1996 TOYOTA LAND CRUISER Bolt

IN0CO−12
FI1066
Z11554
Seal Lock Adhesive
IN−4
−
INTRODUCTION REPAIR INSTRUCTIONS
4
Author: Date:
1996 LAND CRUISER (RM451U)
REPAIR INSTRUCTIONS
GENERAL INFORMATION
BASIC REPAIR HINT
(a) Use fender, seat and floor covers to keep the vehicle
clean and prevent damage.
(b) During disassembly, keep parts in the appropriate order to facilitate reassembly.
(c) Installation and removal of battery terminal: (1) Before performing electrical work, disconnect the
negative (−) terminal cable from the battery.
(2) If it is necessary to disconnect the battery for in- spection or repair, first disconnect the negative ( −)
terminal cable.
(3) When disconnecting the terminal cable, to prevent damage to battery terminal, loosen the cable nut
and raise the cable straight up without twisting or
prying it.
(4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth-
er abrasive objects.
(5) Install the cable ends to the battery terminals after loosening the nut, and tighten the nut after installa-
tion. Do not use a hammer to tap the cable ends
onto the terminals.
(6) Be sure the cover for the positive (+) terminal is properly in place.
(d) Check hose and wiring connectors to make sure that they
are connected securely and correctly.
(e) Non−reusable parts (1) Always replace cotter pins, gaskets, O−rings, oilseals, etc. with new ones.
(2) Non−reusable parts are indicated in the component illustrations by the ” ” symbol.
(f) Precoated parts Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(1) If a precoated part is retightened, loosened orcaused to move in any way, it must be recoated with
the specified adhesive.
(2) When reusing precoated parts, clean off the old
adhesive and dry with compressed air. Then apply
the specified seal lock adhesive to the bolt, nut or
threads.
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BE1367
Medium Current Fuse and High Current Fuse
Equal Amperage Rating
V00076
Abbreviation
Part Name
Symbol
Illustration
FUSE
MEDIUM CURRENT FUSE
HIGH CURRENT FUSE
FUSIBLE LINK
CIRCUIT BREAKER FUSE
M−FUSE
H−FUSE
FL
CB
−
INTRODUCTION REPAIR INSTRUCTIONS
IN−5
5
Author: Date:
1996 LAND CRUISER (RM451U)
(3) Precoated parts are indicated in the component il-
lustrations by the ” ” symbol.
(g) When necessary, use a sealer on gaskets to prevent
leaks.
(h) Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.
(i) Use of special service tools (SST) and special service ma-
terials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where speci-
fied and follow the proper work procedure. A list of SST
and SSM can be found in Preparation section in this
manual.
(j) When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use
one with a lower rating.
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iJ<>~o~BE5594 IN0365
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BE5595IN0366
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BE5596IN0367
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BE5597IN0367
~BE5598SN0368
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AC2QH−01
N16451
AC−16
−
AIR CONDITIONING DRIVE BELT
1996 LAND CRUISER (RM451U)
REMOVAL
1. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)
2. REMOVE COMPRESSOR DRIVE BELT
Loosen the adjusting bolt and remove the drive belt.
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AC2QO−03
N06172
N14293
AC−24
−
AIR CONDITIONING COOLING UNIT
1996 LAND CRUISER (RM451U)
REMOVAL
1. DISCHARGE REFRIGERANT FROM REFRIGERA TION
SYSTEM
HINT:
At the time of installation, refer to the following procedure.
Evacuate air from refrigeration system.
Charge system with refrigerant and inspect for leakage of
refrigerant.
Specified amount:
850 ± 50 g (29.98 ± 1.76 oz.)
2. DISCONNECT SUCTION TUBE AND LIQUID TUBE
FROM COOLING UNIT FITTING
Remove the 2 bolts and both tubes. Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of indtallation, lubricate 2 new O −rings with com-
pressor oil and install the tubes.
3. REMOVE THESE PARTS:
(a) Glove compratment door (See page BO−76)
(b) Glove compratment door reinforcement (See page BO−76 )
4. REMOVE COOLING UNIT
(a) Disconnect the connectors.
(b) Remove the 4 screws, 2 nuts and cooling unit.
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AC2QP−01
N06174
Hexagonal WrenchExpansion Valve
−
AIR CONDITIONING COOLING UNIT
AC−25
1996 LAND CRUISER (RM451U)
DISASSEMBLY
1. REMOVE A/C AMPLIFIER
2. REMOVE RELAY
3. REMOVE WIRE HARNESS
4. REMOVE BLOWER RESISTOR
Remove the 2 screws and blower resistor.
5. SEPARATE UPPER AND LOWER UNIT CASES
(a) Using a knife, cut off the each packing.
(b) Remove 3 clips and 4 screws.
(c) Separate the upper and lower unit cases.
6. REMOVE EVAPORATOR FROM LOWER UNIT CASE
HINT:
If the evaporator was replaced, add compressor oil to the com-
pressor.
Add 40 cc (1.4 fl.oz.)
Compressor oil:
ND−OIL 8 or equivalent
7. REMOVE THERMISTOR
Pull out the thermistor from the evaporator.
8. REMOVE EXPANSION VALVE
Using a hexagon wrench, remove the 2 bolts and separate the
expansion valve and evaporator. Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
HINT:
At the time of reassembly, lubricate 4 new O−rings with com-
pressor oil and install the tubes.
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AC2R1−03
−
AIR CONDITIONING BLOWER UNIT
AC−31
1358
Author: Date:
1996 LAND CRUISER (RM451U)
BLOWER UNIT
REMOVAL
1. REMOVE INSTRUMENT PANEL AND REINFORCE-
MENT (See page BO−76)
2. REMOVE COOLING UNIT (See page AC−24)
3. REMOVE BLOWER UNIT
(a) Disconnect the connectors.
(b) Remove the bolt and 2 nuts, then remove the blower unit.
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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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AC2R8−01
N04963
AC−38
−
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
1996 LAND CRUISER (RM451U)
REASSEMBLY
1. INSTALL COMPRESSOR
(a) Install the compressor with the 4 bolts. Torque: 25 N·m (250 kgf·cm, 18 ft·lbf)
(b) Connect the connector.
2. CONNECT DISCHARGE AND SUCTION HOSES Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
NOTICE:
Hoses 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 INSPECT DRIVE BELT (See page AC−17 )
4. INSTALL ENGINE UNDER COVER
5. CONNECT NEGATIVE ( −) TERMINAL CABLE TO BAT-
TERY
6. EVACUATE AIR FROM REFRIGERATION SYSTEM
7. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT
Specified amount:
850 ± 50 g (29.98 ± 1.76 oz.)
Using a gas leak detector, check for leakage of refrigerant.
If there is leakage, check the tightening torque at the joints.
8. INSPECT A/C OPERATION
Reassembly is in the reverse order of disassembly (See
page AC−35 ).
9. CHECK CLEARANCE OF MAGNETIC CLUTCH
(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.)
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