air conditioning TOYOTA T100 1996 Factory Workshop Manual

Downloaded from www.Manualslib.com manuals search engine AC3IX−01
AC−34
− AIR CONDITIONINGBLOWER UNIT
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE GLOVE COMPARTMENT DOOR
2. REMOVE GLOVE COMPARTMENT REINFORCE-
MENT
3. REMOVE INSTRUMENT PANEL LOWER FINISH PAN-
EL
4. REMOVE COOLING UNIT
5. REMOVE BLOWER UNIT
(a) Disconnect the connectors.
(b) Disconnect the air inlet control cable.
HINT:
At the time of installation, please refer to the following item.
After connection, adjust the control cable.
(c) Remove the nut, 2 bolts and blower unit.

Downloaded from www.Manualslib.com manuals search engine AC0FL−01
− AIR CONDITIONINGBLOWER UNIT
AC−35
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BLOWER MOTOR
Remove the 3 screws and blower motor.
2. REMOVE BLOWER RESISTOR
Remove the 2 screws and blower resistor.

Downloaded from www.Manualslib.com manuals search engine AC0FM−01
AC−36
− AIR CONDITIONINGBLOWER UNIT
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly (See page AC−35).

Downloaded from www.Manualslib.com manuals search engine AC0FN−01
− AIR CONDITIONINGBLOWER UNIT
AC−37
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page AC−34).

Downloaded from www.Manualslib.com manuals search engine AC07W−02
N13080
AC−38
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
1972 Author: Date:
1996 TOYOTA T100 (RM449U)
COMPRESSOR AND MAGNETIC
CLUTCH
ON−VEHICLE INSPECTION
1. SET ON MANIFOLD GAUGE SET
(See page AC−17)
2. START ENGINE
3. INSPECT COMPRESSOR FOR METALLIC SOUND
Check if there is an abnormal metallic sound from the compres-
sor when the A/C switch is on.
If abnormal metallic sound is heard, replace the compressor as-
sembly.
4. INSPECT REFRIGERANT PRESSURE
See ”ON−VEHICLE INSPECTION” of AIR CONDITIONING
SYSTEM on page AC−3.
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. SET OFF MANIFOLD GAUGE SET
(See page AC−18)
8. MAKE THESE VISUAL CHECK:
(a) Leakage of grease from the clutch bearing.
(b) Signs of oil on the pressure plate
If necessary, repair or replace.
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 OPERATION
(a) Disconnect the connector.
(b) Connect the positive (+) lead from the battery to terminal
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.

Downloaded from www.Manualslib.com manuals search engine AC07X−03
I01455
Discharge HoseCompressor Bracket
Compressor
Stator
Rotor Pressure Plate
N·m (kgf·cm,ft·lbf)
Non−reusable part: Specified torqueShim
Snap Ring
 O−Ring  O−Ring
Discharge Hose 3RZ−FE Engine Models:
5VZ−FE Engine Models:
Compressor 
Compressor
Bracket
Suction HoseSuction Hose
Compressor
10 (100, 7)
25 (250, 18)
39 (400, 29)
132 (135, 9)
10 (100, 7)
25 (250, 18)
39 (400, 29)
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC−39
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine AC07Y−02
AC−40
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
1996 TOYOTA T100 (RM449U)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES WITH A/C ON
2. STOP ENGINE
3. DISCONNECT NEGATIVE (−) TERMINAL CABLE FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
5. REMOVE ENGINE UNDER COVER
6. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fitting immediately to keep moisture or dirt out of the system.
7. REMOVE DRIVE BELT (See page AC−15)
8. 5VZ−FE Engine Models:
REMOVE PS PUMP SET BOLT AND NUT
9. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 4 bolts and compressor.

Downloaded from www.Manualslib.com manuals search engine AC07Z−02
AC0943
SST
AC0944
SST
AC0945
SST
AC0946
Shim
Pressure
Plate
AC0947
SST
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC−41
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE PRESSURE PLATE
(a) Using SST and a socket wrench, remove the shaft bolt.
SST 07112−76060
Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf)
(b) Install SST on the pressure plate.
SST 07112−66040
(c) Using SST and socket wrench, remove the pressure
plate.
SST 07112−66040, 07112−76060
(d) Remove the shims from the pressure plate.
2. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114−84020

Downloaded from www.Manualslib.com manuals search engine N20013
R−Shape
RotorSnap Ring
Compressor
AC1743
AC1744
AC0950
SST
N20012
R−Shape
Snap Ring
CompressorStator AC−42
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
1996 TOYOTA T100 (RM449U)
NOTICE:
At the time of reassembly, please refer to the following
item.
The snap ring should be installed so that beveled side
faces up.
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE:
Be careful not to damage the pulley when tapping on the ro-
tor.
3. REMOVE STATOR
(a) Disconnect the stator lead wire from the compressor
housing.
(b) Using SST, remove the snap ring.
SST 07114−84020
NOTICE:
At the time of reassembly, please refer to the following
item.
The snap ring should be installed so that its beveled side
faces up.

Downloaded from www.Manualslib.com manuals search engine AC0951
Stator
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC−43
1996 TOYOTA T100 (RM449U)
(c) Remove the stator.