Toyota land cruiser workshop service manual 1999 2007 air conditioning he thong dieu hoa

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I24826

Center Resistor RH

Integration ControlPanel AssemblyCenter Resistor LH

Radio ReceiverBracket RH

Heater Control Housing

w/o Navigation System:

Radio Receiver Bracket LH

Radio ReceiverBracket RH

RadioReceiver

Heater Control Housing

REMOVE INTEGRATION CONTROL PANEL

3 w/ navigation system:

REMOVE HEATER CONTROL HOUSING

heater control housing

4 REMOVE KNOB

HINT:

Tape up the screwdriver tip before use

5 w/o LEXUS navigation system:

6 w/o navigation system:

REMOVE INTEGRATION CONTROL PANEL

1 w/o Navigation system:

INSPECT ILLUMINATION OPERATION

C10 and negative (-) lead to terminal C19, then checkthat the indicators illuminate

If operation is not as specified, check the faulty bulb

conti-nuity

If continuity exists, replace the heater control

If no continuity exists, replace the bulb

2 w/o Navigation system:

INSPECT INDICATORS OPERATION

C22 and negative (-) lead to terminal C12

switches

If operation is not as specified, replace the heater control

3 INSPECT A/C CONTROL ASSEMBLY CIRCUIT (See page DI-1309 )

A16A8

-AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY

AC-105

4 w/ Navigation system:

INSPECT ILLUMINATION OPERATION

A8 and negative (-) lead to terminal A16

switches

If operation is not as specified, replace the heater control

5 INSPECT A/C CONTROL ASSEMBLY CIRCUIT (See page DI-1309 )

AC1JL-02 -

AIR CONDITIONING AIR CONDITIONING CONTROL ASSEMBLY

When removing/installing or replacing EMV, or when disconnecting/connecting the battery terminal, turn the

IG ON and OFF twice for initial display setting

1 REMOVE CENTER RESISTORS

Disengage the 12 clips and remove the center resistors, thendisconnect the connectors

2 REMOVE INTEGRATION CONTROL PANEL SEMBLY

dis-connect the dis-connectors

3 w/ navigation system:

REMOVE A/C AMPLIFIER

bracket LH

4 w/ LEXUS navigation system:

REMOVE EMV

Remove the 3 screws, the 2 bolts and the EMV

REMOVE INTEGRATION CONTROL PANEL

6 Disconnect the connector clamps.

bracket RH

re-ceiver

7 w/o navigation system:

REMOVE INTEGRATION CONTROL PANEL

bracket LH

bracket RH

2004 LAND CRUISER (RM1071U)

AIR CONDITIONING AMPLIFIER (for Rear A/C)

INSPECTION

1 REMOVE REAR DOOR SCUFF PLATE RH

2 REMOVE REAR FLOOR MAT SUPPORT PLATE

3 REMOVE QUARTER TRIM PANEL RH

4 REMOVE A/C AMPLIFIER

5 INSPECT REAR A/C AMPLIFIER CIRCUIT (See page DI-1309 )

expel the air inside the center hose.

2 INSPECT REFRIGERATION SYSTEM FOR LEAKS

refrig-erant

2004 LAND CRUISER (RM1071U)

3 CHARGE REFRIGERANT INTO REFRIGERATION SYSTEM

If there is no leak after refrigerant leak check, charge the properamount of refrigerant into the refrigeration system

high pressure hand valve

HINT:

No bubbles in the sight glass indicates that the system is fullycharged

CAUTION:

Do not open the high pressure hand valve.

pressure on the gauge through the sight glass

RE-3 SET ON MANIFOLD GAUGE SET

valves

4 EVACUATE AIR FROM REFRIGERATION SYSTEM

vacuum pump adapter

vacu-um pvacu-ump

gauge indicates 750 mmHg (30 in Hg) minimum.HINT:

If the reading is 750 mmHg (30 in Hg) close both hand valves

of the manifold gauge set and stop the vacuum pump

Check the system for leaks and repair if necessary

vac-uum pump

and check that there is no gauge indicator

I24786

Pressure Switch

Compressor and Magnetic Clutch

Ambient Temperature Sensor

Front Heater Unit

 Heater Radiator

 Air Mix Servomotor

 Air Outlet ServomotorSolar Sensor

Front Cooling Unit

 Expansion Valve

 Evaporator

 Evaporator Temperature Sensor

Rear Heater Unit

 Blower Motor

 Power Transistor

 Heater Radiator

 Air Mix Servomotor

 Air Inlet Temperature Sensor

Room Temperature Sensor

(for Rear A/C)

Rear Cooling Unit

 Blower Motor Control Relay

 Air Inlet Servomotor

A/C Amplifier

Integration Control Panel

Room Temperature Sensor

(for Front A/C)

Rear A/C Control Switch

1 INSPECT REFRIGERANT VOLUME

Observe the sight glass on the liquid tube

Test conditions:

1 Bubbles appear in sight glass Insufficient*

(1) Check for gas leakage with gas leak tector and repair, if necessary

de-(2) Add refrigerant until bubbles disappear

2 No bubbles appear in sight glass None, sufficient or too much Refer to item 3 and 4

3 No temperature difference between

com-pressor inlet and outlet Empty or nearly empty

(1) Check for gas leakage with gas leak tector and repair, if necessary

de-(2) Add refrigerant until bubbles disappear

4 Temperature between compressor inlet and

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

5

Immediately after air conditioning system is

turned off, refrigerant in sight glass stays

clear

Too much

(1) Discharge refrigerant (2) Evacuate air and charge proper amount

of purified refrigerant

6 When air conditioning system is turned off,

-*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling

is sufficient

AC-4

-AIR CONDITIONING AIR CONDITIONING SYSTEM

2 INSPECT REFRIGERANT PRESSURE WITH IFOLD GAUGE SET

MAN-Check the trouble area using a set of manifold gauge set Readthe manifold gauge pressure when following conditions are de-tected

Test conditions:

1.37 - 1.57 MPa (14 - 15 kgf/cm 2)

2004 LAND CRUISER (RM1071U)

Symptom seen in

During operation, pressure on low

pressure side sometimes become

a vacuum and sometime normal

Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts

Drier in over-saturated state

Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refriger- ant

(1) Replace condenser (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge proper amount of new refrigerant

Symptom seen in

Pressure low on both low and

high pressure sides

Bubbles seen in sight glass

con-tinuously

Insufficient cooling performance

Gas leakage at some place in frigeration system

re-
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 frigerant

re-(3) If indicated pressure value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak

-AIR CONDITIONING AIR CONDITIONING SYSTEM

Symptom seen in

Pressure low in both low and

high pressure sides

Frost on tube from condenser to

unit

Refrigerant flow obstructed by dirt

in condenser condenser clogged Replace condenser

Symptom seen in

Vacuum indicated on low

pres-sure side, very low prespres-sure

indi-cated on high pressure side

Frost or dew seen on piping

be-fore and after condenser/ drier or

expansion 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 condenser (4) Evacuate air and charge new refrigerant to proper amount (5) For gas leakage from expan- sion valve, replace expansion valve

Condition: Insufficient cooling

I01392

Condition: Insufficient cooling

NOTE : These gauge tions are shown when therefrigeration system hasbeen opened and the refrig-erant charged without vacu-

2004 LAND CRUISER (RM1071U)

condenser

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 formance due to excessive refrig- eration system

per-
Insufficient cooling of condenser

Excessive refrigerant in cycle → refrigerant over charged

Condenser cooling → 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

Symptom seen in

Pressure too high on both low

and high pressure sides

The low pressure piping hot to

touch

Bubbles seen in sight glass

Air entered in refrigeration system

Air present in refrigeration tem

sys-
Insufficient vacuum purging

(1) Check compressor oil to see if

it is dirty or insufficient (2) Evacuate air and charge new refrigerant

-AIR CONDITIONING AIR CONDITIONING SYSTEM

Symptom seen in

Pressure too high on both low

and high pressure sides

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, and place if defective

Symptom seen in

Pressure too high on low and

high pressure sides

Pressure too low on high

2004 LAND CRUISER (RM1071U)

3 INSPECT IDLE-UP SPEED

es-tablished

Test conditions:

Magnetic clutch condition Idle-up speed Magnetic clutch not engaged 700 ± 50 rpm Magnetic clutch engaged 780 ± 50 rpm

If idle speed is not as specified, check the idle control system

4 INSPECT FOR LEAKAGE OF REFRIGERANT

react to volatile gases which are not refrigerant, such asevaporated gasoline and exhaust gas)

refrigeration system

When compressor is OFF: approx 392 - 588 kPa (4 - 6

performing the test

make sure that the gas leak detector does not react to thevolatile gases

If gas leaks are detected, lift up the vehicle

the blower resistor from the cooling unit Then insert thegas leak detector sensor into the unit to perform the test

for approx 20 minutes Then bring the gas leak detectorclose to the pressure switch to perform the test

If you get the liquid refrigerant in your eyes or on your skin:

CAUTION:

Do not rub your eyes or skin.

re-8 DO NOT OVERCHARGE REFRIGERANT SYSTEM WITH REFRIGERANT

If refrigerant is overcharged, it causes problems such as cient cooling, poor fuel economy, engine overheating etc

2004 LAND CRUISER (RM1071U)

9 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

The LAND CRUISER is equipped with SRS (Supplemental straint System) such as the driver airbag and the front passen-ger airbag Failure to carry out service operation in the correctsequence 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

I08494

AC-90

-AIR CONDITIONING AIR INLET TEMPERATURE SENSOR

AIR INLET TEMPERATURE SENSOR

INSPECTION

1 REMOVE FRONT SEATS

2 REMOVE REAR CONSOLE BOX

3 REMOVE FRONT CONSOLE BOX COVER

4 REMOVE LOWER CENTER CLUSTER FINISH PANEL

5 REMOVE FRONT DOOR SCUFF PLATES

6 REMOVE COWL SIDE TRIMS

7 REMOVE REAR DOOR SCUFF PATES

8 REMOVE CENTER PILLAR GARNISHES

9 REMOVE AIR INLET TEMPERATURE SENSOR

10 INSPECT AIR INLET TEMPERATURE SENSOR CUIT (See page DI-1342 )

CIR-11 INSTALL AIR INLET TEMPERATURE SENSOR

12 INSTALL CENTER PILLAR GARNISHES

13 INSTALL REAR DOOR SCUFF PLATES

14 INSTALL COWL SIDE TRIMS

15 INSTALL FRONT DOOR SCUFF PLATES

16 INSTALL REAR CONSOLE BOX

17 INSTALL FRONT SEATS

2004 LAND CRUISER (RM1071U)

AIR MIX SERVOMOTOR (for Front A/C)

INSPECTION

1 REMOVE AIR MIX SERVOMOTOR

2 INSPECT AIR MIX SERVOMOTOR OPERATION (See page DI-1354 )

3 INSPECT AIR MIX DAMPER POSITION SENSOR (See page DI-1345 )

4 INSTALL SERVOMOTOR

1 REMOVE LOWER NO 1 PANEL (See page BO-84 )

2 REMOVE AIR OUTLET SERVOMOTOR

3 INSPECT AIR OUTLET SERVOMOTOR OPERATION

6 and the negative (-) lead to terminal 7

ter-minal and check that the shaft rotates at each position, asshown in the illustration

Connected terminal Position

If operation is not as specified, replace the servomotor

4 INSTALL AIR OUTLET SERVOMOTOR

1 REMOVE AMBIENT TEMPERATURE SENSOR

2 INSPECT AMBIENT TEMPERATURE SENSOR CUIT (See page DI-1319 )

CIR-3 INSTALL AMBIENT TEMPERATURE SENSOR

upper bracket

Blower Unit Case

Air Inlet Servomotor

Blower Motor Control RelayBlower Motor

1 REMOVE AIR INLET SERVOMOTOR

Remove the 3 screws and the air inlet servomotor

2 REMOVE BLOWER MOTOR CONTROL RELAY

3 REMOVE BLOWER MOTOR

4 REMOVE WIRE HARNESS

Remove the screw and the wire harness

AC1KW-05 -

AIR CONDITIONING BLOWER UNIT

AC-57

INSPECTION

1 INSPECT AIR INLET SERVOMOTOR OPERATION (See page DI-1357 )

2 INSPECT AIR INLET DAMPER POSITION SENSOR CIRCUIT (See page DI-1348 )

AC1KY-02 -

AIR CONDITIONING BLOWER UNIT

1 REMOVE FRONT COOLING UNIT (See page AC-24 )

2 REMOVE BLOWER UNIT

1 REMOVE BLOWER MOTOR CONTROL RELAY

2 INSPECT BLOWER MOTOR CONTROL RELAY

Connect the connector to the blower motor control relay and spect the wire harness side connector from the back side asshown in the illustration

in-Test condition:

Blower speed control switch at ”HI” position Approx 13.0 V

If circuit is not as specified, replace the relay

2004 LAND CRUISER (RM1071U)

BLOWER MOTOR CONTROL RELAY

INSPECTION

1 REMOVE BLOWER MOTOR CONTROL RELAY

2 INSPECT BLOWER MOTOR CONTROL RELAY

Connect the connector to the blower motor control relay and spect the wire harness side connector from the back side asshown in the illustration

in-Test condition:

Blower speed control switch at ”HI” position Approx 13.0 V

If circuit is not as specified, replace the relay

I08106

Suction Hose

Discharge Hose

Front Drive Shaft LH

Engine Under Cover

CompressorStator

Snap Ring

Rotor

ShimPressure Plate

1 REMOVE PRESSURE PLATE

At the time of reassembly, the snap ring should be installed

so that beveled side facing up.

At the time of reassembly, the snap ring should be installed

so that its beveled side facing up.

2004 LAND CRUISER (RM1071U)

2 INSTALL FRONT DRIVE SHAFT LH (See page SA-33 )

3 CONNECT DISCHARGE AND SUCTION HOSES

them to the hoses

Torque: 10 N·m (100 kgf·cm, 7 ft·lbf) NOTICE:

Hose should be connected immediately after the caps have been removed.

4 INSTALL AND CHECK DRIVE BELT (See page AC-17 and AC-15 )

5 CONNECT NEGATIVE (-) TERMINAL CABLE TO TERY

BAT-6 EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT

Specified amount: 1,050 ± 50 g (37.03 ± 1.76 oz.)

7 INSPECT FOR LEAKAGE OF REFRIGERANT

Using a gas leak detector, check for leaks of the refrigerant

If there is a leakage, check the tightening torque at the joints

8 INSPECT A/C OPERATION

I06812

I06813 3

2004 LAND CRUISER (RM1071U)

COMPRESSOR AND MAGNETIC CLUTCH

ON-VEHICLE INSPECTION

1 INSPECT COMPRESSOR FOR METALLIC SOUND

Check there is abnormal metallic sound from the compressorwhen the A/C switch is ON

If abnormal metallic sound is heard, replace the compressor sembly

as-2 INSPECT REFRIGERANT PRESSURE (See page AC-3 )

3 INSPECT VISUALLY FOR LEAKAGE OF ANT

REFRIGER-Using a gas leak detector, check for leakage of refrigerant

If there is any leakage, replace the compressor assembly

4 INSPECT COMPRESSOR LOCK SENSOR TANCE

Standard resistance:

570 - 1,050 Ω at 20°C (68 °F)

If resistance is not as specified, replace the compressor

5 CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING

6 CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR ROTOR

7 INSPECT MAGNETIC CLUTCH BEARING FOR NOISE

A/C switch is OFF

If abnormal noise is being emitted, replace the rotor of magneticclutch

8 INSPECT MAGNETIC CLUTCH OPERATION

3 and the negative (-) lead to the body ground

If operation is not as specified, replace the magnetic clutch