−01
−
AIR CONDITIONING COOLING UNIT
AC−27
1996 LAND CRUISER (RM451U)
INSTALLATION
Installation is in the reverse order of removal (See page AC−24 ).
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