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AC-97 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AIR CONDITIONING CONTROL ASSEMBLY AC3P2-01 COMPONENTS Center Resistor LH Center Resistor RH Integration Control Panel Assembly I24826 2004 LAND CRUISER (RM1071U) Author: Date: 2822 AC-98 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY w/ Navigation System: Radio Receiver Bracket LH A/C Amplifier EMV Radio Receiver Bracket RH Radio Receiver Heater Control Housing Integration Control Panel Board Knob I24827 2004 LAND CRUISER (RM1071U) Author: Date: 2823 AC-99 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY w/o Navigation System: Radio Receiver Bracket LH Radio Receiver Bracket RH Radio Receiver Heater Control Housing Knob A/C Amplifier Board Knob Integration Control Panel I25152 2004 LAND CRUISER (RM1071U) Author: Date: 2824 AC-102 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AC3P0-01 DISASSEMBLY w/ navigation system: REMOVE KNOB Using a screwdriver, pull out the knobs HINT: Tape up the screwdriver tip before use I25192 (a) w/ navigation system: REMOVE INTEGRATION CONTROL PANEL Remove the screws (b) Remove the screw and the board w/ navigation system: REMOVE HEATER CONTROL HOUSING Disconnect the connector clamps Remove the screws and pull out the board from the heater control housing REMOVE KNOB Using a screwdriver, pull out the knobs I25193 I24781 (a) (b) I24782 (a) HINT: Tape up the screwdriver tip before use (b) Remove the nut w/o LEXUS navigation system: REMOVE KNOB Using a screwdriver, pull out the knobs HINT: Tape up the screwdriver tip before use I25159 2004 LAND CRUISER (RM1071U) Author: Date: 2827 AC-103 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY (a) w/o navigation system: REMOVE INTEGRATION CONTROL PANEL Remove the screws and pull out the A/C amplifier (b) Remove the screws and the board I25160 I25161 2004 LAND CRUISER (RM1071U) Author: Date: 2828 AC-104 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AC3P1-01 INSPECTION w/o Navigation system: INSPECT ILLUMINATION OPERATION (a) Connect the positive (+) lead from the battery to terminal C10 and negative (-) lead to terminal C19, then check that the indicators illuminate If operation is not as specified, check the faulty bulb (b) Remove the bulb : Bulb C10 C19 I25173 (c) Using the tester as shown in the illustration, test the continuity If continuity exists, replace the heater control If no continuity exists, replace the bulb I07872 w/o Navigation system: INSPECT INDICATORS OPERATION (a) Connect the positive (+) lead from the battery to terminal C22 and negative (-) lead to terminal C12 (b) Check that the indicators come on while operate the switches If operation is not as specified, replace the heater control INSPECT A/C CONTROL ASSEMBLY CIRCUIT (See page DI-1309 ) C22 C12 I25174 2004 LAND CRUISER (RM1071U) Author: Date: 2829 AC-105 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY w/ Navigation system: INSPECT ILLUMINATION OPERATION (a) Connect the positive (+) lead from the battery to terminal A8 and negative (-) lead to terminal A16 (b) Check that the indicators come on while operating the switches If operation is not as specified, replace the heater control INSPECT A/C CONTROL ASSEMBLY CIRCUIT (See page DI-1309 ) A8 A16 I25175 2004 LAND CRUISER (RM1071U) Author: Date: 2830 AC-107 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AC1JL-02 INSTALLATION Installation is in the reverse of removal (See page AC-100 ) HINT: w/ Navigation System: When removing/installing or replacing EMV, or when disconnecting/connecting the battery terminal, turn the IG ON and OFF twice for initial display setting 2004 LAND CRUISER (RM1071U) Author: Date: 2832 AC-106 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AC1JK-02 REASSEMBLY Reassembly is in the reverse of disassembly (See page AC-102 ) 2004 LAND CRUISER (RM1071U) Author: Date: 2831 AC-100 AIR CONDITIONING - AIR CONDITIONING CONTROL ASSEMBLY AC3OZ-01 REMOVAL REMOVE CENTER RESISTORS Disengage the 12 clips and remove the center resistors, then disconnect the connectors 12 Clips I25194 (a) (b) REMOVE INTEGRATION CONTROL PANEL ASSEMBLY Remove the bolts Remove the integration control panel assembly, then disconnect the connectors I25522 (a) (b) w/ navigation system: REMOVE A/C AMPLIFIER Disconnect the connector clamp Remove the screws, the bolts and the radio receiver bracket LH I24447 (c) Remove the screws and the A/C amplifier I24448 w/ LEXUS navigation system: REMOVE EMV Remove the screws, the bolts and the EMV I24449 2004 LAND CRUISER (RM1071U) Author: Date: 2825 AC-20 AIR CONDITIONING - REFRIGERANT LINE REFRIGERANT LINE AC1HU-01 ON-VEHICLE INSPECTION INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant 2004 LAND CRUISER (RM1071U) Author: Date: 2745 AC-22 AIR CONDITIONING - REFRIGERANT LINE AC1HW-04 REPLACEMENT DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTICE: Do not tighten the connections more than specified Part tightened N·m kgf·cm ft·lbf Compressor x Discharge hose 10 100 Compressor x Suction hose 10 100 Condenser x Discharge tube 5.4 55 48 in.·lbf Condenser x Liquid tube 10 100 Nut Bolt 14 140 10 10 100 Nut 22 225 16 Nut (5/8 (5/8”)) Nut (3/4 (3/4”)) Bolt 32 330 24 42 425 31 10 100 Liquid line Discharge line Suction line EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 1,050 ± 50 g (37.03 ± 1.76 oz.) INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leaks of refrigerant If there is leakage, check the tightening torque at the joints INSPECT AIR CONDITIONING OPERATION 2004 LAND CRUISER (RM1071U) Author: Date: 2747 AC-95 AIR CONDITIONING Relay Block - REAR HEATER RELAY REAR HEATER RELAY Junction Block (Built-in Relay) AC3OY-01 INSPECTION I25040 Engine Room J/B HINT: The rear heater relay is built in the engine room junction block Since the relay is constructed with a relay block that is in the junction block as a unit, it is impossible to disconnect the wire harness connecting with the relay block If the relay has a malfunction, replace it with the junction block assembly wire harness together REMOVE ENGINE ROOM J/B INSPECT REAR HEATER RELAY CONTINUITY Condition Tester connection Specified condition Constant 29 - 31 Continuity Apply B+ between terminals 29 and 31 2-3 Continuity If continuity is not as specified, replace the engine room J/B INSTALL ENGINE ROOM J/B 31 29 I25183 2004 LAND CRUISER (RM1071U) Author: Date: 2820 AC-45 AIR CONDITIONING - REAR HEATER UNIT REAR HEATER UNIT AC1KN-05 COMPONENTS Center Pillar Garnish Cowl Side Trim Front Door Scuff Plate Rear Door Scuff plate Console Upper Panel Lower Center Cluster Finish Panel Audio Amplifier Rear Console Box Rear Heater Unit Front Console Box Rear Console End Panel Rear Heater Duct Cooler Bracket I15824 2004 LAND CRUISER (RM1071U) Author: Date: 2770 AC-46 AIR CONDITIONING - REAR HEATER UNIT Power Transistor Air Inlet Temperature Sensor Cover O-Ring Fan Heater Case Heater Radiator Heater Case Heater Radiator Pipe Air Mix Servomotor Blower Motor Non - reusable part I08487 2004 LAND CRUISER (RM1071U) Author: Date: 2771 AC-49 AIR CONDITIONING - REAR HEATER UNIT AC1KP-03 DISASSEMBLY REMOVE AIR MIX SERVOMOTOR Remove the screws and the air mix servomotor I06819 (a) (b) REMOVE HEATER RADIATOR Remove the screws and clamps Pull out the heater radiator (c) Remove the screws, clamps and the heater radiator pipes Remove the O-rings I06821 (d) HINT: At the time of reassembly, not reuse the O-rings I06681 REMOVE POWER TRANSISTOR Remove the screws and the power transistor I06818 (a) (b) REMOVE BLOWER MOTOR Remove the screws and the cover Remove the screws, the holding springs and separate the heater cases I07896 2004 LAND CRUISER (RM1071U) Author: Date: 2774 AC-50 AIR CONDITIONING - REAR HEATER UNIT (c) Remove the nut and the fan (d) Remove the screws and the blower motor I06682 I06683 2004 LAND CRUISER (RM1071U) Author: Date: 2775 AC-51 AIR CONDITIONING - REAR HEATER UNIT AC1KQ-05 INSPECTION INSPECT HEATER RADIATOR If the fins are clogged, clean them with compressed air INSPECT BLOWER MOTOR OPERATION Connect battery positive (+) lead to terminal and battery negative (-) lead to terminal 2, then check that the motor rotates smoothly If operation is not as specified, replace the blower motor INSPECT AIR MIX SERVOMOTOR (See page DI-1354 ) INSPECT AIR MIX DAMPER POSITION SENSOR (See page DI-1345 ) I07898 2004 LAND CRUISER (RM1071U) Author: Date: 2776 AC-53 AIR CONDITIONING - REAR HEATER UNIT AC1KS-02 INSTALLATION Installation is in the reverse of removal (See page AC-47 ) 2004 LAND CRUISER (RM1071U) Author: Date: 2778 AC-52 AIR CONDITIONING - REAR HEATER UNIT AC1KR-02 REASSEMBLY Reassembly is in the reverse of disassembly (See page AC-49 ) 2004 LAND CRUISER (RM1071U) Author: Date: 2777 AC-47 AIR CONDITIONING - REAR HEATER UNIT AC1KO-04 REMOVAL DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant (a) (b) DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES Using pliers, grip the claws of the clip and slide the clip along the hose Disconnect the water hoses I03973 Second Ridge Hose Clip Water Hose I05080 HINT: At the time of installation, push the water hose on to the heater radiator pipe to the second ridge on the pipe REMOVE FRONT SEATS REMOVE REAR CONSOLE BOX REMOVE FRONT CONSOLE BOX COVER REMOVE LOWER CENTER CLUSTER FINISH PANEL REMOVE FRONT DOOR SCUFF PLATE REMOVE COWL SIDE TRIMS REMOVE REAR DOOR SCUFF PLATES 10 REMOVE CENTER PILLAR GARNISHES 11 SLIDE FLOOR CARPET BACKWARD 12 REMOVE COOLER BRACKET Remove the bolts and the cooler bracket I03924 2004 LAND CRUISER (RM1071U) Author: Date: 2772 AC-48 AIR CONDITIONING - REAR HEATER UNIT 13 REMOVE REAR HEATER DUCT Remove the bolt, the screw and the rear heater duct I03975 14 (a) (b) REMOVE REAR HEATER UNIT Disconnect the connector Remove the bolts and the rear heater unit I03976 2004 LAND CRUISER (RM1071U) Author: Date: 2773 AC-87 AIR CONDITIONING - ROOM TEMPERATURE SENSOR (for Front A/C) ROOM TEMPERATURE SENSOR (for Front A/C) AC1LN-04 INSPECTION I06746 (a) (b) (c) (d) (a) (b) (c) REMOVE ROOM TEMPERATURE SENSOR Remove the lower No panel set screw Release the lower No panel set claws Disconnect the connector and the aspirator hose Remove the screw and the room temperature sensor INSPECT ROOM TEMPERATURE SENSOR CIRCUIT (See page DI-1316 ) INSTALL ROOM TEMPERATURE SENSOR Install the room temperature sensor to the lower No panel with the screw Connect the aspirator hose and the connector Install the lower No panel with the screw 2004 LAND CRUISER (RM1071U) Author: Date: 2812 AC-88 AIR CONDITIONING - ROOM TEMPERATURE SENSOR (for Rear A/C) ROOM TEMPERATURE SENSOR (for Rear A/C) AC1LO-05 INSPECTION I06748 REMOVE ROOM TEMPERATURE SENSOR Using a scrwedriver, pull out the room temperature sensor, then disconnect the connector HINT: Tape the screwdriver tip before use INSPECT ROOM TEMPERATURE SENSOR (See page DI-1330 ) INSTALL ROOM TEMPERATURE SENSOR (a) Connect the connector (b) Insert the room temperature sensor to the roof headlining 2004 LAND CRUISER (RM1071U) Author: Date: 2813 AC-86 AIR CONDITIONING - SOLAR SENSOR SOLAR SENSOR AC1LM-05 INSPECTION I06809 REMOVE SOLAR SENSOR Using a screwdriver, pull out the solar sensor, then disconnect the connector HINT: Tape up the screwdriver tip before use INSPECT SOLAR SENSOR CIRCUIT (See page DI-1333 ) INSTALL SOLAR SENSOR (a) Connect the connector (b) Insert the solar sensor to the instrument panel 2004 LAND CRUISER (RM1071U) Author: Date: 2811