TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine AC0F8−01
− AIR CONDITIONINGREFRIGERANT LINE
AC−21
1996 TOYOTA T100 (RM449U)
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TOQUE
NOTICE:
Connections should not be torqued tighter than the specified torque.
Part tightenedN·mkgf·cmft·lbf
Receiver x Liquid tube6.06052 in.·lbf
Condenser x Discharge hose101007
Condenser x Liquid tube1414010
Compressor x Discharge hose101007
Compressor x Suction hose101007
Cooling unit x Liquid tube1414010
Cooling unit x Suction tube3233024
Expansion valve x Evaporator2222516
Expansion valve x Liquid tube1414010
Suction line (Piping joint)3233024
Liquid line (Piping joint)1414010
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 650 ± 50g (22.92 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION

Downloaded from www.Manualslib.com manuals search engine AC0F9−02
I04698
Glove Compartment
Door Reinforcement
Lower Center Cover Glove Compartment DoorLower Finish Panel No. 2
Upper Unit Case
 Packing
A/C Amplifier
 Packing Lower Unit CaseEvaporator
Expansion Valve Cooling Unit
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
 O−Ring
 O−Ring
Thermistor
Pressure Switch
Amplifier Cover
22 (225, 16)
14 (140, 10)
32 (330, 24)
14 (140, 10)
AC−22
− AIR CONDITIONINGCOOLING UNIT
1956 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine AC0FA−01
N06114
Z04401
− AIR CONDITIONINGCOOLING UNIT
AC−23
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant
Specified amount: 650 ± 50 g (22.92 ± 1.76 oz.)
2. DISCONNECT LIQUID TUBE AND SUCTION HOSE
Loosen the 2 nuts and disconnect the both tube and hose.
Torque:
Liquid tube: 14 N·m (140 kgf·cm, 10 ft·lbf)
Suction hose: 32 N·m (330 kgf·cm, 24 ft·lbf)
CAUTION:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O−rings with compressor oil and install the tube
and hose.
3. REMOVE 2 GROMMETS
4. REMOVE DRAIN PIPE GROMMET
5. REMOVE GLOVE COMPARTMENT PARTS
(See page BO−36)
6. REMOVE COOLING UNIT
(a) Disconnect the connectors.
(b) Remove the 5 screws, nut and cooling unit.

Downloaded from www.Manualslib.com manuals search engine AC0FB−02
Z04403
Liquid TubeExpansion Valve
Z04402
AC−24
− AIR CONDITIONINGCOOLING UNIT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE A/C AMPLIFIER
2. SEPARATE COOLING UNIT CASES
(a) Using a knife, cut off each packing.
(b) Remove the 4 clip and 4 screws then separate the cooling
unit cases.
3. REMOVE EVAPORATOR FROM COOLING UNIT CASE
HINT:
At the time of reassembly, please refer to the following item,.
If evaporator is replaced, add compressor oil to evaporator.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND−OIL 8 or equivalent
4. REMOVE THERMISTOR FROM EVAPORATOR
(a) Disconnect the connector from pressure switch.
(b) Pull out the thermistor from evaporator.
5. REMOVE EXPANSION VALVE
(a) Pry out the packing.
(b) Remove the clamp and disconnect heat sensing tube.
(c) Loosen the 2 nuts and remove the expansion valve.
Torque:
Expansion valve x Liquid tube:
14 N·m (140 kgf·cm, 10 ft·lbf)
Expansion valve x Evaporator:
22 N·m (225 kgf·cm, 16 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of reassembly, please refer to the following item.
Lubricate 2 new O−rings with compressor oil and install the
valve.
6. REMOVE PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the pressure switch from liquid tube.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Lock the switch mounted on the tube with on open end
wrench, being careful not to deform the tube and remove
the switch.
At the time of installation, please refer to the following
item.
Lubricate a new O−ring with compressor oil and install the
valve.

Downloaded from www.Manualslib.com manuals search engine AC0FC−01
− AIR CONDITIONINGCOOLING UNIT
AC−25
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC−24).

Downloaded from www.Manualslib.com manuals search engine AC0FD−01
AC−26
− AIR CONDITIONINGCOOLING UNIT
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page AC−23).

Downloaded from www.Manualslib.com manuals search engine AC0FE−01
I04696
Instrument Panel
Reinforcement
Duct Heater to
Register No. 4
No. 2 Brace
No. 1 Brace Center Defroster Nozzle
Heater Unit
Heater Air DuctCooling Unit
Heater Radiator pipe
Heater Radiator
Heater Unit Case Air Vent Duct
 O−Ring
 Non−reusable part
− AIR CONDITIONINGHEATER UNIT
AC−27
1961 Author: Date:
1996 TOYOTA T100 (RM449U)
HEATER UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine AC0FF−02
I01453
N06486
Hose ClipHeater Radiator Pipe
Second ridge Water Hose45 ° Upper
LowerLH
RH
N05820
AC−28
− AIR CONDITIONINGHEATER UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE COOLING UNIT (See page AC−23)
2. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
3. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
(a) Grip the claws of hose clip and slide the hose clip along
the hose.
(b) Disconnect the water hose.
HINT:
At the time of installation, please refer to the following item.
Push the water hose onto the heater radiator pipe as far
as the second ridge on the pipe.
Install the hose clip in the position, as shown in the illustra-
tion.
4. REMOVE INSTRUMENT PANEL AND REINFORCE-
MENT (See page BO−36)
5. DISCONNECT HEATER CONTROL CABLES FROM
HEATER UNIT
HINT:
At the time of installation, please refer to the following item.
After connection, adjust the control cables.
6. REMOVE HEATER TO REGISTER No. 4 DUCT
Remove the screw and the duct.
7. REMOVE HEATER TO REGISTER CENTER DUCT
Remove the screw and duct.

Downloaded from www.Manualslib.com manuals search engine N06076
− AIR CONDITIONINGHEATER UNIT
AC−29
1996 TOYOTA T100 (RM449U)
8. REMOVE HEATER AIR DUCT
Remove the screw and duct.
9. REMOVE HEATER UNIT
Remove the 2 bolts, nut and heater unit.

Downloaded from www.Manualslib.com manuals search engine AC0FG−01
AC−30
− AIR CONDITIONINGHEATER UNIT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE HEATER RADIATOR
(a) Remove the 3 screws and 3 plates.
(b) Pull out the heater radiator.
(c) Remove the 2 clips and heater radiator pipes.
(d) Remove the 2 O−rings from heater radiator pipes.
HINT:
At the time of reassembly, please refer to the following item.
Do not reuse the 2 O−rings.
2. REMOVE AIR VENT DUCT
Remove the 2 screws and duct.