Air Conditioning

AC3S1-02

I11181

I11182

I11200

Register

Knob

Center ClusterIntegration Panel

Connector

Heater Control HousingAirbag Indicator Circuit

Lens

Bulb (Clock Lighting)

Bulb (Panel Lighting)

IntegrationCircuit

Integration Panel

Access Cab, Standard Cab:

-AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration)

AC-87

5114Author: Date:

COMPONENTS

I27026

Register

Knob


Connector

Heater Control Housing

Lens

Bulb

Integration Circuit

Integration Panel

Double Cab:

AC-88 -AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY (Center Cluster Integration)

5115Author: Date:

I11188

AC3S2-02

I11189

I27027 I27949


Double Cab:

I11190


I27028

Double Cab:


5117Author: Date:

DISASSEMBLY1. Access cab, Standard cab:

REMOVE AIRBAG INDICATOR CIRCUITRelease the 2 claws and remove the indicator circuit, then dis-connect the connector.

2. REMOVE BULBS(a) Access cab, standard cab:

Remove the 5 bulbs.(b) Double cab:

Remove the 6 bulbs.

3. Access cab, Standard cab: REMOVE HEATER CONTROL HOUSING

(a) Remove the 5 screws.(b) Remove the heater control housing.

4. Double cab: REMOVE HEATER CONTROL HOUSING

(a) Remove the 5 screws.(b) Remove the heater control housing.

I11191


I27162

Double Cab:

I11192

I27161I27950

Double Cab:



AC-91

5118Author: Date:

5. Access cab, Standard cab: REMOVE INTEGRATION CIRCUIT

(a) Disconnect the 2 connectors.(b) Remove the circuit.

6. Double cab: REMOVE INTEGRATION CIRCUIT

(a) Remove the 2 screws.(b) Remove the circuit.

7. REMOVE LENSRelease the 3 claws, then remove the lens.

I11193

: Bulb

A8B7

AC3S3-02

I27863

: Bulb

B2

B11

I07872


5119Author: Date:

INSPECTION1. Access cab, Standard cab:

INSPECT ILLUMINATION OPERATIONConnect the positive (+) lead from the battery to terminal B7 andthe negative (-) lead to terminal A8 then check that the illumina-tions lights up.If operation is not as specified, check the faulty bulb.

2. Double cab: INSPECT ILLUMINATION OPERATION

Connect the positive (+) lead from the battery to terminal B2 andthe negative (-) lead to terminal B11 then check that the illu-minations lights up.If operation is not as specified, check the faulty bulb.

3. INSPECT BULBSet the tester as shown in the illustration to check for continuity.If continuity exists, replace the heater control.If no continuity exists, replace the bulb.

I11194

ONOFF

A9A1

A12

I27864

ONOFF

A17

A18

I12235

Connector ”A” A1

A12


AC-93

5120Author: Date:

4. Access cab, Standard cab: INSPECT A/C SWITCH CONTINUITYStandard:

Switch condition Tester connection Specified condition

OFF A12 - A9 No continuity

ON A12 - A9 Continuity

If operation is not as specified, replace the integration circuitbulb.

5. Double cab: INSPECT A/C SWITCH CONTINUITYStandard:


OFF A17 - A18 No continuity

ON A17 - A18 Continuity

If operation is not as specified, replace the integration circuitbulb.

6. Access cab, Standard cab: INSPECT A/C INDICATOR OPERATION

(a) Connect the positive (+) lead from the battery to terminalA12 and the negative (-) lead to terminal A1.

(b) Push the A/C button in and check that the A/C indicatorlights up.

If operation is not as specified, replace the integration circuit.

I12236

Connector ”A” A1

A12

A11

A10

I27865

Connector ”A”

A17 A10

I11195

OFF ON

A1

A4B13


5121Author: Date:

(c) Connect the positive (+) lead from the battery to terminalA11 and the negative (-) lead to terminal A10, then checkthat the indicator dims.


7. Double cab:INSPECT A/C INDICATOR OPERATION


(b) Push the A/C button in and check that the A/C indicatorlights up.


8. Access cab, Standard cab: INSPECT AIR INLET CONTROL SWITCH CONTINUITY


OFF B13 - A1 No continuity

ON B13 - A1 Continuity

Illumination circuit A4 - B13 Continuity

If operation is not as specified, replace the integration circuitbulb

I27866

OFF ON

A10

A14

B8

I12237

Connector ”A” A1A4

I12238

Connector ”A” A1A4

A10A11

I27867

Connector ”A”

A10A14


AC-95

5122Author: Date:

9. Double cab: INSPECT AIR INLET CONTROL SWITCH CONTINUITY


OFF B8 - A10 No continuity

ON B8 - A10 Continuity

Illumination circuit A14 - B8 Continuity

If operation is not as specified, replace the integration circuitbulb

10. Access cab, Standard cab: INSPECT AIR INLET INDICATOR OPERATION


(b) Push the air inlet button in and check that the air inlet indi-cator lights up.


(c) Connect the positive (+) lead from the battery to terminalA11 and the negative (-) lead to terminal A10, then checkthat the indicator dims.


11. Double cab: INSPECT AIR INLET INDICATOR OPERATION

(a) Connect the positive (+) lead from the battery to terminalA14 and the negative (-) lead to A10.

(b) Push the air inlet button in and check that the air inlet indi-cator lights up.


AC27I-02


5125Author: Date:

INSTALLATIONThe installation procedures are the removal procedures in reverse order (see page AC-89 ).

I11149

I11150 I11198

Wire harness side

Connector ”A” Connector ”B”

AC3S0-02


AC-83

5110Author: Date:

AIR CONDITIONING CONTROLASSEMBLY (Center ClusterIntegration)ON-VEHICLE INSPECTION1. REMOVE CENTER CLUSTER INTEGRATION PANEL

(See page AC-89 )2. Access cab, Standard cab:

INSPECT A/C CONTROL ASSEMBLY CIRCUIT(a) Disconnect the connectors from the A/C control assembly

and inspect the connectors on the wire harness side, asshown in the chart below.Test condition:

Turn the ignition switch to ON

Tester connection Condition Specified condition

A1 - Ground Constant Continuity

A4 G dTurn ignition switch to ON Battery positive voltage

A4 - GroundTurn ignition switch OFF No voltage

A5 - Ground Constant Battery positive voltage

A13 G dTurn ignition switch to ACC Battery positive voltage

A13 - GroundTurn ignition switch OFF No voltage

B11 - Ground (5VZ-FE engine) Constant Continuity

B20 - B10 Evaporator temperature at 25°C (77°F) 1.5 kΩ

If the result is as specified, replace the amplifier with a new one.If the result is not as specified, inspect the circuits connectedto other parts.

I28084

Connector ”A”Connector ”B”

123456

7891011121314

123456789

101112131415161718192021


5111Author: Date:

(b) Connect the connectors to the A/C control assembly andinspect the connectors on the wire harness side from theback side, as shown in the chart below.Test condition:

Run the engine at idle speed Set the manifold gauge set


B1 - Ground Constant Continuity

B8 - Ground Magnetic clutch is engaged Battery positive voltage

Magnetic clutch is not engaged Below 1.0 V

B13 - Ground Air inlet switch ”FRESH” Below 1.0 V

Air inlet switch ”RECIRC” Battery positive voltage

B15 - Ground Air inlet switch ”RECIRC” Below 1.0 V

Air inlet switch ”FRESH” Battery positive voltage

B19 - Ground A/C switch ON Below 1.0 V

A/C switch OFF Battery positive voltage


I27431

I27444

I28026

Wire harness side

Connector ”A” Connector ”B”


AC-85

5112Author: Date:

3. Double cab: INSPECT A/C CONTROL ASSEMBLY CIRCUIT

(a) Disconnect the connectors from the A/C control assemblyand inspect the connectors on the wire harness side, asshown in the chart below.Test condition:

Turn the ignition switch to ON



A14 - Ground Turn ignition switch ON Battery positive voltage

Turn ignition switch OFF No voltage

A15 - Ground Constant Battery positive voltage

A9 - Ground Turn ignition switch to ACC Battery positive voltage

Turn ignition switch OFF No voltage


I27862

Connector ”A”Connector ”B”


5113Author: Date:

(b) Connect the connectors to the A/C control assembly andinspect the connectors on the wire harness side from theback side, as shown in the chart below.Test condition:

Run the engine at idle speed Set the manifold gauge set



A18 - Ground Magnetic clutch is engaged Battery positive voltage

Magnetic clutch is not engaged Below 1.0 V

B8 - Ground Air inlet switch ”FRESH” Battery positive voltage

Air inlet switch ”RECIRC” Below 1.0 V

B7 - Ground Air inlet switch ”RECIRC” Battery positive voltage

Air inlet switch ”FRESH” Below 1.0 V

B12 - Ground A/C switch ON 9.0 V

A/C switch OFF Below 1.0 V


I11192

I27161I27950

Double Cab:

Access Cab, Standard Cab:AC3S4-02

I11191


I27162

Double Cab:

I11190



5123Author: Date:

REASSEMBLY1. INSTALL LENSInstall the lens.

2. Access cab, Standard cab: INSTALL INTEGRATION CIRCUIT

(a) Connect the 2 connectors.(b) Install the circuit.

3. Double cab: INSTALL INTEGRATION CIRCUIT

(a) Install the circuit.(b) Install the 2 screws.

4. Access cab, Standard cab: INSTALL HEATER CONTROL HOUSING

(a) Connect the connector.(b) Install the heater control housing.(c) Install the 5 screws.

I27028

Double Cab:

I11189

I27027 I27949


Double Cab:

I11188



AC-97

5124Author: Date:

5. Double cab: INSTALL HEATER CONTROL HOUSING

(a) Install the heater control housing.(b) Install the 6 screws.

6. INSTALL BULBS(a) Access cab, standard cab:

Install the 5 bulbs.(b) Double cab:

Install the 6 bulbs.

7. Access cab, Standard cab: INSTALL AIRBAG INDICATOR CIRCUIT

(a) Connect the connector.(b) Install the circuit.

H111757 Clips

AC27E-03


AC-89

5116Author: Date:

REMOVALREMOVE CENTER CLUSTER INTEGRATION PANEL(a) Remove the 3 heater control knobs.(b) Remove the 5 screws.(c) Remove the integration control panel by pulling the por-

tions indicated by arrows in the illustration.(d) Disconnect the connector.

AC22G-08

N13793

Charging Cylinder

High PressureService Valve

Low PressureService Valve

PushAir

N13792

Gas LeakDetector

-AIR CONDITIONING AIR CONDITIONING SYSTEMAC-1 1

5038Author: Date:

CHARGING1. INSTALL CHARGING CYLINDERHINT: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 either the high or low side valve of the manifoldgauge set.(c) Open the valve of the charging cylinder.(d) Press the valve core on the side of the manifold gauge

and expel the air from the center hose.

2. INSPECT REFRIGERATION SYSTEM FOR LEAKS(a) Open the high pressure side valve and charge refrigerant.(b) When the low pressure gauge indicates 98 kPa

(1 kgf/cm2, 14 psi), close the high pressure side valve.(c) Using a gas leak detector, check the system for leakage.CAUTION:Use a refrigerant recovery/recycling machine to recoverthe refrigerant whenever replacing parts.

N13790



I11172

ProperlyCharged

InsufficientlyCharged

AC-12-AIR CONDITIONING AIR CONDITIONING SYSTEM

5039Author: Date:

3. CHARGE REFRIGERANT INTO REFRIGERANT SYS-TEM

If there is no leak after refrigerant leak check, charge the properamount of refrigerant into the refrigeration system.CAUTION: Never run the engine when charging the system

through the high pressure side. Do not open the low pressure side valve when the

system is being charged with liquid refrigerant.(a) Open the high pressure side valve fully.(b) Charge specified amount of refrigerant, then close the

high pressure side valve.HINT:The system is fully charged if bubbles cannot be seen throughthe sight glass.(c) Partially charge the refrigeration system with refrigerant.

(1) Prepare the vehicle: Running engine at 1,500 rpm Single A/C:

Front blower speed control dial at ”HI” posi-tion

Dual A/C:Front and rear blower speed set at ”HI” posi-tion

Single A/C:Front temperature control dial at ”MAX.COOL” position

Dual A/C:Front temperature control dial at ”MAX.COOL” positionRear temperature control set at 18.5°C(65°F)

Air inlet control set at ”RECIRC” Fully open doors (Sliding roof: closed)

(2) Open the low pressure side valve.CAUTION:Do not open the high pressure side valve.

(d) Access cab, Standard cab:Charge refrigerant until bubbles disappear and check thepressure on the gauge through the sight glass.

HINT:Double cab models do not have a sight glass. When inspecting,use a manifold gauge set.

AC0C4-12

N13795

Quick DisconnectAdapter

Charging

Service Valve

Hose

N13794

Vacuum Pump

Vacuum Pump Adapter

N13791


Vacuum Pump Adapter


ManifoldGaugeSet


5037Author: Date:

EVACUATING1. CONNECT QUICK DISCONNECT ADAPTER TO

CHARGING HOSES2. REMOVE CAPS FROM SERVICE VALVES ON RE-

FRIGERANT LINES3. SET MANIFOLD GAUGE SET(a) Close both valves of the manifold gauge set.(b) Connect the quick disconnect adapters to the service

valves.

4. EVACUATE AIR FROM REFRIGERATION SYSTEM(a) Connect the vacuum pump adapter to the vacuum pump.

(b) Connect the center hose of the manifold gauge set to thevacuum pump adapter.

(c) Open both the high and low side valves and run the vacu-um pump.

(d) After 10 minutes or more, check that the low pressuregauge indicates 750 mmHg (30 in. Hg) or more.

HINT:If the reading is 750 mmHg (30 in. Hg) or more, close bothvalves of the manifold gauge set and stop the vacuum pump.Check the system for leaks and repair if necessary.(e) Close both the high and low side valves and stop the vac-

uum pump.(f) Leave the system in this condition for 5 minutes or more

and check that there is no change in gauge indication.

AC3RP-02

I11116

I11117

I29016

Engine Room R/B Heater Main Relay(Marking: HEATER)

Compressor

Condenser

ReceiverPressure Switch

Integration Panel Assembly A/C Amplifier A/C Switch Air Inlet Selector

Heater Control AssemblyHeater Unit Heater Radiator Cooling Unit

Blower Resistor Evaporator Expansion Valve Thermistor

Blower Unit Blower Motor Air Inlet Servomotor

Water Valve


-AIR CONDITIONING AIR CONDITIONING SYSTEMAC-13

5040Author: Date:

LOCATION

H23499

Double Cab:

Engine Room R/B No. 2 Heater Main Relay(Marking: HEATER)

Compressor

Condenser

Pressure Switch Integration Panel Assembly A/C Amplifier A/C Switch Air Inlet Selector

Heater Control Assembly

Heater Unit Heater Radiator

Cooling Unit Blower Resistor Evaporator Expansion Valve Thermistor

Blower Unit Blower Motor Air Inlet Servomotor

Water Valve


5041Author: Date:

I11115

Sight Glass

AC22F-09


5030Author: Date:

ON-VEHICLE INSPECTION1. Access cab, Standard cab:

INSPECT REFRIGERANT VOLUMEObserve the sight glass on the liquid tube.

Test conditions: Running engine at 1,500 rpm Blower speed control switch at ”HI” position A/C switch ON Temperature control dial at ”COOL” position Fully open the doors

Item Symptom Amount of refrigerant Remedy

1 Bubbles are present in sight glass Insufficient*

(1) Check for gas leakage with gas leak de-

tector and repair if necessary

(2) Add refrigerant until bubbles disappear

2 No bubbles are present in sight glass None, sufficient or too much Refer to items 3 and 4

3No temperature difference between com-

pressor inlet and outletEmpty or nearly empty

(1) Check for gas leakage with gas leak de-

tector and repair if necessary

(2) Add refrigerant until bubbles disappear

4Temperature between compressor inlet and

outlet is noticeably differentCorrect or too much Refer to items 5 and 6

5Immediately after air conditioning is turned

off, refrigerant in sight glass stays clearToo much

(1) Discharge refrigerant

(2) Evacuate air and charge proper amount

of purified refrigerant

6When air conditioning is turned off, refriger-

ant foams and then stays clearCorrect -

*: Bubbles in the sight glass with ambient temperature higher than usual can be considered normal if coolingis sufficient.HINT:Double cab models do not have a sight glass. When inspecting, use a manifold gauge set.

I01386

I01387

Condition : Periodically cools and then fails to cool


5031Author: Date:

2. INSPECT REFRIGERANT PRESSURE WITH MAN-IFOLD GAUGE SET

This is a method for checking the A/C system by using a man-ifold gauge set. Read the manifold gauge pressure when thefollowing conditions are established.

Test conditions: Temperature at the air inlet with the switch set

at RECURC is 30 to 35°C (86 to 95°F) Engine running at 1500 rpm Blower speed control switch at ”HI” position Temperature control dial at ”COOL” position

HINT:Gauge indications may vary slightly due to ambient tempera-ture conditions.

(1) Normally functioning refrigeration system.Gauge reading:Low pressure side:0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm 2)High pressure side:1.37 to 1.57 MPa (14 to 16 kgf/cm 2)

(2) Moisture present in refrigeration system.

Symptom seen in

refrigeration systemProbable cause Diagnosis Remedy

During operation, pressure on low

pressure side cycles between vac-

uum and normal

Moisture in refrigeration system

freezes at expansion valve orifice

and temporarily stops cycle, but

normal state is restored after the

ice melts

Drier in oversaturated state

Moisture in refrigeration system

freezes at expansion valve orifice

and blocks circulation of refriger-

ant

(1) Replace receiver

(2) Remove moisture in cycle by

repeatedly evacuating air

(3) Charge proper amount of new

refrigerant

I01388

Condition: Insufficient cooling

I01389



5032Author: Date:

(3) Insufficient cooling

Symptom seen in


Pressure low on both low and

high pressure sides

Bubbles seen in sight glass con-

tinuously

Insufficient cooling performance

Gas leakage in refrigeration sys-

tem

Insufficient refrigerant in system

Refrigerant leaking

(1) Check for gas leakage with gas

leak detector and repair if neces-

sary

(2) Charge proper amount of re-

frigerant

(3) If indicated pressure value is

near 0 when connected to gauge,

create the vacuum after inspecting

and repairing the location of the

leak

(4) Poor circulation of refrigerant

Symptom seen in


Pressure low on both low and

high pressure sides

Frost on tube from receiver to

unit

Refrigerant flow obstructed by dirt

in receiverReceiver clogged Replace receiver

I01449

Condition: Does not cool (Cools from time to time in some cases)

I01390



5033Author: Date:

(5) Refrigerant does not circulate

Symptom seen in


Vacuum indicated on low pres-

sure side, very low pressure indi-

cated on high pressure side

Frost or dew seen on piping on

both sides of receiver/drier or ex-

pansion valve

Refrigerant flow obstructed by

moisture or dirt in refrigeration sys-

tem

Refrigerant flow obstructed by

gas leakage from expansion valve

Refrigerant does not circulate

(1) Check expansion valve

(2) Clean out dirt in expansion

valve by blowing with air

(3) Replace receiver

(4) Evacuate air and charge new

refrigerant to proper amount

(5) For gas leakage from expan-

sion valve, replace expansion

valve

(6) Refrigerant overcharged or insufficient cooling ofcondenser

Symptom seen in


Pressure too high on both low

and high pressure sides

No air bubbles seen through the

sight glass even when the engine

rpm is lowered

Unable to develop sufficient per-

formance due to excessive refrig-

erant

Insufficient cooling of condenser

Excessive refrigerant in

cycle→refrigerant overcharged

Condenser cooling

insufficient→condenser fins

clogged or cooling fan faulty

(1) Clean condenser

(2) Check cooling fan with fluid

coupling operation

(3) If (1) and (2) are in normal

state, check amount of refrigerant

and charge proper amount of re-

frigerant

I01392


NOTE : These gauge indica-tions are shown when therefrigeration system has beenopened and the refrigeranthas been charged withoutvacuum purging.

I01450



5034Author: Date:

(7) Air present in refrigeration system

Symptom seen in




The low pressure piping hot to

the touch

Bubbles seen in sight glass

Air in refrigeration system

Air present in refrigeration sys-

tem

Insufficient vacuum purging

(1) Check compressor oil to see if

it is dirty or insufficient

(2) Evacuate air and charge new

refrigerant

(8) Expansion valve malfunction

Symptom seen in




Frost or large amount of dew on

piping on low pressure side

Trouble in expansion valve

Excessive refrigerant in low

pressure piping

Expansion valve opened too

wide

Check expansion valve

Replace if defective

I01393

Condition : Does not cool


5035Author: Date:

(9) Insufficient compressor compression

Symptom seen in




Pressure too low on high pres-

sure side

Internal leak in compressor

Low compression

Leak from valve or broken sliding

parts

Repair or replace compressor

3. INSPECT IDLE-UP SPEED(a) Warm up the engine.(b) Inspect idle-up speed when the following conditions are

established. Warm up engine Blower speed control switch at ”HI” position A/C switch ON Temperature control dial at ”COOL” position

Magnetic clutch condition Idle-up speed

1GR-FE Engine -

Magnetic clutch not engaged 700 ± 50 rpm

Magnetic clutch engaged 700 ± 50 rpm

2UZ-FE Engine -

Magnetic clutch not engaged 750 ± 50 rpm

Magnetic clutch engaged 800 ± 50 rpm

If idle speed is not as specified, check the Idle control system.4. INSPECT FOR LEAKAGE OF REFRIGERANT(a) Perform under the following conditions:

Stop the engine. Secure good ventilation (If not, the gas leak detec-

tor may react to volatile gases witch are not refriger-ant, such as evaporated gasoline and exhaust gas.)

Repeat the test 2 or 3 times. Make sure that there is some refrigerant remaining

in the refrigeration system.When the compressor is OFF: approx. 392 to 588kPa (4 to 6 kgf/ cm2, 57 to 85 psi)


5036Author: Date:

(b) Bring the gas leak detector close to the drain hose beforeperforming the test.

HINT: After the blower motor stopped, leave the cooling unit for

more than 15 minutes. Bring the gas leak detector sensor under the drain hose. When bringing the gas leak detector close to the drain

hose, make sure that the gas leak detector does not reactto the volatile gases.

If such reaction is unavoidable, the vehicle must be lifted up.(c) If gas leak is not detected on the drain hose, remove the

blower motor linear controller from the cooling unit. Theninsert the gas leak detector sensor into the unit and per-form the test.

(d) Disconnect the connector and leave the pressure switchfor approx. 20 minutes. Then bring the gas leak detectorclose to the pressure switch and perform the test.

(e) Bring the gas leak detector close to the refrigerant linesand perform the test.

AC2810

AC0C1-14

AC2811

N11084

Wrong Okay

HILO HILO


5028Author: Date:

AIR CONDITIONING SYSTEMPRECAUTION1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED

AREA OR NEAR AN OPEN FLAME2. ALWAYS WEAR EYE PROTECTION

3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT INYOUR EYES OR ON YOUR SKIN

If liquid refrigerant gets in your eyes or on your skin.(a) Wash the area with lots of cool water.CAUTION:Do not rub your eyes or skin.(b) Apply clean petroleum jelly to the skin.(c) Go immediately to a physician or hospital for professional

treatment.4. NEVER HEAT CONTAINER OR EXPOSE IT TO OPEN

FLAME5. BE CAREFUL NOT TO DROP CONTAINER OR NOT TO

APPLY PHYSICAL SHOCKS TO IT

6. DO NOT OPERATE COMPRESSOR WITHOUTENOUGH REFRIGERANT IN REFRIGERATION SYS-TEM

If there is not enough refrigerant in the refrigerant system, oil lu-brication will be insufficient and compressor burnout may occur.Necessary care should be taken to avoid this.7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE

COMPRESSOR IS OPERATINGIf the high pressure valve is opened, refrigerant flows in the re-verse direction and could cause the charging cylinder to rup-ture, so open and close only the low pressure valve.8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH

REFRIGERANTIf refrigerant is overcharged, it causes problems such as insuffi-cient cooling, poor fuel economy, engine overheating, etc.


5029Author: Date:

9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)The TOYOTA TUNDRA is equipped with an SRS (Supplemen-tal Restraint System) such as the driver and front passenger air-bags. Failure to carry out service operation in the correct se-quence could cause the SRS to unexpectedly deploy duringservicing, possibly leading to a serious accident. Before servic-ing (including removal or installation of parts, inspection or re-placement), be sure to read the precautionary notices in the RSsection.

I11143

AC3RY-02

I04551

2 1

I28079

2 1

I11143

-AIR CONDITIONING BLOWER MOTORAC-77

5104Author: Date:

BLOWER MOTORINSPECTION1. REMOVE BLOWER MOTOR(a) Double cab:

Remove the 2 screws and motor cover.(b) Disconnect the connector.(c) Remove the 3 screws and motor.

2. Standard cab, Access cab:INSPECT BLOWER MOTOR OPERATION

Connect the positive (+) lead from the battery to terminal 1 andthe negative (-) lead to terminal 2, then check that the motor op-erates smoothly.If operation is not as specified, replace the blower motor.

3. Double cab:INSPECT BLOWER MOTOR OPERATION

Connect the positive (+) lead from the battery to terminal 1 andthe negative (-) lead to terminal 2, then check that the motor op-erates smoothly.If operation is not as specified, replace the blower motor.

4. INSTALL BLOWER MOTOR(a) Install the motor with the 3 screws.(b) Connect the connector.

AC23E-05

I11127

N09039

2 1

34

I11127

AC-78-AIR CONDITIONING BLOWER RESISTOR

5105Author: Date:

BLOWER RESISTORINSPECTION1. REMOVE GLOVE COMPARTMENT PARTS2. REMOVE LOWER NO. 2 FINISH PANEL3. REMOVE LOWER CENTER COVER4. REMOVE LOWER LH FINISH PANEL5. REMOVE LOWER COVER (See page BO-1 11)6. REMOVE NO. 4 HEATER TO REGISTER DUCT

7. REMOVE BLOWER RESISTOR(a) Disconnect the connector.(b) Remove the 2 screws and blower resistor.

8. INSPECT BLOWER RESISTOR RESISTANCE


1-4 Constant 3.3 ± 0.2 Ω

1-3 Constant 1.9 ± 0.1 Ω

1-2 Constant 2.9 ± 0.2 Ω

If resistance is not as specified, replace the blower resistor.

9. INSTALL BLOWER RESISTOR(a) Install the blower resistor with the 2 screws.(b) Connect the connector.

10. INSTALL NO. 4 HEATER TO REGISTER DUCT11. INSTALL LOWER COVER12. INSTALL LOWER LH FINISH PANEL13. INSTALL LOWER CENTER COVER14. INSTALL LOWER NO. 2 FINISH PANEL15. INSTALL GLOVE COMPARTMENT PARTS

(See page BO-120 )

AC3RW-02

I11132

I11157

I11178

Lower LHFinish Panel Cooling Unit

Blower Unit

Lower Cover

Lower Center Cover

Heater to RegisterDuct No. 4

Cowl Side Trim RH

Front Door Scuff Plate RH

Lower No. 2Finish Panel

Glove Compartment Door

Blower Unit Case

Air Inlet Servomotor

Blower Motor


-AIR CONDITIONING BLOWER UNITAC-45

5072Author: Date:

BLOWER UNITCOMPONENTS

I27021

Lower LH Finish Panel Cooling Unit

Blower Unit

Lower Cover


Cowl Side Trim RH



Air Inlet Servomotor

Blower Motor

Double Cab:

Blower Unit Case


Instrument Side Panel RH

Console Box Assy

Console Panel UPR

Console Box Assy RR Motor Cover

AC-46-AIR CONDITIONING BLOWER UNIT

5073Author: Date:

AC0CW-05


5075Author: Date:

DISASSEMBLY1. REMOVE BLOWER MOTOR(a) Double cab:

Remove the 2 screws and motor cover.(b) Remove the 3 screws and blower motor.2. REMOVE AIR INLET SERVOMOTORRemove the 3 screws and servomotor.

I28077

To ”FRESH”

2

5

AC274-03

I28078

To ”RECIRC”1

5


5076Author: Date:

INSPECTIONINSPECT AIR INLET SERVOMOTOR OPERATION(a) Connect the positive (+) lead from the battery to terminal

5 and the negative (-) lead to terminal 2.(b) Check the motor arm rotates counterclockwise and stops

in the ”FRESH” position.

(c) Connect the positive (+) lead from the battery to terminal5 and the negative (-) lead to terminal 1.

(d) Check the motor arm rotates counterclockwise and stopsin the ”RECIRC” position.

AC0CX-02


5078Author: Date:


AC0CY-03


5077Author: Date:

REASSEMBLYThe reassembly procedures are the disassembly procedures in reverse order (see page AC-48 ).

AC0CV-05


5074Author: Date:

REMOVAL1. REMOVE COOLING UNIT (See page AC-31 )2. REMOVE BLOWER UNIT(a) Double cab:

Remove the 2 screws and motor cover.(b) Disconnect the connector from the blower motor.(c) Disconnect the air inlet damper control cable from the blower unit.HINT:At the time of installation, refer to the following:After connection, adjust the control cable.(d) Remove the nut, bolt and blower unit.

AC3SE-01

I28952

N⋅m (kgf⋅cm, ft⋅lbf) : Specified torqueNon-reusable part

Magnet Clutch Assy

Magnet Clutch Washer

Snap Ring

Cooler Compressor Assy

Snap Ring

18 (183, 13)

-AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH (1GR-FE)AC-53

5080Author: Date:

COMPONENTS

I28956

SST

AC3SG-01

E37447 I28957

E37448 I28958


5082Author: Date:

DISASSEMBLY1. REMOVE MAGNET CLUTCH(a) Place the compressor and magnetic clutch in a vise.(b) Using SST, remove the bolt, the magnet clutch hub and

the magnet clutch washer.SST 09960-10010 (09962-01000, 09963-00500)

(c) Using a snap ring expander, remove the snap ring and themagnet clutch rotor.

(d) Remove the screw and disconnect the connector.

(e) Using a snap ring expander, remove the snap ring and themagnet clutch stator.

I28955

AC3SI-01

I28954

I28953

AC-58-AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH (1GR-FE)

5085Author: Date:

INSTALLATION1. INSTALL COMPRESSOR AND MAGNET CLUTCH(a) Install the compressor and the magnetic clutch with the 4

bolts.Torque: 24 N ⋅m (245 kgf ⋅cm, 18 ft ⋅lbf)

(b) Connect the connector.

2. INSTALL SUCTION HOSE(a) Remove the attached vinyl tape from the hose.(b) Sufficiently apply compressor oil to a new O-ring and the

fitting surfaces of the compressor and magnetic clutch.Compressor oil: ND-OIL 8 or equivalent

(c) Install the O-ring on the suction hose sub-assy.(d) Install the suction hose sub-assy on the compressor and

magnetic clutch with the nut.Torque: 10 N ⋅m (100 kgf ⋅cm, 7 in. ⋅lbf)

3. INSTALL DISCHARGE HOSE(a) Remove the attached vinyl tape from the hose.(b) Sufficiently apply compressor oil to a new O-ring and the

fitting surfaces of the compressor and magnetic clutch.Compressor oil: ND-OIL 8 or equivalent

(c) Install the O-ring on the discharge hose sub-assy.(d) Install the discharge hose sub-assy on the compressor

and magnetic clutch with the nut.Torque: 10 N ⋅m (100 kgf ⋅cm, 7 in. ⋅lbf)

4. INSTALL AND CHECK DRIVE BELT(See page AC-19 and AC-17 )

5. INSTALL ENGINE UNDER COVER6. CONNECT NEGATIVE (-) TERMINAL CABLE TO BAT-

TERY7. EVACUATE AIR FROM REFRIGERATION SYSTEM8. CHARGE SYSTEM WITH REFRIGERANT

Specified amount: Access cab, Standard cab:600 ± 50 g (21.16 ± 1.76 oz.)Double cab:530 ± 50 g (18.69 ± 1.76 oz.)

9. INSPECT FOR LEAKAGE OF REFRIGERANTUsing a gas leak detector, check for leakage of refrigerant.If there is leakage, check the tightening torque at the joints.

AC3SD-01

I28951

I28951


5079Author: Date:

COMPRESSOR AND MAGNETICCLUTCH (1GR-FE)ON-VEHICLE INSPECTION1. SET MANIFOLD GAUGE SET (See page AC-20 )2. START ENGINE3. INSPECT COMPRESSOR FOR METALLIC SOUNDCheck if a metallic sound can be heard from the compressorwhen the A/C switch is on.If a metallic sound cannot be heard, replace the compressor as-sembly.4. INSPECT REFRIGERANT PRESSURE

(See page AC-3 )5. STOP ENGINE6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-

ANT FROM SAFETY SEALUsing a gas leak detector, check for leakage of refrigerant.If there is any leakage, replace the compressor assembly.7. REMOVE MANIFOLD GAUGE SET

(See page AC-22 )8. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH

BEARING9. CHECK FOR SIGNS OF OIL ON PRESSURE PLATEIf necessary, repair or replace the pressure plate.10. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE(a) Start the engine.(b) Check if abnormal noise is heard from near the compres-

sor when the A/C switch is OFF.If abnormal noise is being emitted, replace the magnetic clutch.

11. INSPECT MAGNETIC CLUTCH OPERATION(a) Disconnect the connector.(b) Connect the positive (+) lead from the battery to terminal

3 on the magnetic clutch connector and the negative (-)lead to body ground.

(c) Check that the magnetic clutch is energized.If operation is not as specified, replace the magnetic clutch.

12. INSPECT COMPRESSOR LOCK SENSOR RESIS-TANCE

(a) Disconnect the connector.(b) Measure the resistance between terminals 1 and 2.

Standard resistance:165 to 205 Ω at 20°C (68°F)

If resistance is not as specified, replace the compressor.

I28959

AC3SH-01

I28960

I28961

I28962

SST


5083Author: Date:

REASSEMBLY1. INSTALL MAGNET CLUTCH(a) Fit the parts as shown in the illustration, and install the

magnet clutch stator.

(b) Using a snap ring expander, install a new snap ring withthe chamfered side facing up.

(c) Install the screw and connect the connector.

(d) Using a snap ring expander, install the magnet clutch ro-tor and a new snap ring with the chamfered side facing up.

(e) Install the magnet clutch washer and the magnet clutchhub.

NOTICE:Do not change the combination of the magnet clutch wash-ers used before disassembly.

(f) Using SST, install the magnet clutch hub and the magnetclutch washer with the bolt.SST 09960-10010 (09962-01000, 09963-00500)Torque: 18 N ⋅m (183 kgf ⋅cm, 13 ft ⋅lbf)

I28963


5084Author: Date:

2. INSPECT MAGNET CLUTCH CLEARANCE(a) Set the dial indicator to the magnet clutch hub.(b) Connect the positive battery lead to terminal 1 of the mag-

net clutch connector and the negative lead to the earthwire. Turn the magnet clutch on and off and measure theclearance.Standard clearance:0.35 to 0.60 mm (0.013 to 0.023 in.)

If the measured value is not within the standard range, removethe magnet clutch hub and adjust it with magnet clutch wash-ers.NOTICE:Adjustment should be performed with 3 or less magnetclutch washers.3. INSPECT COMPRESSOR OILWhen replacing the compressor and magnetic clutch with anew one, after gradually removing the refrigerant gas from theservice valve, drain the following amount of oil from the newcompressor and magnetic clutch before installation.

Standard:(Oil capacity inside the new compressor and magnet-ic clutch: 120 + 15 cc (4.0 + 0.5 fl. oz.) ) - (Remainingoil amount in the removed compressor and magneticclutch) = (Oil amount to be removed when replacing)

NOTICE: When checking the compressor oil level, observe the

precautions in the cooler removal/installation. Because compressor oil remains in the pipes of the

vehicle, if a new compressor and magnetic clutch isinstalled without removing some oil inside, the oilamount becomes e xcessive, preventing heat ex-change in the refrigerant cycle and causing refriger-ant failure.

If the remaining oil in the removed compressor andmagnetic clutch is too small in volume, check for anoil leakage.

Be sure to use ND-OIL 8 or equivalent for compressoroil.

AC3SF-01

I28953

I28954

I28955


5081Author: Date:

REMOVAL1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR

APPROX. 10 MINUTES2. STOP ENGINE3. DISCONNECT NEGATIVE (- ) TERMINAL CABLE

FROM BATTERY4. DISCHARGE REFRIGERANT FROM REFRIGERATION

SYSTEM5. REMOVE ENGINE UNDER COVER

6. DISCONNECT DISCHARGE HOSE(a) Remove the nut and disconnect the discharge hose sub-

assy from the compressor and magnetic clutch.(b) Remove the O-ring from the discharge hose sub-assy.NOTICE:Seal the openings of the disconnected parts using vinyltape to prevent moisture and foreign matter from entering.

7. DISCONNECT SUCTION HOSE(a) Remove the nut and disconnect the suction hose sub-

assy from the compressor and magnetic clutch.(b) Remove the O-ring from the suction hose sub-assy.NOTICE:Seal the openings of the disconnected parts using vinyltape to prevent moisture and foreign matter from entering.

8. REMOVE COMPRESSOR AND MAGNETIC CLUTCH(a) Disconnect the connector.(b) Remove the 4 bolts and the compressor and magnetic

clutch.

AC3SK-01

I28850

Suction Hose

O-Ring

Compressor Bracket

47 (475, 34)

47 (475, 34)

10 (100, 7)

Discharge Hose

Cooler BracketCompressor

Drive Belt

Stator

Rotor

Pressure PlateShim

Snap Ring

Compressor

N·m (kgf·cm,ft·lbf) Non-reusable part

: Specified torque

25 (250, 18)25 (250, 18)

13.2 (135, 9)

AC-60-AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH (2UZ-FE)

5087Author: Date:

COMPONENTS

AC0943

SST

AC3SM-01

AC0944

SST

AC0945

SST

AC0946

Shim

PressurePlate

AC0947

SST


5089Author: Date:

DISASSEMBLY1. REMOVE PRESSURE PLATE(a) Using SST and a socket wrench, remove the shaft bolt.

SST 07112-76060Torque: 13.2 N·m (135 kgf·cm, 9 ft·lbf)

(b) Install SST on the pressure plate.SST 07112-66040

(c) Using SST and a socket wrench, remove the pressureplate.SST 07112-66040, 07112-76060,

(d) Remove the shims from the pressure plate.

2. REMOVE ROTOR(a) Using SST, remove the snap ring.

SST 95994-10020

N20013

R-Shape Rotor

Snap Ring

Compressor

AC1743

AC1744

AC0950

SST

N20012

R-ShapeSnap Ring

Compressor

Stator

-AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH (2UZ-FE)AC-63

5090Author: Date:

NOTICE:The snap ring should be installed so that its beveled sidefaces up.

(b) Using a plastic hammer, remove the rotor from 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 95994-10020

NOTICE:The snap ring should be installed so that its beveled sidefaces up.

AC0951

Stator


5091Author: Date:

(c) Remove the stator.

AC3SO-01


5093Author: Date:

INSTALLATION1. INSTALL COMPRESSOR(a) Install the compressor with the cooler bracket with the 4 bolts and nut.

Torque: 25 N·m (250 kgf·cm, 18 in.·lbf)(b) Connect the connector.2. CONNECT DISCHARGE AND SUCTION HOSESConnect both hoses with the 2 nuts.

Torque: 10 N·m (100 kgf·cm, 7 in.·lbf)NOTICE:Hoses should be connected immediately after the caps have been removed.HINT:Lubricate 2 new O-rings with compressor oil and install them to the hoses.3. INSTALL AND CHECK DRIVE BELT (See page AC-19 and AC-17 )4. CONNECT NEGATIVE (-) TERMINAL CABLE TO BATTERY5. EVACUATE AIR FROM REFRIGERATION SYSTEM6. CHARGE SYSTEM WITH REFRIGERANT

Specified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)Double cab: 530 ± 50 g (18.69 ± 1.76 oz.)

7. INSPECT FOR LEAKAGE OF REFRIGERANTUsing a gas leak detector, check for leakage of refrigerant.If there is leakage, check the tightening torque at the joints.

AC3SJ-01

I11134

3

I11133

1

2


5086Author: Date:

COMPRESSOR AND MAGNETICCLUTCH (2UZ-FE)ON-VEHICLE INSPECTION1. SET MANIFOLD GAUGE SET (See page AC-20 )2. START ENGINE3. INSPECT COMPRESSOR FOR METALLIC SOUNDCheck if a metallic sound can be heard from the compressorwhen the A/C switch is on.If a metallic sound cannot be heard, replace the compressor as-sembly.4. INSPECT REFRIGERANT PRESSURE

(See page AC-3 )5. STOP ENGINE6. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-

ANT FROM SAFETY SEALUsing a gas leak detector, check for leakage of refrigerant.If there is any leakage, replace the compressor assembly.7. REMOVE MANIFOLD GAUGE SET

(See page AC-22 )8. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH

BEARING9. CHECK FOR SIGNS OF OIL ON PRESSURE PLATEIf necessary, repair or replace.10. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE(a) Start the engine.(b) Check if abnormal noise is heard from near the compres-

sor when the A/C switch is OFF.If abnormal noise is being emitted, replace the magnetic clutch.

11. INSPECT MAGNETIC CLUTCH OPERATION(a) Disconnect the connector.(b) Connect the positive (+) lead from the battery to terminal

3 and the negative (-) lead to body ground.(c) Check that the magnetic clutch is energized.If operation is not as specified, replace the magnetic clutch.

12. INSPECT COMPRESSOR LOCK SENSOR RESIS-TANCE

(a) Disconnect the connector.(b) Measure the resistance between terminals 1 and 2.

Standard resistance:65 to 125 Ω at 20 °C (68 °F)

If resistance is not as specified, replace the compressor.

AC3SN-01

N04963

Dial Indicator


5092Author: Date:

REASSEMBLYReassembly is in the reverse order of disassembly(See page AC-62 ).AFTER REASSEMBLY, CHECK MAGNETIC CLUTCHCLEARANCE(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 range, adjust theclearance using shims to obtain the standard clearance.

Standard thickness:0.1 mm (0.004 in.)0.3 mm (0.012 in.)0.5 mm (0.020in.)

AC3SL-01


5088Author: Date:

REMOVAL1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES2. STOP ENGINE3. DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM5. DISCONNECT DISCHARGE AND SUCTION HOSESRemove the 2 nuts and disconnect both hoses.NOTICE:Cap the openings immediately to keep moisture or dirt out of the system.6. REMOVE DRIVE BELT (See page AC-18 )7. REMOVE COMPRESSOR(a) Disconnect the connector.(b) Remove the 4 bolts and nut.(c) Remove the cooler bracket.(d) Remove the compressor.

AC0DA-02

-AIR CONDITIONING CONDENSERAC-73

5100Author: Date:


AC0D8-01

AC-70-AIR CONDITIONING CONDENSER

5097Author: Date:

CONDENSERON-VEHICLE INSPECTION1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGEIf 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 LEAKAGEUsing a gas leak detector, check for leakage of refrigerant.If there is leakage, check the tightening torque at the joints.

AC3SP-01

I11184


I27022

Double Cab:

-AIR CONDITIONING CONDENSERAC-71

5098Author: Date:

REMOVAL1. DISCHARGE REFRIGERANT FROM REFRIGERATION

SYSTEMHINT:At the time of installation, refer to the following: Evacuate air from the refrigeration system. Charge the system with refrigerant and inspect for leak-

age of refrigerant.Specified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)Double cab: 530 ± 50 g (18.69 ± 1.76 oz.)

2. A/T models:REMOVE A/T OIL COOLER

3. REMOVE HORN4. REMOVE HOOD LOCK5. REMOVE CENTER BRACE6. REMOVE RECEIVER AND HOLDER

(See page AC-68 )

I11186


I27023

Double Cab:

I11187


I27024

Double Cab:

AC-72-AIR CONDITIONING CONDENSER

5099Author: Date:

7. DISCONNECT LIQUID TUBE AND DISCHARGE HOSERemove the 2 bolts and disconnect both tube and hose.

Torque:10 N·m (100 kgf·cm, 7 ft·lbf)NOTICE:Cap the openings immediately to keep moisture or dirt outof the system.HINT:At the time of installation, refer to the following:Lubricate 2 new O-rings with compressor oil and install themto the tubes.

8. REMOVE CONDENSER(a) Remove the 2 bolts and 2 lower brackets.(b) Remove the 4 bolts and 2 upper brackets.(c) Pull the condenser forward and then upward.HINT:At the time of installation, refer to the following:If the condenser is replaced, add compressor oil to the com-pressor.

Add 40 to 50 cc (1.4 to 1.7 fl.oz.)Compressor oil: ND-OIL 8 or equivalent

AC3RS-02

I28072

Lower LHFinish Panel

Lower Center Cover

Lower Cover

O-Ring

SuctionTube

Liquid Tube

O-Ring

Clamp

Cooling Unit


Cowl Side Trim RH




Upper Unit Case

Evaporator

Thermistor

5.4 (55, 18 in.·lbf)

Expansion Valve

O-Ring

Grommet

Liquid andSuction Tube

Drain Hose

Packing

Blower ControllerN·m (kgf·cm, ft·lbf) : Specified torque

Non-reusable part

PackingInsulator

Grommet

O-Ring

Lower Unit Case


Clamp

-AIR CONDITIONING COOLING UNITAC-29

5056Author: Date:

COMPONENTS

I27029

Lower LHFinish Panel

Lower Cover

O-Ring

Suction Tube

Liquid Tube

O-Ring

Clamp




Upper Unit Case

Evaporator

Thermistor

5.4 (55, 48 in.·lbf)

Expansion Valve

O-Ring

Grommet

Liquid andSuction Tube

Drain Hose

Packing

Blower ControllerN·m (kgf·cm, ft·lbf) : Specified torque Non-reusable part

Packing

Insulator

Grommet

O-Ring

Lower Unit Case

Instrument Side Panel RH

Cowl Side Trim RHConsole Box Assy FR

Console Panel UPR

Console Box Assy RR


Double Cab:

Clamp

AC-30-AIR CONDITIONING COOLING UNIT

5057Author: Date:

AC272-03

I28074

I28075


5060Author: Date:

DISASSEMBLY1. REMOVE BLOWER RESISTORRemove the 2 screws and blower resistor.

2. SEPARATE UPPER AND LOWER UNIT CASES(a) Disconnect the connector clamp from the upper unit case.(b) Using a knife, cut off each packing.(c) Remove the clip and 6 screws.(d) Separate the upper and lower unit cases, then pull out the

thermistor from the evaporator.3. REMOVE EVAPORATOR FROM LOWER UNIT CASEHINT:At the time of reassembly, refer to the following:If the evaporator is replaced, add compressor oil to the com-pressor.

Add 40 to 50 cc (1.4 to 1.7 fl.oz.)Compressor oil: ND-OIL 8 or equivalent

4. REMOVE EXPANSION VALVEUsing a hexagon wrench (5.0 mm, 0.20 in.), remove the 2 boltsand separate the expansion valve, evaporator and tubes.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)HINT:At the time of reassembly, refer to the following:Lubricate 4 new O-rings with compressor oil and install themto the tubes and valve.

AC22L-04

E50650

I28118


5061Author: Date:

INSPECTION1. CHECK EVAPORATOR FINS FOR BLOCKAGEIf the fins are clogged, clean them with compressed air.2. CHECK FITTING FOR CRACKS OR SCRATCHESIf necessary, repair or replace.

3. INSPECT THERMISTOR RESISTANCE(a) Remove the A/C evaporator temperature sensor (cooler

thermister No.1).(b) Measure the resistance according tor the value(s) in the

table below.Standard:


1 - 2 -10 °C (14°F) 7.40 to 9.20 kΩ

1 - 2 -5 °C (23°F) 5.65 to 7.00 kΩ

1 - 2 0°C (32°F) 4.35 to 5.40 kΩ

1 - 2 5°C (41°F) 3.40 to 4.20 kΩ

1 - 2 10°C (50°F) 2.68 to 3.30 kΩ

1 - 2 15°C (59°F) 2.10 to 2.60 kΩ

1 - 2 20°C (68°F) 1.66 to 2.10 kΩ

1 - 2 25°C (77°F) 1.32 to 1.66 kΩ

1 - 2 30°C (86°F) 1.05 to 1.35 kΩ

NOTICE: Even slightly touching the sensor may change the re-

sistance value. Be sure to hold the connector of thesensor.

When measuring, the sensor temperature must bethe same as the ambient temperature.

I28120

Temperature (C)

Resistance (kΩ)

(32°F) (68°F) (104°F)(-4.0 °F)


5062Author: Date:

HINT:As the temperature increases, the resistance decreases (seethe graph below).

If the result is not as specified, replace the sensor.

AC0CJ-02


5064Author: Date:


AC271-03

I11127

I11171


5055Author: Date:

COOLING UNITON-VEHICLE INSPECTION1. INSPECT FOR LEAKAGE OF REFRIGERANT(a) Remove the glove compartment door.(b) Remove the lower No. 2 finish panel.(c) Remove the lower center cover.(d) Remove the lower LH finish panel.(e) Remove the lower cover (See page BO-1 11).

(f) Remove the blower resistor.(1) Disconnect the connector.(2) Remove the 2 screws and blower resistor.

(g) Using a gas leak detector, check for leakage.If there is leakage, check the tightening torque at the joints orcheck the evaporator.(h) Install the blower resistor with the 2 screws.(i) Install the lower cover.(j) Install the lower LH finish panel.(k) Install the lower center cover.(l) Install the lower No. 2 finish panel.(m) Install the glove compartment door (See page BO-120 ).2. INSPECT EXPANSION VALVE(a) Check quantity of gas during refrigeration cycle.(b) Set the manifold gauge set.(c) Run the engine.

(1) Run the engine at 1,500 rpm for at least 5 minutes.(2) Then check that the high pressure reading is 1.37

to 1.57 Mpa (14 to 16 kgm/cm2, 199 to 288 psi).(d) Check the expansion valve.If the expansion valve is faulty, the low pressure reading willdrop to 0 kPa (0 kgf/cm2, 0 psi).HINT:When the low pressure reading drops to 0 kPa (0 kgf/cm2, 0psi), there is no difference in temperature between the IN andOUT sides of the receiver.

3. INSPECT THERMISTOR RESISTANCE(a) Disconnect the connector.(b) Measure the resistance between terminals.

Standard resistance: 1,500 Ω at 25°C (77°F)If resistance is not as specified, replace the thermistor.

AC0CI-02


5063Author: Date:


AC3RT-02

I28855

I03838

SST

I03839

SSTPush

SST

Pull

ReleaseLever


5058Author: Date:


SYSTEMHINT:At the time of installation, refer to the following: Evacuate air from the refrigeration system. Charge system with refrigerant and inspect for leakage of

refrigerant.Specified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)Double cab: 530 ± 50 g (18.69 ± 1.76 oz.)

2. DISCONNECT LIQUID AND SUCTION TUBE(a) Using SST, remove the piping clamp.

SST 09870-00025 (Liquid tube)

(1) Install SST to the piping clamp.HINT:Confirm the directions of the piping clamp claw and SST usingthe illustration on the caution label.

(2) Push down SST and release the clamp lock.NOTICE:Be careful not to deform the tubes, when pushing SST.

(3) Pull SST slightly and push the release lever, then re-move the piping clamp with SST.

(4) Remove the piping clamp from SST.(b) Disconnect both tubes.

I06919

Disconnect the tube by hand

Screwdriver

Tube

I06878

Connect WrongGap

I11125


5059Author: Date:

NOTICE: Do not use tools like a screwdriver to remove the

tube. Cap the openings immediately to keep moisture or

dirt out of the system.

HINT:At the time of installation, refer to the following: Lubricate 2 new O-rings with compressor oil and install

them to the tubes. After connection, check the claw of the piping clamp is se-

curely engaged.3. REMOVE GLOVE COMPARTMENT PARTS4. REMOVE LOWER NO. 2 FINISH PANEL5. REMOVE LOWER CENTER COVER6. REMOVE LOWER LH FINISH PANEL7. REMOVE LOWER COVER (See page BO-1 11)8. REMOVE NO. 4 HEATER TO REGISTER DUCT

9. REMOVE COOLING UNIT(a) Disconnect the connectors.(b) Remove the 3 screws, bolt and the cooling unit.

I28949

1GR-FE:

AC3SC-01

I28950

1GR-FE:P/S Pump

Water PumpIdler No.2

Generator

Tensioner

A/C CompressorIdler No.1

Crankshaft

Idler No.2

EM6656

2UZ-FE:

-AIR CONDITIONING DRIVE BELTAC-19

5046Author: Date:

INSTALLATION1. 1GR-FE engine:

INSTALL DRIVE BELT(a) While turning the belt tensioner counterclockwise, align

the holes. Insert a 6 mm (0.24 in.) bar into the holes to fixthe belt tensioner.

(b) Install the drive belt.(c) While turning the belt tensioner counterclockwise, re-

move the bar.

(d) If it is hard to install the drive belt, perform the followingprocedures:(1) Wrap the drive belt around all the pulleys and idlers,

except for the P/S pump, as shown in the illustra-tion.

(2) While releasing belt tension by turning the belt ten-sioner counterclockwise, wrap the drive belt aroundthe P/S pump.

(e) Install the engine under cover.

2. 2UZ-FE engine:INSTALL DRIVE BELT

Turn the drive belt tensioner counterclockwise and install thedrive belt.

CH0086

Correct Wrong

AC3SB-01

B00808

2UZ-FE: AB

-AIR CONDITIONING DRIVE BELTAC-17

5044Author: Date:

DRIVE BELTON-VEHICLE INSPECTION1. INSPECT DRIVE BELT’S INSTALLATION CONDITIONCheck that the drive belt fits properly in the ribbed grooves.

2. 1GR-FE engine:INSPECT DRIVE BELT TENSIONER

Check that nothing gets caught in the tensioner by turning itclockwise and counterclockwise.If a malfunction exists, replace the tensioner.

3. 2UZ-FE engine:INSPECT DRIVE BELT TENSION

Check that the tension is within the range A on the auto tension-er scale.If the tension is not within the range A on the scale, replace thebelt with a new one.HINT:When replacing the drive belt with a new one, the belt tensionshould be within range B on the belt tensioner scale.

I28948

1GR-FE:

AC26X-03

EM6656

2UZ-FE:

AC-18-AIR CONDITIONING DRIVE BELT

5045Author: Date:

REMOVAL1. 1GR-FE engine:

REMOVE DRIVE BELT(a) Remove the engine under cover.(b) Loosen the belt tension by turning the belt tensioner

counterclockwise, and remove the drive belt from the belttensioner.

2. 2UZ-FE engine:REMOVE DRIVE BELT

Loosen the drive belt tension by turning the drive belt tensionercounterclockwise, and remove the drive belt.

AC06V-04

I11156

I11155

I11180

Heater Control Assembly

Connector


Knob

Mode Control Cable(Color: Yellow)

Water Valve Control Cable(Color: Black)

Blower Speed Control Switch

Air Mix Control Cable(Color: Black)

Heater ControlHousing Base

Def. Mode Switch

Heater to Register Duct No. 2

Lower LH Finish Panel


Lower No. 2 Finish Panel


AC-100-AIR CONDITIONING HEATER CONTROL ASSEMBLY

5127Author: Date:

COMPONENTS

AC27K-03

I11162

(a)

(b)

(c)

(a)

I11163

I11164


5129Author: Date:

DISASSEMBLY1. REMOVE HEATER CONTROL CABLES(a) Using a screwdriver, push the claws left and right.HINT:Tape the screwdriver tip before use.(b) Pull the cable rearward until the claws are disengaged.(c) Remove the cable.(d) Remove the inner cable from the heater control assembly.

2. REMOVE BLOWER SPEED CONTROL SWITCH(a) Disconnect the connector.(b) Remove the 2 screws.(c) Remove the switch.

3. REMOVE DEF. MODE SWITCHRelease the 2 claws, then remove the switch.HINT:Tape the screwdriver tip before use.

I11165

OFFLO M1 M2

HI

AC27L-03

I11166

To ”DEF. or F/DEF.”

I11167

ONOFF

-AIR CONDITIONING HEATER CONTROL ASSEMBLYAC-103

5130Author: Date:

INSPECTION1. INSPECT BLOWER SPEED CONTROL SWITCH CON-

TINUITY

Switch position/ Circuit Tester connection Specified condition

OFF - No continuity

LO 1 - 3 Continuity

M1 1 - 3 - 4 Continuity

M2 1 - 3 - 8 Continuity

HI 1 - 3 - 5 Continuity

Illumination circuit 6 - 7 Continuity

If continuity is not as specified, replace the switch and check thebulb.

2. INSPECT DEF. MODE SWITCH(a) Check the continuity exists between terminals 1 and 3 of

the blower switch connector when turning the mode se-lector to the DEF. position and F/DEF. position.

If no continuity exists, proceed to the next step.

(b) Check the continuity exists between the terminals of theA/C mode switch.

If no continuity exists, replace the A/C mode switch.If continuity exists, check or replace the heater control housingbase.

I11159

Mode Control Cable

Water Valve ControlCable

Air Mix Control Cable

AC27P-03

I12239

I11161


5132Author: Date:

INSTALLATION1. INSTALL HEATER CONTROL ASSEMBLY(a) Connect the connectors.(b) Pass the heater control as shown in the illustration.

(c) When using the removed one:Install the heater control assembly.

(d) When using a new one:Install the heater control assembly.

I28081

To ”FACE”

I11169

To ”COOL”

I11170

To ”COOL”


5133Author: Date:

2. ADJUST HEATER CONTROL CABLES(a) Set the mode control dial at the ”FACE” position.(b) Set the temperature control dial at the ”MAX. COOL” posi-

tion.

(c) Adjust the mode control cable.Pull the air inlet control link to the ”FACE” position, con-nect the control cable and lock the clamp.

HINT:Lock the clamp while lightly pushing the outer cable in the direc-tion shown by the arrow in the illustration.

(d) Adjust the air mix control cable.Pull the air inlet control link to the ”COOL” position, con-nect the control cable and lock the clamp.

HINT:Lock the clamp while lightly pulling the outer cable in the direc-tion shown by the arrow in the illustration.

(e) Adjust the water valve control cable.Pull the air inlet control link to the ”COOL” position, con-nect the control cable and lock the clamp.

HINT:Lock the clamp while lightly pulling the outer cable in the direc-tion, shown by the arrow in the illustration.

3. INSTALL HEATER TO REGISTER DUCT NO. 44. INSTALL LOWER NO. 2 FINISH PANEL5. INSTALL GLOVE COMPARTMENT PANEL6. INSTALL HEATER TO REGISTER DUCT NO. 27. INSTALL LOWER LH FINISH PANEL

(See page BO-120 )

H111757 Clips


5134Author: Date:

8. INSTALL CENTER CLUSTER INTEGRATION PANEL(a) When replacing the heater control assembly:

Pull off the cover.(b) Install the center cluster integration panel, then connect

the 2 connectors.(c) Install the 5 screws.(d) Install the 3 heater control knobs.

I11154

AC27J-03


5126Author: Date:

HEATER CONTROL ASSEMBLYON-VEHICLE INSPECTIONINSPECT HEATER CONTROL DIAL AND LEVER OPERA-TIONMove the control dial and lever left and right and check for stiff-ness and binding through the full range of the levers.If a click sound cannot be heard or recoil is felt, adjust the con-trol cable or check the control cable and heater control assem-bly.

I11164

AC27M-03

I11163


5131Author: Date:

REASSEMBLY1. INSTALL DEF. MODE SWITCHInstall the switch.HINT:After installation, check that the 2 claws are securely engaged.

2. INSTALL BLOWER SPEED CONTROL SWITCH(a) Install the switch with the 2 screws.(b) Connect the connector.

3. INSTALL HEATER CONTROL CABLESInstall the heater control cables to the heater control assembly.

H111757 Clips

I28080

Mode Control Cable

Water Valve ControlCable

Air Mix Control Cable

AC27O-03

I11160


5128Author: Date:

REMOVAL1. REMOVE CENTER CLUSTER INTEGRATION PANEL(a) Remove the 3 heater control knobs.(b) Remove the 5 screws.(c) Remove the integration control panel by pulling the por-

tions indicated by arrows in the illustration.(d) Disconnect the connector.

2. REMOVE LOWER LH FINISH PANEL3. REMOVE HEATER TO REGISTER DUCT NO. 24. REMOVE GLOVE COMPARTMENT DOOR5. REMOVE LOWER NO. 2 FINISH PANEL6. REMOVE HEATER TO REGISTER DUCT NO. 4

(See page BO-1 11)7. DISCONNECT HEATER CONTROL CABLES

8. REMOVE HEATER CONTROL ASSEMBLYRemove the heater control assembly, then disconnect the con-nectors.

AC3RU-02

I11128

Non-reusable part

Instrument Panel

Reinforcement

Defroster Nozzle

Center Heater to Register Duct

Brace No.1

Brace No.2


Heater UnitCooling Unit

Heater Radiator

Foot Air Duct

Air Vent Duct

Heater Unit Case

O-RingClamp

GrommetHeater RadiatorPipe

Packing

ClampClamp

Clamp

Clamp


AC-38-AIR CONDITIONING HEATER UNIT

5065Author: Date:

HEATER UNITCOMPONENTS

I27019

Non-reusable part

Instrument Panel

Reinforcement

Defroster Nozzle

Center Heater to Register Duct

Brace No.1

Brace No.2


Heater Unit

Cooling Unit

Heater Radiator

Air Vent Duct

Heater Unit Case

O-Ring

Grommet

Heater Radiator Pipe

Clamp

Double Cab:

Foot Air Duct

Packing

Floor Heater Air No. 1 LH Duct

Air Duct RR No. 3

Air Duct RR No. 1

Air Duct RR No. 2

Floor Heater Air No. 1 RH Duct

Air Duct RR No. 4

Air Duct RR No. 5

-AIR CONDITIONING HEATER UNITAC-39

5066Author: Date:

I28076

AC22M-05


5068Author: Date:

DISASSEMBLY1. REMOVE HEATER RADIATOR(a) Remove the 3 screws and 3 clamps.(b) Pull out the heater radiator.(c) Remove the 2 screws and 2 clips, then disconnect the

heater radiator pipes.2. REMOVE AIR VENT DUCTRemove the 2 screws and duct.

AC22N-02


5069Author: Date:

INSPECTIONINSPECT FINS FOR BLOCKAGEIf the fins are clogged, clean them with compressed air.

AC0CO-02


5071Author: Date:


AC0CN-02


5070Author: Date:


AC3RV-02

I28830

I11197

Water Hose

Heater RadiatorPipe

Upper

LH RH

45 ± 10°LowerHose Clip

Second Ridge

LH RH

I11130


I27020

Double Cab:


5067Author: Date:

REMOVAL1. REMOVE COOLING UNIT (See page AC-31 )2. DRAIN ENGINE COOLANT FROM RADIATORHINT:It is not necessary to drain out all the coolant.

3. DISCONNECT WATER HOSES FROM HEATER RA-DIATOR PIPES

(a) Using pliers, grip the claws of clips and slide the clipsalong the hoses.

(b) Disconnect the water hoses.

HINT:At the time of installation, refer to the following: Push the water hose onto the heater radiator pipe up to

the second ridge on the pipe. Install the hose clip to the position shown in the illustra-

tion.4. REMOVE INSTRUMENT PANEL AND REINFORCE-

MENT (See page BO-1 11)5. REMOVE DEFROSTER NOZZLE AND HEATER TO

REGISTER DUCT6. REMOVE HEATER UNITRemove the 3 nuts and heater unit.

I28082

Heater Main RelayAC3RZ-02

I27025Heater Main Relay

Z19533

3 4 5

21

3 4 5

1 2

AC-82-AIR CONDITIONING HEATER MAIN RELAY

5109Author: Date:

HEATER MAIN RELAYINSPECTION1. Access cab, Standard cab:

REMOVE HEATER MAIN RELAY FROM ENGINEROOM RELAY BLOCK

2. Double cab:REMOVE HEATER MAIN RELAY FROM ENGINEROOM RELAY BLOCK NO. 2

3. INSPECT HEATER MAIN RELAY (Marking: HEATER)CONTINUITY

Condition Tester connection Specified condition

Constant2 - 4

3 - 5Continuity

Apply B+ between

terminals 3 and 51 - 2 Continuity

If continuity is not as specified, replace the relay.

AC0CB-12

N06553

AC-22-AIR CONDITIONING MANIFOLD GAUGE SET

5049Author: Date:

SET OFF1. CLOSE BOTH VALVES OF MANIFOLD GAUGE SET2. DISCONNECT QUICK DISCONNECT ADAPTERS

FROM SERVICE VALVES ON REFRIGERANT LINEHINT: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

I28849

Low Pressure Charging Hose

High PressureCharging Hose

1GR-FE:

I11119


High PressureCharging Hose

Access Cab, Standard Cab 2UZ-FE:

AC3RQ-02

AC-20-AIR CONDITIONING MANIFOLD GAUGE SET

5047Author: Date:

MANIFOLD GAUGE SETSET ON1. CONNECT CHARGE HOSE TO MANIFOLD GAUGE

SETTighten the nuts by hand.CAUTION:Do not connect the wrong hoses.2. CONNECT QUICK DISCONNECT ADAPTERS TO

CHARGING HOSESTighten the nuts by hand.3. CLOSE BOTH VALVES OF MANIFOLD GAUGE SET4. REMOVE CAPS FROM SERVICE VALVES ON RE-

FRIGERANT LINE

I27018

Double Cab 2UZ-FE:


High Pressure Charging Hose

N04392

Sleeve

-AIR CONDITIONING MANIFOLD GAUGE SETAC-21

5048Author: Date:

5. CONNECT QUICK DISCONNECT ADAPTERS TO SER-VICE VALVES

HINT:Push the quick disconnect adapter onto the service valve, thenslide. Slide the sleeve of the quick disconnect adapter down-ward to lock it.

AC0E9-03

-AIR CONDITIONING PRESSURE SWITCHAC-81

5108Author: Date:


I11146

2 1

Z13470

Low pressure High pressuresideside

ON (Continuity)

3,140 kpa196 kpa(2.0 kgf/cm2, 28psi)OFF (No Continuity)

(32.0 kgf/cm2, 455psi)OFF (No Continuity)

AC0E7-05

-AIR CONDITIONING PRESSURE SWITCHAC-79

5106Author: Date:

PRESSURE SWITCHON-VEHICLE INSPECTION1. SET MANIFOLD GAUGE SET (See page AC-20 )2. DISCONNECT CONNECTOR3. RUN ENGINE AT APPROX. 2,000 rpm4. SET BLOWER SPEED CONTROL SWITCH TO ”HI”

POSITION5. SET TEMPERATURE CONTROL LEVER TO ”MAX.

COOL” POSITION6. A/C SWITCH ON7. INSPECT PRESSURE SWITCH OPERATION(a) Connect the positive (+) lead from the ohmmeter to termi-

nal 1 and the negative (-) lead to terminal 2.(b) Check continuity between terminals when refrigerant

pressure is changed, as shown in the illustration.If operation is not as specified, replace the pressure switch.

AC0E8-09

I11147

AC-80-AIR CONDITIONING PRESSURE SWITCH

5107Author: Date:


SYSTEMHINT:At the time of installation, refer to the following: Evacuate sir from the refrigeration system. Charge the system with refrigerant and inspect for leak-

age of refrigerant.Specified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)Double cab: 530 ± 50 g (18.69 ± 1.76 oz.)

2. REMOVE PRESSURE SWITCH FROM LIQUID TUBEDisconnect the connector and remove the pressure switch.

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf)HINT: Being careful not to deform the tube, lock the switch

mounted on the tube with an open end wrench, and re-move the switch.

At the time of installation, refer to the following:Lubricate a new O-ring with the compressor oil and installit to the switch.

AC278-02

-AIR CONDITIONING RECEIVERAC-69

5096Author: Date:


AC276-01

-AIR CONDITIONING RECEIVERAC-67

5094Author: Date:

RECEIVERON-VEHICLE INSPECTIONINSPECT FITTINGS FOR LEAKAGEUsing a gas leak detector, check for leakage.If there is leakage, check the tightening toque at the joints.

AC277-03

I11138

AC-68-AIR CONDITIONING RECEIVER

5095Author: Date:


SYSTEMHINT:At the time of the installation, refer to the following: Evacuate air from the refrigeration system. Charge the system with refrigerant and inspect for leak-

age of refrigerant.Specified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)

2. DISCONNECT 2 LIQUID TUBES FROM RECEIVERRemove the 2 bolts and disconnect both tubes.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)NOTICE:Cap the openings immediately to keep moisture or dirt outof the system.HINT:At the time of the installation, refer to the following:Lubricate 2 new O-rings with compressor oil and install themto the tubes.3. REMOVE RECEIVER(a) Remove the holder bolt and pull the receiver downward.HINT:At the time of the installation, refer to the following:If the receiver is replaced, add compressor oil to the compres-sor.

Add 20 cc (0.71 fl.oz.)Compressor oil: ND-OIL 8 or equivalent

(b) Remove the bolt and holder.

AC3RR-02

I28831

10 (100, 7)

Suction Hose

Discharge Hose

5.4 (55, 48 in.·lbf)

Liquid Tube

Condenser

N·m (kgf·cm, ft·lbf) : Specified torque

1GR-FE:

Piping Clamp

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

Piping Clamp

AC-24-AIR CONDITIONING REFRIGERANT LINE

5051Author: Date:

LOCATION

I28071

Access Cab, Standard Cab 2UZ-FE:

Suction Tube

Suction Hose5.4 (55, 48 in.·lbf)

10 (100, 7)

Liquid Tube

Discharge Hose


Condenser

Piping Clamp

Piping Clamp

Piping Clamp

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

-AIR CONDITIONING REFRIGERANT LINEAC-25

5052Author: Date:

I27017

Suction Hose

10 (100, 7)

Liquid Tube

Discharge Hose


Suction Hose

5.4 (55, 48 in.·lbf)

Double Cab:

Condenser

Piping Clamp

Piping Clamp

Piping Clamp

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)

AC-26-AIR CONDITIONING REFRIGERANT LINE

5053Author: Date:

AC0CC-03


5050Author: Date:

REFRIGERANT LINEON-VEHICLE INSPECTION1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS2. INSPECT HOSES AND TUBES FOR LEAKAGEUsing a gas leak detector, check for leakage of refrigerant.

AC0CE-08


5054Author: Date:

REPLACEMENT1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM2. REPLACE FAULTY TUBE OR HOSENOTICE:Cap the openings immediately to keep moisture or dirt out of the system.3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUENOTICE:Do not exceed specified torque.

Part tightened N·m kgf·cm ft·lbf

Receiver x Liquid tube 5.4 55 48 in.·lbf

Condenser x Discharge hose 5.4 55 48 in.·lbf

Condenser x Liquid tube 5.4 100 48 in.·lbf

Compressor x Discharge hose 10 100 7

Compressor x Suction hose 10 100 7

Expansion valve x Evaporator 5.4 55 48 in.·lbf

4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANTSpecified amount: Access cab, Standard cab: 600 ± 50 g (21.16 ± 1.76 oz.)Double cab: 530 ± 50 g (18.69 ± 1.76 oz.)

5. INSPECT FOR LEAKAGE OF REFRIGERANTUsing a gas leak detector, check for leakage of refrigerant.6. INSPECT AIR CONDITIONING OPERATION

AC22H-05

-AIR CONDITIONING TROUBLESHOOTINGAC-15

5042Author: Date:

TROUBLESHOOTINGPROBLEM SYMPTOMS TABLEUse the table below to help find the cause of the problem. The numbers indicate the priority of the likely causeof the problem. Check each part in order. If necessary, replace these parts.

Symptom Suspected Area See page

No blower operation

9. HTR Fuse

10.Heater main relay

11.Blower motor

12.Blower resistor

13.Blower speed control switch

14.Wire harness

-

AC-82

AC-77

AC-78

AC-103

-

No air temperature control

1. Engine coolant volume

2. Heater control assembly

3. Water valve

-

AC-99

AC-74

No compressor operation

1. Refrigerant volume

2. A.C Fuse

3. Magnetic clutch 1GR-FE:

2UZ-FE:

4. Compressor 1GR-FE:

2UZ-FE:

5. Pressure switch

6. Heater main relay

7. Blower speed control switch

8. A/C switch

9. Integration control and panel

10.Thermistor

11.Wire harness

AC-3

-

AC-52

AC-59

AC-52

AC-59

AC-79

AC-82

AC-103

AC-92

AC-83

AC-28

-

Compressor operates intermittently


2. Pressure switch

3. A/C switch

4. Thermistor

5. Wire harness

AC-3

AC-79

AC-92

AC-28

-

No cool air comes out


2. Refrigerant pressure

3. Drive belt


2UZ-FE:


2UZ-FE:

6. Pressure switch

7. Thermistor

8. A/C switch


10.Heater control assembly

11.Wire harness

AC-3

AC-3

AC-17

AC-52

AC-59

AC-52

AC-59

AC-79

AC-28

AC-92

AC-83

AC-99

-

AC-16-AIR CONDITIONING TROUBLESHOOTING

5043Author: Date:

Cool air comes out only at high engine rpm


2. Drive belt


2UZ-FE:


2UZ-FE:

5. Condenser

6. Receiver

7. Expansion valve

8. Evaporator

9. Thermistor

10.A/C switch

11.Wire harness

AC-3

AC-17

AC-52

AC-59

AC-52

AC-59

AC-70

AC-67

AC-28

AC-34

AC-28

AC-92

-

Insufficient cooling


2. Drive belt


2UZ-FE:


2UZ-FE:

5. Condenser

6. Receiver

7. Expansion valve

8. Evaporator

9. Refrigerant lines

10.Pressure switch

11.Integration control and panel

12.Heater control assembly

AC-3

AC-17

AC-52

AC-59

AC-52

AC-59

AC-70

AC-67

AC-28

AC-34

AC-23

AC-79

AC-83

AC-99

No engine idle-up with A/C switch ON


2. Idle control system 1GR-FE:

2UZ-FE:

3. Wire harness

AC-83

DI-266

DI-712

-

*2A/C indicator blinks


2UZ-FE:

5. Drive belt

6. Compressor lock sensor 1GR-FE:

2UZ-FE:

7. A/C amplifier

AC-52

AC-59

AC-17

AC-52

AC-59

AC-83

No warm air comes out

1. Engine coolant volume

2. Heater control assembly

3. Water valve

4. Heater radiator

-

AC-99

AC-74

AC-42

AC27C-02

AC-76-AIR CONDITIONING WATER VALVE

5103Author: Date:


AC27A-02

AC-74-AIR CONDITIONING WATER VALVE

5101Author: Date:

WATER VALVEON-VEHICLE INSPECTION1. WARM UP ENGINE2. DISCONNECT WATER VALVE CONTROL CABLE3. INSPECT WATER VALVE OPERATION(a) Check that warm air comes out from the vent when the water valve lever is moved to the ”WARM” posi-

tion.(b) Check that cool air comes out when the water valve is moved to the ”COOL” position.If operation is not as specified, replace the water valve.4. CONNECT WATER VALVE CONTROL CABLE

AC27B-03

I11139

I11140

I11199

Hose Clip

Water Valve

Heater Radiator Pipe Lower

Upper

RrFr

LHRH

Water Hose

I11141

-AIR CONDITIONING WATER VALVEAC-75

5102Author: Date:

REMOVAL1. DRAIN ENGINE COOLANT FROM RADIATORHINT:It is not necessary to drain out all the coolant.

2. DISCONNECT WATER VALVE CONTROL CABLEFROM WATER VALVE

HINT:At the time of installation, refer to the following:After connection, adjust the control cable (See page AC-105 ).

3. DISCONNECT WATER HOSES(a) Using pliers, grip the claws of the hose clips and slide the

hose clips along the hoses.(b) Disconnect the water hoses.

HINT:At the time of installation, refer to the following: Heater radiator pipe:

Push the water hose onto the heater radiator pipe up tothe second ridge on the pipe.

Water valve:Push the water hose onto the water valve pipe up to thewater valve.

Install the hose clip in the position shown in the illustra-tion.

4. REMOVE WATER VALVERemove the bolt and water valve.

Air Conditioning

Documents

glove compartment door

beveled side faces

chamfered side facing

center cluster integration

magnet clutch washer

magnet clutch hub

magnet clutch washers

gas leak detector