engine TOYOTA T100 1996 Factory Service Manual

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.

Downloaded from www.Manualslib.com manuals search engine AC080−02
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.)

Downloaded from www.Manualslib.com manuals search engine AC081−02
− 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

Downloaded from www.Manualslib.com manuals search engine AC0FO−01
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.

Downloaded from www.Manualslib.com manuals search engine AC0FP−02
N13103
− AIR CONDITIONINGRECEIVER
AC−47
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 650 ± 50 g (22.92 ± 1.76 oz.)
2. REMOVE RADIATOR GRILLE
3. DISCONNECT LIQUID TUBE BETWEEN RECEIVER
AND COOLING UNIT
Remove the bolt and disconnect the liquid tube.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O−rings with compressor oil and install the
tube.
4. REMOVE RECEIVER FROM RECEIVER HOLDER
Remove the holder bolt and pull the receiver upward from the
holder
HINT:
At the time of installation, please refer to the following item.
If receiver is replaced, add compressor oil to receiver.
Add 20 cc (0.71 fl.oz.)
Compressor oil: ND−OIL 8 or equivalent

Downloaded from www.Manualslib.com manuals search engine AC0FQ−01
AC−48
− AIR CONDITIONINGRECEIVER
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page AC−47).

Downloaded from www.Manualslib.com manuals search engine AC0FR−01
− 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.

Downloaded from www.Manualslib.com manuals search engine AC0FS−02
N13104
AC−50
− AIR CONDITIONINGCONDENSER
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
HINT:
At the time of installation, please refer to the following item.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of refrig-
erant.
Specified amount: 650 ± 50 g (22.92 ± 1.76 oz.)
2. REMOVE RADIATOR GRILE
3. REMOVE HORNS
4. REMOVE HOOD LOCK SET BOLTS
5. REMOVE CENTER BRACE
6. REMOVE 2 LIQUID TUBES
(a) Remove the 2 bolt and disconnect the liquid tubes from
receiver.
Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate 2 new O−rings with compressor oil and install the
tubes.
(b) Loosen the nut and disconnect the 2 clamps, then re-
move the liquid tube.
Torque: 14 N·m (140 kgf·cm, 10 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of installation, please refer to the following item.
Lubricate a new O−ring with compressor oil and install the
tubes.