clutch TOYOTA LAND CRUISER 1986 Factory Repair Manual

AC1HO-05
I24786
Pressure Switch Compressor and Magnetic Clutch
Ambient Temperature Sensor
CondenserNo.1 Junction Block
 HTR Relay
 RR HTR Relay
 MG CLT Relay
- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-13
2738 Author
: Date
:
2004 LAND CRUISER (RM1071U)
LOCATION

- AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC-9
2734 Author
: Date
:
2004 LAND CRUISER (RM1071U)
3. INSPECT IDLE-UP SPEED
(a) Warm up engine
(b) Inspect idle-up speed when following conditions are es-
tablished.
Test conditions:

Fan speed selector at ºHIº position

Temperature control dial at ºCOOLº position

A/C switch ON

Put gear shift in neutral
Magnetic clutch conditionIdle-up speed
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged780 ± 50 rpm
If idle speed is not as specified, check the idle control system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Stop engine.
(b) Secure good ventilation (The gas leak detector may not
react to volatile gases which are not refrigerant, such as
evaporated gasoline and exhaust gas)
(c) Repeat the test 2 or 3 times
(d) Make sure that there is some refrigerant remaining in the
refrigeration system.
When compressor is OFF: approx. 392 - 588 kPa (4 - 6
kgf´cm
2, 57 - 85 psi)
(e) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:

After the blower motor stops, leave the cooling for more
than 15 minutes.

Expose the gas leak detector sensor 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 gas leaks are detected, lift up the vehicle.
(f) If gas leaks are not detected on the drain hose, remove
the blower resistor from the cooling unit. Then insert the
gas leak detector sensor into the unit to perform the test.
(g) Disconnect the connector and leave the pressure switch
for approx. 20 minutes. Then bring the gas leak detector
close to the pressure switch to perform the test.
(h) Bring the gas leak detector close to the refrigerant lines.

AC1IL-03
I08106
Suction HoseDischarge Hose
Front Drive Shaft LH
Engine Under Cover
Compressor Stator

Snap RingRotor
Shim Pressure Plate
49 (500, 36)
13.2 (135, 9)
10 (100, 7)
49 (500, 36)
Drive Belt
Compressor and
Magnetic Clutch

O-ring
I06761
I06762
N´m (kgf´cm, ft´lbf) : Specified torque

Non reusable part
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC-61
2786 Author
: Date
:
2004 LAND CRUISER (RM1071U)
COMPONENTS

AC1IN-04
AC0943
SST
AC0944
SST
AC0945
SST
AC0946
Shim
Pressure
Plate
AC0947
SST
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC-63
2788 Author
: Date
:
2004 LAND CRUISER (RM1071U)
DISASSEMBLY
1. 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 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 95994-10020

N20013
R-Shape
RotorSnap Ring
Compressor
AC1743
AC1744
AC0950
SST
N20012
R-Shape
Snap Ring
CompressorStator AC-64
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
2789 Author
: Date
:
2004 LAND CRUISER (RM1071U)
NOTICE:
At the time of reassembly, the snap ring should be installed
so that beveled side facing 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 95994-10020
NOTICE:
At the time of reassembly, the snap ring should be installed
so that its beveled side facing up.

AC0951
Stator
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC-65
2790 Author
: Date
:
2004 LAND CRUISER (RM1071U)
(c) Remove the stator.

AC1IP-04
I06811
I06808
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC-67
2792 Author
: Date
:
2004 LAND CRUISER (RM1071U)
INSTALLATION
1. INSTALL COMPRESSOR
(a) Install the compressor with 3 bolts.
Torque: 49 N´m (500 kgf´cm, 36 ft´lbf)
(b) Connect the connector.
2. INSTALL FRONT DRIVE SHAFT LH
(See page SA-33)
3. CONNECT DISCHARGE AND SUCTION HOSES
(a) Lubricate 2 new O-rings with compressor oil and install
them to the hoses.
(b) Connect the both hoses with 2 bolts.
Torque: 10 N´m (100 kgf´cm, 7 ft´lbf)
NOTICE:
Hose should be connected immediately after the caps have
been removed.
4. INSTALL AND CHECK DRIVE BELT
(See page AC-17 and AC-15)
5. CONNECT NEGATIVE (-) TERMINAL CABLE TO BAT-
TERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM
AND CHARGE SYSTEM WITH REFRIGERANT
Specified amount: 1,050 ± 50 g (37.03 ± 1.76 oz.)
7. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leaks of the refrigerant.
If there is a leakage, check the tightening torque at the joints.
8. INSPECT A/C OPERATION

AC1IK-03
I068122
1
I06813
3
AC-60
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
2785 Author
: Date
:
2004 LAND CRUISER (RM1071U)
COMPRESSOR AND MAGNETIC
CLUTCH
ON-VEHICLE INSPECTION
1. INSPECT COMPRESSOR FOR METALLIC SOUND
Check there is abnormal metallic sound from the compressor
when the A/C switch is ON.
If abnormal metallic sound is heard, replace the compressor as-
sembly.
2. INSPECT REFRIGERANT PRESSURE
(See page AC-3)
3. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-
ANT
Using a gas leak detector, check for leakage of refrigerant.
If there is any leakage, replace the compressor assembly.
4. INSPECT COMPRESSOR LOCK SENSOR RESIS-
TANCE
(a) Disconnect the connector.
(b) Measure resistance between terminal 1 and 2.
Standard resistance:
570 - 1,050 W at 20°C (68 °F)
If resistance is not as specified, replace the compressor.
5. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH
BEARING
6. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR
ROTOR
7. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start engine.
(b) Check for abnormal noise from the compressor when the
A/C switch is OFF.
If abnormal noise is being emitted, replace the rotor of magnetic
clutch.
8. INSPECT MAGNETIC CLUTCH OPERATION
(a) Disconnect the connector.
(b) Connect the positive (+) lead from the battery to terminal
3 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.

AC1IO-03
N04963
Dial Indicator AC-66
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
2791 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REASSEMBLY
Reassembly is in the reverse of disassembly
(See page AC-63).
AFTER REASSEMBLY, CHECK 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 battery posi-
tive (+) terminal.
(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 (0.020in.)

AC1IM-03
I06808
I06811
AC-62
- AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
2787 Author
: Date
:
2004 LAND CRUISER (RM1071U)
REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR
APPROX. 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (- ) TERMINAL CABLE
FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
5. REMOVE ENGINE UNDER COVER
6. REMOVE DRIVE BELT (See page AC-16)
7. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
8. REMOVE FRONT DRIVE SHAFT LH
(See page SA-26)
9. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 3 bolts and the compressor.