TOYOTA T100 1996 Factory Service Manual

Downloaded from www.Manualslib.com manuals search engine AC0EZ−01
N13793
Charging Cylinder High Pressure
Service Valve Low Pressure
Service ValvePush
Air
N13792
Gas Leak
Detector
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC−11
1996 TOYOTA T100 (RM449U)
CHARGING
1. INSTALL CHARGING CYLINDER
HINT:
When handling the charging cylinder, always follow the direc-
tions given in the instruction manual.
(a) Charge the proper amount of refrigerant into the charging
cylinder.
(b) Connect the center hose to the charging cylinder.
CAUTION:
Do not open both high and low hand valves of manifold
gauge set.
(c) Open the valve of charging cylinder.
(d) Press the valve core on the side of manifold gauge and
expel the air inside of the center hose.
2. INSPECT REFRIGERATION SYSTEM FOR LEAKS
(a) Open the high pressure hand valve and charge refriger-
ant.
(b) When the low pressure gauge indicates 98 kPa
(1 kgf/cm
2, 14 psi) close the high pressure hand valve.
(c) Using a gas leak detector, check the system for leakage.
If leak is found, repair the faulty component or connection.
CAUTION:
Use the refrigerant recovery/ recycling machine to recover
the refrigerant whenever replacing parts.

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Low Pressure
Service Valve
High Pressure
Service Valve
AC−12
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
1996 TOYOTA T100 (RM449U)
3. CHARGE REFRIGERANT INTO REFRIGERANT SYS-
TEM
If there is no leak after refrigerant leak check, charge the proper
amount of refrigerant into refrigeration system.
CAUTION:
Never run the engine when charging the system
through the high pressure side.
Do not open the low pressure hand valve when the
system is being charged with liquid refrigerant.
(a) Open the high pressure hand valve fully.
(b) Charge specified amount of refrigerant, then close the
high pressure hand valve.
HINT:
A fully charged system is indicated by the sight glass being free
of any bubbles.
4. SET OFF MANIFOLD GAUGE SET
(a) Close both hand valves of manifold gauge set.
(b) Disconnect the quick disconnect adapters from the ser-
vice valves.
5. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINES

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N13105
Compressor
Engine Room Relay Block
 Heater Main Relay
(Marking: HEATER)
Receiver
Condenser
Blower Unit
 Blower Motor
 Blower Resistor
Heater Control Assembly
 Blower Speed Control Switch
 Defroster Mode Switch Heater Unit
 Heater Radiator
A/C Switch
Cooling Unit
 Evaporator
 Expansion Valve
 A/C Amplifier
 Thermistor
 Pressure Switch
− AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC−13
1996 TOYOTA T100 (RM449U)
LOCATION

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Correct Wrong
AC0F1−01
Z17871
Compressor
CrankshaftPulley Crankshaft
Compressor Pulley
Idle pulley Idle pulley 3RZ−FE5VZ−FE
N01881
DENSOBorroughs AC−14
− AIR CONDITIONINGDRIVE BELT
1948 Author: Date:
1996 TOYOTA T100 (RM449U)
DRIVE BELT
ON−VEHICLE INSPECTION
1. INSPECT DRIVE BELT’S INSTALLATION CONDITION
Check that the drive belt fits properly in the ribbed grooves.
2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt tension.
Drive belt tension:
New belt 160 ± 25 lbf
Used belt 100 ± 20 lbf
HINT:
”New belt” refers to a belt which has been used less than
5 minutes on a running engine.
”Used belt” refers to a belt which has been used on a run-
ning engine for 5 minutes or more.
After installing the drive belt, check that it fits properly in
the ribbed grooves.

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N06121Adjusting Bolt
Idle pulley
lock nut
− AIR CONDITIONINGDRIVE BELT
AC−15
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE PS PUMP DRIVE BELT
3RZ−FE: (See page SR−36)
5VZ−FE: (See page SR−46)
2. REMOVE ENGINE UNDER COVER
3. LOOSEN IDLE PULLEY LOCK NUT
4. REMOVE COMPRESSOR DRIVE BELT
Loosen drive belt tension by adjusting bolt and remove the drive
belt.

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N06121
Idle Pulley Lock Nut
Adjusting Bolt
AC−16
− AIR CONDITIONINGDRIVE BELT
1996 TOYOTA T100 (RM449U)
INSTALLATION
1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY
Torque: 2.5 N·m (25 kgf·cm, 22 in.·lbf)
2. INSTALL DRIVE BELT
3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TEN-
SION
Drive belt tension:
New belt: 160 ± 25 lbf
Used belt: 100 ± 25 lbf
4. TIGHTEN IDLE PULLEY LOCK NUT
Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
5. INSTALL PS PUMP DRIVE BELT
6. INSTALL ENGINE UNDER COVER

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Low Pressure
Charging HoseHigh Pressure
Charging Hose
AC0F4−01
N04392
Sleeve
− AIR CONDITIONINGMANIFOLD GAUGE SET
AC−17
1951 Author: Date:
1996 TOYOTA T100 (RM449U)
MANIFOLD GAUGE SET
SET ON
1. CONNECT CHARGE HOSE TO MANIFOLD GAUGE
SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4. REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINE
5. CONNECT QUICK DISCONNECT ADAPTERS TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then
slide, then slide the sleeve of the quick disconnect adapter
downward to lock it.

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N06553
AC−18
− AIR CONDITIONINGMANIFOLD GAUGE SET
1996 TOYOTA T100 (RM449U)
SET OFF
1. CLOSE BOTH HAND VALVE OF MANIFOLD GAUGE
SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to un-
lock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE

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− 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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N12919
Condenser
Compressor
N·m (kgf·cm, ft·lbf)Cooling Unit
Discharge Hose
Liquid TubeReceiver Liquid Tube
Suction Hose
: Specified torque
 Non−reusable part
10 (100, 7)
14 (140, 10)
5.4 (55, 48 in.·lbf)32 (330, 24)
10 (100, 7)
10 (100, 7)
14 (140, 10)
AC−20
− AIR CONDITIONINGREFRIGERANT LINE
1996 TOYOTA T100 (RM449U)
COMPONENTS