clutch TOYOTA LAND CRUISER 1996 J80 Workshop Manual

IN0CI−02
IN−38
−
INTRODUCTION TERMS
1996 LAND CRUISER (RM451U)
GLOSSARY OF SAE AND TOYOTA TERMS
This glossary lists all SAE− J1930 terms and abbreviations used in this manual in compliance with SAE\
rec-
ommendations, as well as their TOYOTA equivalents.
SAE
ABBREVIATIONSSAE TERMSTOYOT A TERMS
( ) −−ABBREVIA TIONS
A/CAir ConditioningAir Conditioner
ACLAir CleanerAir Cleaner, A/CL
AIRSecondary Air InjectionAir Injection (AI)
APAccelerator Pedal−
B+Battery Positive Voltage+B, Battery Voltage
BAROBarometric PressureHAC
CACCharge Air CoolerIntercooler
CARBCarburetorCarburetor
CFIContinuous Fuel Injection−
CKPCrankshaft PositionCrank Angle
CLClosed LoopClosed Loop
CMPCamshaft PositionCam Angle
CPPClutch Pedal Position−
CTOXContinuous T rap Oxidizer−
CTPClosed Throttle PositionLL ON, Idle ON
DFIDirect Fuel Injection (Diesel)Direct Injection (DI)
DIDistributor Ignition−
DLC1
DLC2
DLC3Data Link Connector 1
Data Link Connector 2
Data Link Connector 31: Check Connector
2: Total Diagnosis Comunication Link (TDCL)
3: OBD II Diagnostic Connector
DTCDiagnostic Trouble CodeDiagnostic Code
DTMDiagnostic Test Mode−
ECLEngine Control Level−
ECMEngine Control ModuleEngine ECU (Electronic Control Unit)
ECTEngine Coolant T emperatureCoolant Temperature, Water Temperature (THW)
EEPROMElectrically Erasable Programmable Read Only Memory
Electrically Erasable Programmable Read Only Memory
(EEPROM),
Erasable Programmable Read Only Memory (EPROM)
EFEEarly Fuel EvaporationCold Mixture Heater (CMH), Heat Control Valve (HCV)
EGRExhaust Gas RecirculationExhaust Gas Recirculation (EGR)
EIElectronic IgnitionTOYOTA Distributorless Ignition (TDI)
EMEngine ModificationEngine Modification (EM)
EPROMErasable Programmable Read Only MemoryProgrammable Read Only Memory (PROM)
EVAPEvaporative EmissionEvaporative Emission Control (EVAP)
FCFan Control−
FEEPROMFlash Electrically Erasable Programmable
Read Only Memory−
FEPROMFlash Erasable Programmable Read Only Memory−
FFFlexible Fuel−
FPFuel PumpFuel Pump
GENGeneratorAlternator
GNDGroundGround (GND)
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−
INTRODUCTION TERMS
IN−39
1996 LAND CRUISER (RM451U)
HO2S
Heated Oxygen SensorHeated Oxygen Sensor (HO2S)
IACIdle Air ControlIdle Speed Control (ISC)
IATIntake Air TemperatureIntake or Inlet Air T
emperature
ICMIgnition Control Module−
IFIIndirect Fuel InjectionIndirect Injection (IDL)
IFSInertia Fuel−Shutoff−
ISCIdle Speed Control−
KSKnock SensorKnock Sensor
MAFMass Air FlowAir Flow Meter
MAPManifold Absolute PressureManifold Pressure
Intake V acuum
MCMixture Control
Electric Bleed Air Control Valve (EBCV)
Mixture Control Valve (MCV)
Electric Air Control Valve (EACV)
MDPManifold Dif ferential Pressure−
MFIMultiport Fuel InjectionElectronic Fuel Injection (EFI)
MILMalfunction Indicator LampCheck Engine Lamp
MSTManifold Surface T emperature−
MVZManifold Vacuum Zone−
NVRAMNon−Volatile Random Access Memory−
O2SOxygen SensorOxygen Sensor, O2 Sensor (O2S)
OBDOn−Board DiagnosticOn− Board Diagnostic System (OBD)
OCOxidation Catalytic ConverterOxidation Catalyst Convert (OC), CCo
OPOpen LoopOpen Loop
PAIRPulsed Secondary Air InjectionAir Suction (AS)
PCMPowertrain Control Module−
PNPPark/Neutral Position−
PROMProgrammable Read Only Memory−
PSPPower Steering Pressure−
PTOXPeriodic Trap OxidizerDiesel Particulate Filter (DPF)
Diesel Particulate Trap (DPT)
RAMRandom Access MemoryRandom Access Memory (RAM)
RMRelay Module−
ROMRead Only MemoryRead Only Memory (ROM)
RPMEngine SpeedEngine Speed
SCSuperchargerSupercharger
SCBSupercharger BypassE−ABV
SFISequential Multiport Fuel InjectionElectronic Fuel Injection (EFI), Sequential Injection
SPLSmoke Puff Limiter−
SRIService Reminder Indicator−
SRTSystem Readiness Test−
STScan Tool−
TBThrottle BodyThrottle Body
TBIThrottle Body Fuel InjectionSingle Point Injection
Central Fuel Injection (Ci)
TCTurbochargerTurbocharger
TCCTorque Converter ClutchTorque Converter
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AC2QC−03
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC−3
1996 LAND CRUISER (RM451U)
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem.The numbers i\
ndicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
No blower operation
4. HTR Fuse
5. Heater main relay
6. Blower motor
7. Blower resistor
8. Blower speed control switch
9. Wire harness−
AC−64
AC−52
AC−57
AC−69 −
No air temperature control
1. Engine coolant volume
2. A/C control assembly
3. Water valve−
AC−69
AC−49
No compressor operation
1. Refrigerant volume
2. A.C Fuse
3. Magnetic clutch
4. Compressor
5. Pressure switch
6. Heater main relay
7. Blower speed control switch
8. A/C switch
9. A/C amplifier
10.Thermistor
11. Wire harnessAC−5 −
AC−33
AC−33
AC−61
AC−64
AC−69
AC−69
AC−74
AC−60 −
Compressor operates intermitently
1. Refrigerant volume
2. Pressure switch
3. A/C amplifier
4. Thermistor
5. Wire harnessAC−5
AC−61
AC−74
AC−60 −
No cool air comes out
1. Refrigerant volume
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
6. Pressure switch
7. Thermistor
8. A/C switch
9. A/C amplifier
10.A/C control assembly
11. Wire harnessAC−5
AC−5
AC−15
AC−33
AC−33
AC−61
AC−60
AC−69
AC−74
AC−69 −
Cool air comes out only at high engine rpm
1. Refrigerant volume
2. Drive bel
3. Magnetic clutch
4. Compressor
5. Condenser
6. Receiver
7. Expansion valve
8. Evaporator
9. Thermistor
10.A/C amplifier
11. Wire harnessAC−5
AC−15
AC−33
AC−33
AC−42
AC−39
AC−47
AC−45
AC−60
AC−74 −
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AC−4
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
1996 LAND CRUISER (RM451U)
Insuf
ficient cooling
1. Refrigerant volume
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Receiver
7. Expansion valve
8. Evaporator
9. Refrigerant line
10.Pressure switch
11. A/C amplifier
12.A/C control assemblyAC−5
AC−15
AC−33
AC−33
AC−42
AC−39
AC−47
AC−45
AC−20
AC−61
AC−74
AC−69
No engine idle up when A/C switch ON
1. A/C amplifier
2. ECM
3. Wire harnessAC−74 −
−
No warm air comes out
1. Engine coolant volume
2. A/C control assembly
3. Water valve
4. Heater radiator−
AC−69
AC−49
AC−46
A/C indicator does not light up when mode lever at DEF. position
1. Defroster mode switch
2. A/C switch
3. Wire harnessAC−69
AC−69 −
Rear heater:
SymptomSuspect AreaSee page
No blower operation
1. RR HTR Fuse
2. Rear heater relay
3. Rear heater switch
4. Rear blower motor
5. Rear blower resistor−
AC−65
AC−77
AC−55
AC−58
No warm air come out1. Engine coolant volume
2. Rear heater radiator−
AC−46
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AC−10
−
AIR CONDITIONING AIR CONDITIONING SYSTEM
1996 LAND CRUISER (RM451U)
3. INSPECT IDLE−UP SPEED
(a) Warm up engine
(b) Inspect idle −up speed when the these conditions are es-
tablished:
Blower switch HI
Electrical load OFF
A/C switch ON
Put gear shift in neutral
Magnetic clutch conditionIdle speed
Magnetic clutch not engaged650 ± 50 rpm
Magnetic clutch engaged800 ± 50 rpm
If idle speed is not as specified, check the IAC valve and air in-
take system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:
Stop engine.
Secure good ventilation (If not, the gas leak detec-
tor may react to volatile gases which are not refrig-
erant, such as evaporated gasoline and exhaust
gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approximately 392 − 588
KPa (4 − 6 kgf/cm
2, 57 − 35 psi)
(b) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:
After the blower motor is stopped, leave the cooling unit
for more than 15 minutes.
Expose the gas leak detector sensor the 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 such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected on the drain hose, remove the
power transistor from the cooling unit. Then insert the gas
leak detector sensor into the unit and perform the test.
(d) Disconnect the connector and leave the pressure switch for approximately 20 minutes. Then bring the gas leak de-
tector close to the pressure switch and perform the test.
(e) Bring the gas leak detector close to the refrigerant lines and perform the test.
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AC2R5−01
N06158
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−33
1360
Author: Date:
1996 LAND CRUISER (RM451U)
COMPRESSOR AND MAGNETIC
CLUTCH
ON−VEHICLE INSPECTION
1. INSTALL MANIFOLD GAUGE SET (See page AC−18 )
2. START ENGINE
Run the engine at 1,500 rpm.
3. INSPECT COMPRESSOR FOR METALLIC SOUND
Check if there is a metallic sound from the compressor when the
A/C switch is on.
If metallic sound is heard, replace the compressor assembly.
4. INSPECT REFRIGERANT PRESSURE (See page AC−5 )
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. REMOVE MANIFOLD GAUGE SET (See page
AC−19 )
8. MAKE THESE VISUAL CHECKS:
(a) Leakage of grease from the clutch bearing.
(b) Signs of oil on the pressure plate or rotor. Repair or replace, as necessary.
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
(a) Disconnect the connector from the magnetic clutch.
(b) Connect the positive (+) lead from the battery to the termi-
nal 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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AC2R6−01
Z17949
Pressure Plate Rotor
Shim
Startor
Snap Ring Compressor
13.2
(135, 9)
Z17948
Suction Hose
Discharge Hose
Drive Belt
Compressor Compressor Bracket
O−Ring O−Ring
37 (375, 27)
N·m (kgf·cm, ft·lbf) : Specified torque
 Non− reusable part
10 (100, 7)
25 (250, 18)
37 (375, 27)
10 (100, 7)
AC−34
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
1996 LAND CRUISER (RM451U)
COMPONENTS
N16453 N14067
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AC2R7−04
AC0943
SST
AC0944
SST
AC0945
SST
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−35
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. RUN ENGINE AT IDLE SPEED WITH A/C SWITCH ON
FOR 10 MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE ( −) TERMINAL CABLE
FROM BATTERY
4. DISCHARGE REFRIGERANT FROM REFRIGERA TION
SYSTEM
5. DISCONNECT DISCHARGE AND SUCTION HOSES
Remove the 2 bolts and disconnect the both hoses.
NOTICE:
Cap the open fittings immediately to keep the moisture or
dirt out of the system.
6. REMOVE ENGINE UNDER COVER
7. REMOVE DRIVE BELT (See page AC−16)
8. REMOVE COMPRESSOR
(a) Disconnect the connector.
(b) Remove the 4 bolts and pull the compressor upward.
9. REMOVE COMPRESSOR (See page AC−35 )
10. 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 a SST on the pressure plate. SST 07112 −66040
(c) Using SST and a socket wrench, remove the pressure plate.
SST 07112 −76060
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AC0946
ShimPressure
Plate
AC0947
SST
N20013
Snap Ring
R−Shape Compressor
AC1743
AC1744
AC−36
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
1996 LAND CRUISER (RM451U)
(d) Remove the shims from the pressure plate.
11. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114 −84020
NOTICE:
The snap ring should be installed so that its 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.
12. REMOVE STATOR
(a) Disconnect the stator lead wire from the compressor housing.
p
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AC0950
SST
N20012
R−ShapeStatorSnap Ring
Compressor
AC0951
Stator
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC−37
1996 LAND CRUISER (RM451U)
(b) Using SST, remove the snap ring.
SST 07114 −84020
NOTICE:
The snap ring should be installed so that its beveled side
faces up.
(c) Remove the stator.
6
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