heater TOYOTA T100 1996 Factory Repair Manual

Downloaded from www.Manualslib.com manuals search engine AC0G3−01
I04699
I04700
Heater Radiator Pipe
Water Hose
Hose Clip
Lower
Second RidgeUpper
− AIR CONDITIONINGWATER VALVE
AC−63
1996 TOYOTA T100 (RM449U)
REMOVAL
1. DRAIN ENGINE COOLANT FROM RADIATOR
HINT:
It is not necessary to drain out all coolant.
2. DISCONNECT WATER VALVE CONTROL CABLE
FROM WATER VALVE
HINT:
At the time of installation, please refer to the following item.
After installation, adjust the control cable (See page AC−91).
3. DISCONNECT WATER HOSES
(a) Using pliers grip the claws of hose clip and slide the clip
along the hose.
(b) Disconnect the water hose.
HINT:
At the time of installation, please refer to the following item.
Push the water hose onto the heater radiator pipe as far
as second ridge on the pipe.
Push the water hose onto the pipe of water valve pipe as
far as water valve.
4. REMOVE WATER VALVE
Remove the bolt and water valve.

Downloaded from www.Manualslib.com manuals search engine Z19533
34 5
2 134 5
12AC0GI−01
AC−78
− AIR CONDITIONINGHEATER MAIN RELAY
2012 Author: Date:
1996 TOYOTA T100 (RM449U)
HEATER MAIN RELAY
INSPECTION
INSPECT HEATER MAIN RELAY (Making: HTR) CONTINU-
ITY
ConditionTester connectionSpecified condition
Constant2 − 4
3 − 5Continuity
Apply B+ between
terminals 3 and 51 − 2Continuity
If continuity is not as specified, replace the relay.

Downloaded from www.Manualslib.com manuals search engine N05725
AC0GP−01
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC−85
2019 Author: Date:
1996 TOYOTA T100 (RM449U)
HEATER CONTROL ASSEMBLY
ON−VEHICLE INSPECTION
INSPECT HEATER CONTROL LEVER OPERATION
Move the control lever and dials left and right check for stiffness
and binding the full range of the lever and dials.
If there is stiffness and binding, adjust the heater control cable.

Downloaded from www.Manualslib.com manuals search engine AC0GQ−01
I01458
Instrument Panel
Heater Control Assembly
Heater Control KnobHeater Control Panel A/C Switch
Air Inlet Control Cable
Air Mix Control Cable Water Valve Control Cable
Mode Control Cable
Heater Control Base
Blower Speed Control Switch
Defroster Mode Switch
Bulb
AC−86
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TOYOTA T100 (RM449U)
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine AC0GR−02
I04701
Water Valve Control CableAir Inlet Control Cable
Air Mix Control Cable Mode Control Cable
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC−87
1996 TOYOTA T100 (RM449U)
REMOVAL
1. REMOVE INSTRUMENT PANEL
(See page BO−36)
2. DISCONNECT HEATER CONTROL CABLES
3. REMOVE HEATER CONTROL ASSEMBLY
Remove the 2 screws and pull out the heater control assembly,
then disconnect the connector.

Downloaded from www.Manualslib.com manuals search engine AC0GS−01
N05794
N17972
AC−88
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE BLOWER SPEED CONTROL SWITCH
(a) Pull out the bulb.
(b) Disconnect the bulb holder.
(c) Using a screwdriver, pry loose the clip and push out the
blower speed control switch to rear of the heater control
assembly.
2. REMOVE DEFROSTER MODE SWITCH
(a) Disconnect the connector clamp.
(b) Remove the screw and switch.

Downloaded from www.Manualslib.com manuals search engine Z16144
M1 M2
AC3IY−01
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC−89
1996 TOYOTA T100 (RM449U)
INSPECTION
INSPECT BLOWER SPEED CONTROL SWITCH CONTINU-
ITY
Position/ CircuitTester connectionSpecified condition
OFF−No continuity
LO5 − 6Continuity
M11 − 5 − 6Continuity
M22 − 5 − 6Continuity
HI5 − 6 − 8Continuity
Illumination circuit3 − 4Continuity
Switch continuity:
If continuity is not as specified, replace the switch.
Illumination circuit:
If continuity is not as specified, test the bulb.

Downloaded from www.Manualslib.com manuals search engine AC0GU−01
AC−90
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TOYOTA T100 (RM449U)
REASSEMBLY
Reassembly is in the reverse order of disassmebly (See page AC−88)

Downloaded from www.Manualslib.com manuals search engine AC0GV−02
N05735
FRESH Clamp
RECIRC
N05736
Clamp
DEF
FACE
N05734
Clamp
COOL
WARM
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
AC−91
1996 TOYOTA T100 (RM449U)
INSTALLATION
Installation is in the reverse order of removal (See page
AC−87).
1. AFTER INSTALLATION, INSPECT HEATER CONTROL
LEVER OPERATION
Move the control lever and dials left and right check for stiffness
and binding the full range of the lever.
If there is stiffness and binding, proceed next step.
2. ADJUST HEATER CONTROL CABLES
(a) Set heater control assembly in these conditions:
(1) Air inlet control lever in ”FRESH” position
(2) Mode control lever in ”FACE” position
(3) Temperature control lever in ”Max. WARM” position
(b) Adjust the air inlet control cable.
Set the air inlet damper control damper on ”FRESH” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pushing the outer cable in the
direction shown by arrow.
(c) Adjust mode control cable.
Set the air inlet damper control damper on ”FACE” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.
(d) Adjust air mix control cable.
Set the air inlet damper control damper on ”WARM” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.

Downloaded from www.Manualslib.com manuals search engine N05737Clamp COOL
WARM
AC−92
− AIR CONDITIONINGHEATER CONTROL ASSEMBLY
1996 TOYOTA T100 (RM449U)
(e) Adjust water valve control cable.
Set the air inlet damper control damper on ”WARM” posi-
tion, install the control cable and lock the clamp.
HINT:
Lock the clamp during lightly pulling the outer cable in the direc-
tion shown by arrow.