check engine TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine AC0F6−01
− AIR CONDITIONINGREFRIGERANT LINE
AC−19
1953 Author: Date:
1996 TOYOTA T100 (RM449U)
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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− 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

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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.

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N04963
Dial Indicator AC−44
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassembly
(See page AC−41).
AFTER REASSEMBLY, CHECK THE MAGNETIC CLUTCH
CLEARANCE
(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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− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC−45
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. INSTALL COMPRESSOR
(a) Install the compressor with 4 bolts.
Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the connector.
2. CONNECT DISCHARGE AND SUCTION HOSES
Connect the both hoses with the 2 bolts.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Hose 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 CHECK DRIVE BELT
(See page AC−16, AC−14)
4. INSTALL ENGINE UNDER COVER
5. 5VZ− FE Engine Models:
INSTALL PS PUMP SET BOLT AND NUT
Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)
6. CONNECT NEGATIVE (−) TERMINAL CABLE TO BATTERY
7. EVACUATE AIR FROM REFRIGERATION SYSTEM
8. CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 650 ± 50 g (22.92 ± 1.76 oz.)
9. 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.
10. INSPECT A/C OPERATION

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AC−46
− AIR CONDITIONINGRECEIVER
1980 Author: Date:
1996 TOYOTA T100 (RM449U)
RECEIVER
ON−VEHICLE INSPECTION
INSPECT FITTINGS FOR LEAKAGE
Using a gas leak detector, check for leakage.
If there is leakage, check the tightening toque at the joints.

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− AIR CONDITIONINGCONDENSER
AC−49
1983 Author: Date:
1996 TOYOTA T100 (RM449U)
CONDENSER
ON−VEHICLE INSPECTION
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air.
NOTICE:
Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers.
2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.

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AC−54
− AIR CONDITIONINGEVAPORATOR
1996 TOYOTA T100 (RM449U)
INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
2. CHECK FITTING FOR CRACKS FOR SCRATCHES
If necessary, repair or replace.

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− AIR CONDITIONINGEXPANSION VALVE
AC−59
1993 Author: Date:
1996 TOYOTA T100 (RM449U)
EXPANSION VALVE
ON−VEHICLE INSPECTION
1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE
2. SET ON MANIFOLD GAUGE SET (See page AC−17)
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), check the receiver’s IN and OUT sides for no tem-
perature difference.

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AC−62
− AIR CONDITIONINGWATER VALVE
1996 Author: Date:
1996 TOYOTA T100 (RM449U)
WATER VALVE
ON−VEHICLE INSPECTION
1. WARM UP ENGINE
2. DISCONNECT WATER VALVE CONTROL CABLE
3. INSPECT WATER VALVE OPERATION
(a) Check that warm air blown out the vent when the water valve lever is moved to ”WARM” position.
(b) Check that cool air blown out when the water valve is moved to the ”COOL” position.
If operation is not as specified, replace the water valve.
4. CONNECT WATER VALVE CONTROL CABLE
After connection, adjust the control cable.