1996 TOYOTA T100 torque

Downloaded from www.Manualslib.com manuals search engine AC0F9−02
I04698
Glove Compartment
Door Reinforcement
Lower Center Cover Glove Compartment DoorLower Finish Panel No. 2
Upper Unit Case
 Packing
A/C Amplifier
 Packing Lower Unit CaseEvaporator
Expansion Valve Cooling Unit
N·m (kgf·cm, ft·lbf) : Specified torque
 Non−reusable part
 O−Ring
 O−Ring
Thermistor
Pressure Switch
Amplifier Cover
22 (225, 16)
14 (140, 10)
32 (330, 24)
14 (140, 10)
AC−22
− AIR CONDITIONINGCOOLING UNIT
1956 Author: Date:
1996 TOYOTA T100 (RM449U)
COOLING UNIT
COMPONENTS

Downloaded from www.Manualslib.com manuals search engine AC0FA−01
N06114
Z04401
− AIR CONDITIONINGCOOLING UNIT
AC−23
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. DISCONNECT LIQUID TUBE AND SUCTION HOSE
Loosen the 2 nuts and disconnect the both tube and hose.
Torque:
Liquid tube: 14 N·m (140 kgf·cm, 10 ft·lbf)
Suction hose: 32 N·m (330 kgf·cm, 24 ft·lbf)
CAUTION:
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
and hose.
3. REMOVE 2 GROMMETS
4. REMOVE DRAIN PIPE GROMMET
5. REMOVE GLOVE COMPARTMENT PARTS
(See page BO−36)
6. REMOVE COOLING UNIT
(a) Disconnect the connectors.
(b) Remove the 5 screws, nut and cooling unit.

Downloaded from www.Manualslib.com manuals search engine AC0FB−02
Z04403
Liquid TubeExpansion Valve
Z04402
AC−24
− AIR CONDITIONINGCOOLING UNIT
1996 TOYOTA T100 (RM449U)
DISASSEMBLY
1. REMOVE A/C AMPLIFIER
2. SEPARATE COOLING UNIT CASES
(a) Using a knife, cut off each packing.
(b) Remove the 4 clip and 4 screws then separate the cooling
unit cases.
3. REMOVE EVAPORATOR FROM COOLING UNIT CASE
HINT:
At the time of reassembly, please refer to the following item,.
If evaporator is replaced, add compressor oil to evaporator.
Add 40 cc (1.4 fl.oz.)
Compressor oil: ND−OIL 8 or equivalent
4. REMOVE THERMISTOR FROM EVAPORATOR
(a) Disconnect the connector from pressure switch.
(b) Pull out the thermistor from evaporator.
5. REMOVE EXPANSION VALVE
(a) Pry out the packing.
(b) Remove the clamp and disconnect heat sensing tube.
(c) Loosen the 2 nuts and remove the expansion valve.
Torque:
Expansion valve x Liquid tube:
14 N·m (140 kgf·cm, 10 ft·lbf)
Expansion valve x Evaporator:
22 N·m (225 kgf·cm, 16 ft·lbf)
NOTICE:
Cap the open fittings immediately to keep moisture or dirt
out of the system.
HINT:
At the time of reassembly, please refer to the following item.
Lubricate 2 new O−rings with compressor oil and install the
valve.
6. REMOVE PRESSURE SWITCH
(a) Disconnect the connector.
(b) Remove the pressure switch from liquid tube.
Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)
HINT:
Lock the switch mounted on the tube with on open end
wrench, being careful not to deform the tube and remove
the switch.
At the time of installation, please refer to the following
item.
Lubricate a new O−ring with compressor oil and install the
valve.

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I01455
Discharge HoseCompressor Bracket
Compressor
Stator
Rotor Pressure Plate
N·m (kgf·cm,ft·lbf)
Non−reusable part: Specified torqueShim
Snap Ring
 O−Ring  O−Ring
Discharge Hose 3RZ−FE Engine Models:
5VZ−FE Engine Models:
Compressor 
Compressor
Bracket
Suction HoseSuction Hose
Compressor
10 (100, 7)
25 (250, 18)
39 (400, 29)
132 (135, 9)
10 (100, 7)
25 (250, 18)
39 (400, 29)
− AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC−39
1996 TOYOTA T100 (RM449U)
COMPONENTS

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 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 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 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.