AIR CONDITIONING SYSTEM
AC-1
A¿¿N1-M
PRECAUTIONS FOR SERVICING R134a AIR
CONDITIONINGS
1. USE OF NEW REFRIGERANT R134a
The very different characteristi...
4. TIGHTEN CONNECTING PARTS SECURELY
Securely tighten the connecting parts to prevent leak-
ing of refrigerant gas.
• Appl...
3. USE VACUUM PUMP ADAPTER
By connecting a vacuum pump adapter, the vacuum
pump can be used for both R134a and R12 air con...
3. BE CAREFUL THAT LIQUID REFRIGERANT DOES
NOT GET IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or...
CAUTION:
• Be sure to connect both the high and low pressure
quick-connectors onto the A/C system when eva-
cuating. If on...
SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
Failure to carry out service operations in the correct
sequence could cause the airbag...
DESCRIPTION
PARTS LOCATION
-AIR CONDITIONING SYSTEM DESCRIPTION
AC-8
WIRING DIAGRAM
USA
-AIR CONDITIONING SYSTEM DESCRIPTION
AC-9
Canada
-AIR CONDITIONING SYSTEM DESCRIPTION
AC-10
DAMPERS POSITION
-AIR CONDITIONING SYSTEM DESCRIPTION
AC-1 1
PREPARATION
SST (SPECIAL SERVICE TOOLS)
(07117-88070) Refrigerant Charging Hose
(07117-78050) Refrigerant Charging Gauge
(...
RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set
LUBRICANT
When replacing compressor
When replacing evaporator
W...
USE OF MANIFOLD GAUGE SET
MANIFOLD GAUGE SET INSTALLATION
1. CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts...
TROUBLESHOOTING
You will find the troubles easier using the table well shown below. In this table, each number
shows the p...
Engine coolant temperature switch
Wiring and wiring connections
Vacuum switching valve (VSV)
Inspect refrigeration control...
REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET
This is a method in which the trouble is located by using a manifold...
(1) Check for gas leak-
age with leak detector
and repair if necessary
(2) Charge refrigerant to
proper amount
(3) If pres...
(1) Check heat sensing
tube, expansion valve
and EPR
(2) Clean out dirt in expan-
sion valve by blowing
with air
If not ab...
6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER
(1) Clean condenser
(2) Check fan motor oper-
ation
(3) !f ...
8. EXPANSION VALVE IMPROPERLY
MOUNTED/HEAT SENSING TUBE DEFECTIVE
(OPENS TOO WIDE)
S Pressure too high on
both low and hig...
REFRIGERANT VOLUME
REFRIGERANT VOLUME INSPECTION
1. RUN ENGINE AT APPROX. 1,500 RPM
2. SET TEMPERATURE CONTROL AT MAX. COO...
2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge: Nippondenso ...
IDLE-UP SPEED
IDLE UP SPEED INSPECTION
1. WARM UP ENGINE
2. SET VEHICLE IN FOLLOWING CONDITION
• Blower switch high positi...
REFRIGERANT LINES
LOCATIONS
-AIR CONDITIONING SYSTEM REFRIGERANT LINES
AC-25
REFRIGERANT LINES REPLACEMENT
1. RECOVER REFRIGERANT IN REFRIGERATION
SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the ...
COOLING UNIT
COOLING UNIT REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started after 90 s...
1. REMOVE UPPER AND LOWER CASE
(a) Disconnect and remove the wire harness.
(b) Remove the 2 clips and the 4 screws.
(c) Re...
2. INSTALL THERMISTOR
3. INSTALL UPPER AND LOWER CASE TO EVAPORA-
TOR
(a) Install the blower resistor to the lower case.
(...
6. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf)
7. CONNECT SUC...
BLOWER UNIT
BLOWER UNIT REMOVAL
1. REMOVE COOLING UNIT
(See page AC-25 )
2. REMOVE BLOWER UNIT
(a) Disconnect the connecto...
4. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
(a) Grip the claws of the hose clip with pliers and slide the
clip ...
HEATER UNIT INSTALLATION
Install by following the removal procedure in reverse
order.
HINT:
• Push the water hose onto the...
COMPRESSOR
ON-VEHICLE INSPECTION
Magnetic Clutch:
INSPECT MAGNETIC CLUTCH FOR FOLLOWING
(a) Inspect the pressure plate and...
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10
MINUTES
2. STOP ENGINE
3. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUT...
8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the com-
pressor.
...
3. REMOVE STATOR
(a) Using a screwdriver and disconnect the stator lead
wires from the compressor housing.
(b) Using a pla...
MAGNETIC CLUTCH ASSEMBLY
1. INSTALL STATOR
(a) Install the stator on the compressor.
(b) Using SST, install a new snap rin...
3. INSTALL PRESSURE PLATE
(a) Adjust the clearance between the pressure plate and
rotor by putting shims on the compressor...
COMPRESSOR INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING
BOLTS
Torque: 25 N-m (250 kgf-cm, 18 ft-lbf)
2. INSTALL DRIV...
RECEIVER REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION
SYSTEM
2. DISCONNECT (-) NEGATIVE CABLE FROM BAT-
TERY
CAUTION:...
3. REMOVE FOLLOWING PARTS
• Front grille
• Horn
• Hood lock
• Center brace
• Condenser fan
4. DISCONNECT LIQUID TUBE AND D...
2. INSTALL RADIATOR SUPPORT
3. INSTALL RECEIVER WITH RECEIVER BRACKET TO
CONDENSER
4. CONNECT LIQUID TUBE TO RECEIVER
Torq...
EVAPORATOR INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed
air.
NOTIC...
HEATER RADIATOR
HEATER RADIATOR REMOVAL
1. REMOVE HEATER UNIT
(See page AC-32 )
2. REMOVE HEATER RADIATOR
(a) Remove the 2...
BLOWER MOTOR
MOTOR REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started after 90 seconds ...
CONDENSER FAN REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started after 90 seconds from
...
EXPANSION VALVE
ON-VEHICLE INSPECTION
1. CHECK QUANTITY OF GAS DURING REFRIGERA-
TION CYCLE
2. INSTALL MANIFOLD GAUGE SET
...
2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY
BLOWING AIR INTO PIPES
(a) Connect the VSV terminals to the battery terminals...
4. CHECK FOR OPEN CIRCUIT
Using an ohmmeter, the resistance between the 2
terminals.
Resistance:
30 - 34 W at 20 C (68 F)
...
BLOWER RESISTOR
BLOWER RESISTOR REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started afte...
HEATER MAIN RELAY
RELAY REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started after 90 sec...
MAGNETIC CLUTCH RELAY
RELAY REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must be started after 90...
CONDENSER FAN RELAY NO.2 AND
NO.3 (USA)
RELAYS REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION: Work must ...
CONDENSER FAN RELAY NO.2 AND
NO.3 (Canada)
RELAYS REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
CAUTION: Work must...
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 TO RELAY BLOCK NO.5
2. CONNECT NEGATIVE (-) CABLE TO BA...
THERMISTOR INSPECTION
INSPECT THERMISTOR RESISTANCE
(a) Measure the resistance between terminals at 25 C
(77 F).
Resistanc...
REVOLUTION DETECTING SENSOR
(w Power Steering)
SENSOR INSPECTION
MEASURE SENSOR RESISTANCE
Measure the resistance between ...
REFRIGERANT TEMPERATURE
SWITCH
SWITCH REMOVAL AND INSTALLATION
See ”Discharge Valve Removal or Installation” on page
AC-35...
SWITCHES REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION
SYSTEM
2. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
CAUTION:...
BLOWER SPEED CONTROL SWITCH
SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) GABLE FROM BAT-
TERY
CAUTION: Work must be started a...
SWITCH INSTALLATION
1. INSTALL BLOWER SPEED CONTROL SWITCH
(a) Connect the connector to the blower speed control
switch.
(...
AIR CONDITIONING SWITCH
SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE PROM BAT-
TERY
CAUTION: Work must be started after...
AIR CONDITIONING CONTROL
ASSEMBLY
ON-VEHICLE INSPECTION
INSPECT A/C CONTROL LEVERS OPERATION
Move the control levers left ...
A/C CONTROL ASSEMBLY
INSTALLATION
1. INSTALL A/C CONTROL ASSEMBLY
(a) Install the blower switch to the A/C control assembl...
AMPLIFIER INSPECTION
INSPECT A/C AMPLIFIER CONNECTOR ON WIRE
HARNESS SIDE
Test conditions:
• Ignition switch ON
• Temperat...
If continuity is not as specified, replace the A/C ampli-
fier.
Tester connection to
terminal number
Tester connection to
...
SERVICE SPECIFICATIONS
SERVICE DATA
TORQUE SPECIFICATIONS
0.5 ± 0.15 mm (0.02 ± 0.0059 in.)
Compressor x Compressor bracke...
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Air conditioning system

  1. 1. AIR CONDITIONING SYSTEM AC-1
  2. 2. A¿¿N1-M PRECAUTIONS FOR SERVICING R134a AIR CONDITIONINGS 1. USE OF NEW REFRIGERANT R134a The very different characteristics of refrigerants R134a and R12 have determined the design of their respective air conditioning systems. Under no circum- stances allow R12 to enter an R134a system, or vice versa, because serious damage could occur. GENERAL DESCRIPTION NEW AIR CONDITIONING SYSTEM WITH R134a Refrigerant R12(CFC12), previously used in automo- bile air conditioning systems is believed to contribute towards the depletion the earth’s ozone layer. The ozone layer help to protect us against the harmful ultraviolet rays of the sun. 2. USE OF PROPER COMPRESSOR OIL Compressor oil used in conventional R12 air condi- tioning systems cannot be used in R134a air condi- tioning systems. Always use genuine Toyota R134a air conditioning oil ND - OIL 9, made expressly for use with R134a. If even a small amount of the wrong oil is changed, it will result in clouding of the refrigerant. A large amount will cause the compressor to seize up. A newly developed refrigerant, R134a (HFC 134a), does not the destroy the ozone layer. -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-2
  3. 3. 4. TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent leak- ing of refrigerant gas. • Apply a few drops of compressor oil to O-ring fittings for easy tightening and to prevent leaking of refrigerant gas. CAUTION: Apply only ND-OIL 9 compressor oil • Tighten the nuts using 2 wrenches to avoid twist- ing the tube. • Tighten the O-ring fittings or the bolted type fittings to the specified torque. 5. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS Insert a plug immediately in the disconnected parts to prevent the ingress of moisture and dust. 6. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL IMMEDIATELY BEFORE INSTALLATION 3. USE OF PROPER O-RINGS AND SEALS O-rings and seals used for conventional R12 air conditioning systems cannot be used for R134a air conditioning systems. Always use genuine Toyota R134a system O-rings and seals for R134a air conditioning systems. If O-rings and/or seals for R12 air conditioning sys- tems are used by mistake in the connections of an R 134a air conditioning system, the O-ring and seals will foam and swell resulting in leakage of refrigerant. 7. WHEN DISCONNECTING THE PLUG, TAKE CARE SO THAT OIL WILL NOT AGAIN -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-3
  4. 4. 3. USE VACUUM PUMP ADAPTER By connecting a vacuum pump adapter, the vacuum pump can be used for both R134a and R12 air conditioning systems. The vacuum pump adaptor has an internal magnetic valve. When evacuation is completed and the vacuum pump switch is turned off, the magnetic valve opens allow. ing the introduction of atmospheric air into the manifold gauges to prevent the back flow of oil from the vacuum pump into the gauge hose. CAUTION: Be sure to turn off the manifold gauge valve immediately after evacuating the system. Then you may switch off the vacuum pump. If this order is reversed, the line wilI be temporarily open to atmosphere. SERVICE TOOLS FOR R134a AIR CONDITIONING When servicing R134a air conditioning systems always use the R134a dedicated manifold gauges, gas leak detector and vacuum pump adaptor. 1. USE MANIFOLD GAUGES FOR R134a AIR CONDI- TIONING Always use R134a dedicated manifold gauges to pre- vent R12 and R12 compressor oil contaminating the R134a system. 2. USE R134a GAS LEAK DETECTOR Similarly, always use an R134a dedicated leak detec- tor. The R12 leak detector is not sufficiently sensitive. -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-4
  5. 5. 3. BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR 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 profes- sional treatment. HANDLING PRECAUTIONS FOR REFRIGERANT CONTAINER 1. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 2. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT HANDLING PRECAUTIONS FOR REFRIGERANT 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION CHARGING AND LEAK-CHECK METHODS Evacuate the refrigeration system according to the following procedures. Fill refrigerant in gas state until gauge pressure reads 1 kg/cm2 Abnormal indication of manifold gauges Check and correct pipe joints Refrigerant Charge Refrigerant Charge Start Evacuation Stop Evacuation Leave for 5 min. Gas Leak Check Airtight Check 10 min. -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-5
  6. 6. CAUTION: • Be sure to connect both the high and low pressure quick-connectors onto the A/C system when eva- cuating. If only one side is connected, the system would be open to atmosphere through the other connector, making it impossible to maintain vacuum. • Be sure to turn off the manifold gauge valve imme- diately after evacuating the system. Then you may switch off the vacuum pump. PRECAUTIONS WHEN CHARGING REFRIGERANT 1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT CYCLE If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and com- pressor burnout may occur, so take care to avoid this. 2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILST COMPRESSOR IS OPERATING If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the low pres- sure valve only. 3. BE CAREFUL NOT TO OVERCHARGE WITH RE- FRIGERANT IN SYSTEM If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. ELECTRICAL PARTS Before removing and inspecting the electrical parts, set the ignition switch to the LOCK position and disconnect the negative (-) terminal cable from bat- tery. CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is discon- nected from the battery. -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-6
  7. 7. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Failure to carry out service operations in the correct sequence could cause the airbag system to deploy, possibly leading to a serious accident. During removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the RS section before performing the operation. -AIR CONDITIONING SYSTEM GENERAL DESCRIPTION AC-7
  8. 8. DESCRIPTION PARTS LOCATION -AIR CONDITIONING SYSTEM DESCRIPTION AC-8
  9. 9. WIRING DIAGRAM USA -AIR CONDITIONING SYSTEM DESCRIPTION AC-9
  10. 10. Canada -AIR CONDITIONING SYSTEM DESCRIPTION AC-10
  11. 11. DAMPERS POSITION -AIR CONDITIONING SYSTEM DESCRIPTION AC-1 1
  12. 12. PREPARATION SST (SPECIAL SERVICE TOOLS) (07117-88070) Refrigerant Charging Hose (07117-78050) Refrigerant Charging Gauge (07117-88080) Refrigerant Charging Hose (07117-58080) Quick Coupler (07117-88060) Refrigerant Charging Hose (07117-58090) Quick Coupler (07117-58070) T-Joint (07117-58060) Refrigerant Drain Service Valve Suction (Blue) Suction (diam. 13 mm) Discharge (Red) Utility (Green) Discharge (diam. 16 mm) 07110-58060 Air Conditioner Service Tool Set 07116-38360 Gas Leak Detector Assembly 07112-66040 Magnetic Clutch Remover 07112-76060 Magnetic Clutch Stopper 07114-84020 Snap Ring Pliers -AIR CONDITIONING SYSTEM PREPARATION AC-12
  13. 13. RECOMMENDED TOOLS 09082-00050 TOYOTA Electrical Tester Set LUBRICANT When replacing compressor When replacing evaporator When replacing condenser When replacing receiver 40 cc (1.4 fl.oz.) 40 cc (1.4 fl.oz.) 120 cc (4.1 fl.oz.) 10 cc (2.9 fl.oz.) Compressor oil Classification ND-OIL 8 CapacityItem -AIR CONDITIONING SYSTEM PREPARATION AC-13
  14. 14. USE OF MANIFOLD GAUGE SET MANIFOLD GAUGE SET INSTALLATION 1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. 2. CONNECT QUICK CONNECTORS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVES ON RE- FRIGERANT LINE MANIFOLD GAUGE SET REMOVAL 1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 2. DISCONNECT QUICK CONNECTORS. FROM SER- VICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick connector upward to unlock the connector and remove it from the ser- vice valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIG- ERANT LINE 5. CONNECT QUICK CONNECTORS TO SERVICE VALVES HINT: Push the quick connector onto the service valve, then slide the sleeve of the quick connector downward to lock it. -AIR CONDITIONING SYSTEM USE OF MANIFOLD GAUGE SET AC-14
  15. 15. TROUBLESHOOTING You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts. Cool air comes out only at high engine rpm No engine idle up when A/C switch on InspectA/Ccontrolleveradjustment Inspectcoolingsystemforrefrigerant Compressor operates immediately Inspectenginecoolantvolume Cool air comes out immediately Inspectvolumeofrefrigerant No air temperature control No condenser fan operation Blowerspeedcontrolswitch CondenserfanrelayNo.2 Condenserfanfuse CondenserfanrelayNo.3 Inspectdrivebelttension Inspectoutletaircontrol No compressor operation No warm air comes out Radiatorfanmainrelay No cool air cones out Part Name No blower operation Condenserfanmotor Insufficient cooling Heatermainrelay Blowerresistor Blowermotor AC-54 AC-55 AC-54 AC-55 See Page Trouble AC-61 AC-23 AC-47 AC-51 AC-52 AC-22 AC-46 AC-64 -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-15
  16. 16. Engine coolant temperature switch Wiring and wiring connections Vacuum switching valve (VSV) Inspect refrigeration control Inspect refrigerant lines Magnetic clutch relay High pressure switch Dual pressure switch Expansion valve Magnetic clutch Heater radiator A/C amplifier A/C switch Compressor Thermistor Condenser Evaporator AC-49 AC-66 A/C fuse Receiver AC-60 AC-60 AC-53 AC-63 AC-41 AC-48 AC-34 AC-44 AC-42 AC-57 AC-34 -AIRCONDITIONINGSYSTEMTROUBLESHOOTING AC-16
  17. 17. REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. (See ”USE OF MANIFOLD GAUGE SET” on page AC-14 ) Read the manifold gauge pressure when the following conditions are established: (a) Temperature at the air inlet with the switch set at RECIRC is 30 - 35_C (86 - 95°F) (b) Engine running at 1,500 rpm (c) Blower speed control switch set at high (d) Temperature control set at max. cool HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. 1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM Gauge reading: Low pressure side: 0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2) High pressure side: 1.37 - 1.57 MPa (14 - 16 kgf/cm2) -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-17
  18. 18. (1) Check for gas leak- age with leak detector and repair if necessary (2) Charge refrigerant to proper amount (3) If pressure indicated value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak S Drier in oversaturated state ↓ S Moisture in refrigeration system freezes at expan- sion valve orifice and blocks circulation of re- frigerant S Moisture entered in re- frigeration system freezes at expansion valve orifice and tempo- rarily stops cycle, but normal state is restored after a time when the ice melts (1) Replace receiver/drier (2) Remove moisture in cycle through repeat- edly evacuating air (3) Charge new refrigerant to proper amount S Pressure low on both low and high pressure sides S Bubbles seen in sight glass continuously S Insufficient cooling performance S During operation, pres- sure on low pressure side sometimes becomes a vacuum and sometimes normal 2. MOISTURE PRESENT IN REFRIGERATION SYSTEM S Insufficient refrigerant in system ↓ S Refrigerant leaking Condition: Periodically cools and then fails to cool S Gas leakage at some place in refrigeration system 3. INSUFFICIENT REFRIGERANT Symptom seen in refrigeration system Condition: Insufficient cooling Symptom seen in refrigeration system Probable cause Probable cause Diagnosis Diagnosis Remedy Remedy -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-18
  19. 19. (1) Check heat sensing tube, expansion valve and EPR (2) Clean out dirt in expan- sion valve by blowing with air If not able to remove dirt, replace expansion valve (3) Replace receiver (4) Evacuate air and charge new refrigerant to proper amount. For gas leakage from heat sensing tube, re- place expansion valve. S Refrigerant flow ob- structed by moisture or dirt in refrigeration sys- tem S Refrigerant flow ob- structed by gas leakage from expansion valve heat sensing tube S Vacuum indicated on low pressure side, very low pressure indicated on high pressure side S Frost or dew seen on piping before and after receiver/drier or expan- sion valve 5. REFRIGERANT DOES NOT CIRCULATE Condition: Does not cool (Cools from time to time in some cases) S Pressure low on both low and high pressure sides S Frost on tubes from receiver to unit 4. POOR CIRCULATION OF REFRIGERANT S Refrigerant flow ob- structed by dirt in re- ceiver S Refrigerant does not cir- culate Symptom seen in refrigeration system Condition: Insufficient cooling Symptom seen in refrigeration system Probable cause S Replace receiverS Receiver clogged Probable cause Diagnosis Diagnosis Remedy Remedy -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-19
  20. 20. 6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER (1) Clean condenser (2) Check fan motor oper- ation (3) !f (1) and (2) are in nor- mal state, check amount of refrigerant Charge proper amount of refrigerant NOTE: These gauge indications are shown when the re- frigeration system has been opened and the refrig- erant charged without vacuum purging. S Excessive refrigerant in cycle → refrigerant over- charged S Condenser cooling insuf- ficient → condenser fins clogged or fan motor faulty S Pressure too high on both low and high pressure sides S No air bubbles seen through the sight glass even when the engine rpm is lowered. S Pressure too high on both low and high pressure sides S The low pressure piping is hot to the touch S Bubbles seen insight glass S Unable to develop suffi- cient performance due to excessive refrigerant in system S Insufficient cooling of condenser (1) Check compressor oil to see if dirty or insuffi- cient (2) Evacuate air and charge new refrigerant S Air present in refrigera- tion system ↓ S Insufficient vacuum purging 7. AIR PRESENT IN REFRIGERATION SYSTEM Condition: Does not cool down sufficiently Condition: Does not cool sufficiently S Air entered in refrigera- tion system Symptom seen in refrigeration system Symptom seen in refrigeration system Probable cause Probable cause Diagnosis Diagnosis Remedy Remedy -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-20
  21. 21. 8. EXPANSION VALVE IMPROPERLY MOUNTED/HEAT SENSING TUBE DEFECTIVE (OPENS TOO WIDE) S Pressure too high on both low and high pressure sides S Frost or large amount of dew on piping on low pressure side (1) Check heat sensing tube installed condition (2) If (1) is normal, check expansion valve Replace if defective S Excessive refrigerant in low pressure piping ↓ S Expansion valve opened too wide S Compression defective ↓ Valve leaking or broken, sliding parts S Pressure too high on low pressure side S Pressure too low on high pressure side S Trouble in expansion valve or heat sensing tube not installed cor- rectly 9. DEFECTIVE COMPRESSION COMPRESSOR S Internal leak in compres- sor S Repair or replace com- pressor Condition: Insufficient cooling Symptom seen in refrigeration system Symptom seen in refrigeration system Condition: Does not cooI ^ Diagnosis Probable cause Probable cause Diagnosis Remedy Remedy -AIR CONDITIONING SYSTEM TROUBLESHOOTING AC-21
  22. 22. REFRIGERANT VOLUME REFRIGERANT VOLUME INSPECTION 1. RUN ENGINE AT APPROX. 1,500 RPM 2. SET TEMPERATURE CONTROL AT MAX. COOL 3. SET BLOWER SWITCH AT ’HI’ 4. SET AIR INLET CONTROL AT ’RECIRC’ 5. TURN A/C SWITCH ON 6. FULLY OPEN DOORS 7. INSPECT AMOUNT OF REFRIGERANT Observe the sight glass on the liquid tube. REFRIGERANT CHARGE VOLUME Specified amount: 700 ±50 g (24.69 ± 1.76 oz.) * Bubbles in the sight glass with ambient tempera- tures higher can be considered normal if cooling is sufficient. (1) Check for gas leakage with gas leak tester and repair if necessary (2) Add refrigerant until bubbles disap- pear (1) Check for gas leakage with gas leak tester and repair if necessary (2) Add refrigerant until bubbles disap- pear (1) Recover refrigerant (2) Evacuate air and charge proper amount of purified refrigerant Immediately after air conditioning is turned off, refrigerant in sight glass stays clear When air conditioning is turned off, re- frigerant foams and then stays clear No temperature difference between compressor inlet and outlet Temperature between compressor inlet and outlet is noticeably different No bubbles present in sight glass Bubbles present in sight glass None, sufficient or too much Empty or nearly empty Amount of refrigerant Refer to items 3 and 4 Refer to items 5 and 6Correct or too much Insufficient* Symptom Too much Remedy Correct Item -AIR CONDITIONING SYSTEM REFRIGERANT VOLUME AC-22
  23. 23. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt ten- sion. Belt tension gauge: Nippondenso BTG-20 (95506- 00020) or Borroughs No. BT-33-73F Drive belt tension: New belt 160 ± 25 lbf Used belt 100 ± 20 lbf HINT: • ”New belt” refers to a belt which has been used less than 5 minutes on a running engine. • ”Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. • After installing the drive belt, check that it fits properly in the ribbed grooves. DRIVE BELT TENSION DRIVE BELT TENSION INSPECTION 1. MAKE SURE THAT DRIVE BELT IS INSTALLED CORRECTLY Check that the drive belt fits properly in the ribbed groves. -AIR CONDITIONING SYSTEM DRIVE BELT TENSION AC-23
  24. 24. IDLE-UP SPEED IDLE UP SPEED INSPECTION 1. WARM UP ENGINE 2. SET VEHICLE IN FOLLOWING CONDITION • Blower switch high position • A/C switch on • Magnetic clutch on 3. INSPECT IDLE UP SPEED Standard: 950 ± 50 RPM IDLE-UP SPEED ADJUSTMENT ADJUST IDLE-UP SPEED Adjust idle-up speed with the idle adjusting screw of the VSV. -AIR CONDITIONING SYSTEM IDLE-UP SPEED AC-24
  25. 25. REFRIGERANT LINES LOCATIONS -AIR CONDITIONING SYSTEM REFRIGERANT LINES AC-25
  26. 26. REFRIGERANT LINES REPLACEMENT 1. RECOVER REFRIGERANT IN REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE HINT: Cap the open fittings immediately to keep mois- ture or dirt out of the system. 3. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torque tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 700 ± 50 g (24.69 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refriger- ant. 6. INSPECT AIR CONDITIONING OPERATION ON-VEHICLE INSPECTION 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak tester, check for leakage of refriger- ant. -AIR CONDITIONING SYSTEM REFRIGERANT LINES AC-26
  27. 27. COOLING UNIT COOLING UNIT REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 3. DISCONNECT SUCTION TUBE FROM COOLING UNIT OUTLET FITTING 4. DISCONNECT LIQUID TUBE FROM COOLING UNIT INLET FITTING HINT: Cap the open fittings immediately to keep mois- ture out of the system. 5. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 6. DISCONNECT CONNECTOR FROM WIRE HARNESS 7. REMOVE EARTH WIRE 8. REMOVE A/C AMPLIFIER (a) Disconnect the connector from the A/C amplifier. (b) Remove the 3 screws and the A/C amplifier. 9. REMOVE COOLING UNIT Remove the 3 screws, nuts and the cooling unit. -AIR CONDITIONING SYSTEM COOLING UNIT AC-27
  28. 28. 1. REMOVE UPPER AND LOWER CASE (a) Disconnect and remove the wire harness. (b) Remove the 2 clips and the 4 screws. (c) Remove the upper and the lower case. (d) Remove the A/C main relay from the upper case. (e) Remove the blower resistor from the lower case. COOLING UNIT DISASSEMBLY -AIR CONDITIONING SYSTEM COOLING UNIT AC-28
  29. 29. 2. INSTALL THERMISTOR 3. INSTALL UPPER AND LOWER CASE TO EVAPORA- TOR (a) Install the blower resistor to the lower case. (b) Install the A/C main relay to the upper case. (c) Install the upper and lower case to the evaporator. (d) Install the 2 clips and 4 tapping screws. (e) Connect the connectors of wire harness. COOLING UNIT ASSEMBLY 1. CONNECT EXPANSION VALVE, SUCTION AND LIQUID TUBES TO EVAPORATOR Torque the bolts. Torque: 5.4 N-m (55 kgf-cm. 48 in.-Ibf) 3. REMOVE EXPANSION VALVE, SUCTION AND LIQUID TUBES FROM EVAPORATOR 2. REMOVE THERMISTOR FROM EVAPORATOR -AIR CONDITIONING SYSTEM COOLING UNIT AC-29
  30. 30. 6. CONNECT LIQUID TUBE TO COOLING UNIT INLET FITTING Torque the nut. Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf) 7. CONNECT SUCTION TUBE TO COOLING UNIT OUTLET FITTING Torque the nut. Torque: 32 N-m (330 kgf-cm, 24 ft-Ibf) 8. IF EVAPORATOR WAS REPLACED, ADD COMPRES- SOR OIL TO COMPRESSOR Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 9 9. CONNECT NEGATIVE (-) CABLE TO BATTERY 10. EVACUATE AIR FROM REFRIGERATION SYSTEM 11. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 700 ± 50 g (24.69 ± 1.76 oz.) COOLING UNIT INSTALLATION 1. INSTALL COOLING UNIT Install the cooling unit with the 3 nuts and 4 screws. 2. INSTALL A/C AMPLIFIER (a) Install the A/C amplifier to the cooling unit with the 2 screws. (b) Connect the connector to the A/C amplifier. 3. INSTALL EARTH WIRE TO BODY 4. CONNECT CONNECTOR TO WIRE HARNESS OF VE- HICLE SIDE 5. INSTALL INSTRUMENT LOWER FINISH PANEL -AIR CONDITIONING SYSTEM COOLING UNIT AC-30
  31. 31. BLOWER UNIT BLOWER UNIT REMOVAL 1. REMOVE COOLING UNIT (See page AC-25 ) 2. REMOVE BLOWER UNIT (a) Disconnect the connector from the blower motor. (b) Disconnect the air inlet damper control cable from the blower motor. (e) Remove the nut, 2 screws and the blower unit. BLOWER UNIT INSTALLATION 1. INSTALL BLOWER UNIT (a) Install the blower unit with the nut and 2 screws. (b) Connect the air inlet damper control cable to the blower unit. HINT: For installing the control cable, refer to ”Adjust- ment of A/C Control Cables”. (c) Connect the connector to the blower motor. 2. INSTALL COOLING UNIT (See page AC-30 ) -AIR CONDITIONING SYSTEM BLOWER UNIT AC-31
  32. 32. 4. DISCONNECT WATER HOSES FROM HEATER RA- DIATOR PIPES (a) Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it dose not clamp the hose to the pipe. (b) Disconnect the water hoses. 5. REMOVE PIPE GROMMETS 6. REMOVE A/C CONTROL ASSEMBLY (See page AC-64 ) HEATER UNIT HEATER UNIT REMOVAL 1. REMOVE SAFETY PAD See ”Instrument Panel” on BO section. 2. REMOVE COOLING UNIT (See page AC-25 ) 3. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 8. REMOVE INSTRUMENT PANEL REINFORCEMENT NO. 1 BRACE Remove the 2 nuts, 2 bolts and the No. 1 brace. 9. REMOVE INSTRUMENT PANEL REINFORCEMENT NO. 2 BRACE Remove the 2 nuts, a bolts and the No. 2 brace. 7. REMOVE HEATER TO REGISTER CENTER DUCT Remove the 3 screws and the duct. 10. REMOVE HEATER UNIT Remove the screw, nut and the heater unit. -AIR CONDITIONING SYSTEM HEATER UNIT AC-32
  33. 33. HEATER UNIT INSTALLATION Install by following the removal procedure in reverse order. HINT: • Push the water hose onto the heater radiator pipe as far as the ridge on the pipe. • Install the hose clip in a position, as shown to the left. -AIR CONDITIONING SYSTEM HEATER UNIT AC-33
  34. 34. COMPRESSOR ON-VEHICLE INSPECTION Magnetic Clutch: INSPECT MAGNETIC CLUTCH FOR FOLLOWING (a) Inspect the pressure plate and the rotor for signs of oil. (b) Check the clutch bearings for noise and grease leak- age. (c) Connect the positive (+) lead from the battery to the terminal on the magnetic clutch connector and the negative (-) lead to the body ground. (d) Check that the magnetic clutch is energized. If the magnetic clutch is not energized, replace the magnetic clutch. Compressor: 1. INSTALL MANIFOLD GAUGE SET 2. RUN ENGINE AT APPROX. 2,000 RPM 3. INSPECT COMPRESSOR FOR FOLLOWING (a) High pressure gauge reading is not lower and low pressure gauge reading is not higher than normal. (b) Check that the metallic sound. (c) Check that the leakage from shaft seal. -AIR CONDITIONING SYSTEM COMPRESSOR AC-34
  35. 35. 1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10 MINUTES 2. STOP ENGINE 3. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 5. REMOVE UNDER COVER 6. DISCONNECT CONNECTOR FROM MAGNETIC CLUTCH 7. DISCONNECT 2 HOSES FROM COMPRESSOR SER- VICE VALVE Cap the open fitting immediately to keep moisture and dust out of the system. COMPRESSOR REMOVAL -AIR CONDITIONING SYSTEM COMPRESSOR AC-35
  36. 36. 8. REMOVE COMPRESSOR (a) Loosen the compressor drive belt. (b) Remove the compressor mounting bolts and the com- pressor. 1. REMOVE PRESSURE PLATE (a) Using a socket and SST, remove the shaft nut. SST 07112-76060 (b) Install SST to the pressure plate. SST 07112 - 66040 MAGNETIC CLUTCH DISASSEMBLY -AIR CONDITIONING SYSTEM COMPRESSOR AC-36
  37. 37. 3. REMOVE STATOR (a) Using a screwdriver and disconnect the stator lead wires from the compressor housing. (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapp- ing on the rotor. (c) Using SST and the socket, remove the pressure plate. SST 07112-76060, 07112-66040 2. REMOVE ROTOR (a) Using SST, remove the snap ring. SST 07114-84020 (d) Remove the shims from the shaft. -AIR CONDITIONING SYSTEM COMPRESSOR AC-37
  38. 38. MAGNETIC CLUTCH ASSEMBLY 1. INSTALL STATOR (a) Install the stator on the compressor. (b) Using SST, install a new snap ring. SST 07114-84020 (c) Connect the stator lead wires to the compressor hous- ing. NOTICE: The snap ring should be installed so that its beveled side faces up. (b) Using SST, remove the snap ring. SST 07114-84020 (c) Remove the stator. -AIR CONDITIONING SYSTEM COMPRESSOR AC-38
  39. 39. 3. INSTALL PRESSURE PLATE (a) Adjust the clearance between the pressure plate and rotor by putting shims on the compressor shaft. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within tolerance, change the number of shims to obtain the standard clearance. 2. INSTALL ROTOR (a) Install the rotor on the compressor shaft. (b) Using SST, install a new snap ring. SST 07114-84020 (b) Using SST and torque wrench, install the shaft nut. SST 07112-76060 Torque: 14 N-m (140 kgf-cm, 10 ft-lbf) NOTICE: The snap ring should be installed so that its beveled side faces up. -AIR CONDITIONING SYSTEM COMPRESSOR AC-39
  40. 40. COMPRESSOR INSTALLATION 1. INSTALL COMPRESSOR WITH 4 MOUNTING BOLTS Torque: 25 N-m (250 kgf-cm, 18 ft-lbf) 2. INSTALL DRIVE BELT See Drive Belt Tension Adjustment on page AC-23 . 3. CONNECT 2 HOSES TO COMPRESSOR SERVICE VALVES Torque: Discharge line 10 N-m (100 kgf-cm, 8 ft-lbf) Suction line 10 N-m (100 kgf-cm. 8 ft-lbf) 4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS 5. CONNECT NEGATIVE (-) CABLE TO BATTERY 6. EVACUATE AIR FROM REFRIGERATION SYSTEM 7. CHARGE SYSTEM WITH REFRIGERANT AND IN. SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 700 ±50 g (24.69 ± 1.76 oz.) 4. INSPECT CLEARANCE OF MAGNETIC CLUTCH (a) Set the dial-gauge to the pressure plate of the mag- netic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor, when connect the negative (-) terminal of the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± 0.0059 in.) If the clearance is not within standard clearance adjust the clearance using shims to obtain the stand- ard clearance. -AIR CONDITIONING SYSTEM COMPRESSOR AC-40
  41. 41. RECEIVER REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT (-) NEGATIVE CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 3. REMOVE FRONT GRILLE 4. DISCONNECT 2 LIQUID TUBES FROM RECEIVER HINT: Cap the open fittings immediately to keep mois- ture out of the system. 5. REMOVE RECEIVER FROM RECEIVER HOLDER RECEIVER INSTALLATION 1. INSTALL RECEIVER IN RECEIVER HOLDER HINT: Do not remove the blind plugs until ready for connection. 2. CONNECT 2 LIQUID TUBES TO RECEIVER Torque the bolt. Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf) 3. INSTALL FRONT GRILLE 4. CONNECT NEGATIVE (-) CABLE TO BATTERY 5. IF RECEIVER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 9 6. EVACUATE AIR FROM REFRIGERATION SYSTEM 7. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 700 ± 50 g (24.69 ± 1.76 oz.) RECEIVER ON-VEHICLE INSPECTION INSPECT SIGHT GLASS, FUSIBLE PLUG AND FIT- TINGS FOR LEAKAGE Use a gas leak tester. Repair as necessary. -AIR CONDITIONING SYSTEM RECEIVER AC-41
  42. 42. 3. REMOVE FOLLOWING PARTS • Front grille • Horn • Hood lock • Center brace • Condenser fan 4. DISCONNECT LIQUID TUBE AND DISCHARGE HOSE FROM CONDENSER FITTING HINT: Cap the open fittings immediately to keep mois- ture out of the system. 5. REMOVE RECEIVER WITH RECEIVER BRACKET FROM CONDENSER 6. REMOVE RADIATOR SUPPORT BRACKETS 7. REMOVE CONDENSER (a) Remove the 2 condenser mounting bolts. (b) Remove the 2 condenser brackets. CONDENSER ON-VEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER FITTINGS FOR LEAKAGE Repair as necessary. CONDENSER REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is discon- nected from the battery. -AIR CONDITIONING SYSTEM CONDENSER AC-42
  43. 43. 2. INSTALL RADIATOR SUPPORT 3. INSTALL RECEIVER WITH RECEIVER BRACKET TO CONDENSER 4. CONNECT LIQUID TUBE TO RECEIVER Torque the bolt. Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf) 5. CONNECT LIQUID TUBE AND DISCHARGE HOSE TO CONDENSER Torque the bolt. Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf) 6. INSTALL FOLLOWING PARTS • Condenser fan • Center brace • Hood lock • Horn • Front grille 7. CONNECT NEGATIVE (-) CABLE TO BATTERY 8. IF CONDENSER WAS REPLACED, ADD COMPRES- SOR OIL TO COMPRESSOR Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 9 9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM 10. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 700 ± 50 g (24.69 ± 1.76 oz.) CONDENSER INSTALLATION 1. INSTALL CONDENSER Install the condenser with the 2 condenser brackets and the 2 mounting bolts. (c) Pull the condenser out. -AIR CONDITIONING SYSTEM CONDENSER AC-43
  44. 44. EVAPORATOR INSPECTION 1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. 2. CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary. REMOVAL AND INSTALLATION OF EVAPORATOR See item of cooling unit. -AIR CONDITIONING SYSTEM CONDENSER AC-44
  45. 45. HEATER RADIATOR HEATER RADIATOR REMOVAL 1. REMOVE HEATER UNIT (See page AC-32 ) 2. REMOVE HEATER RADIATOR (a) Remove the 2 screws and the 2 plates. (b) Pull the heater radiator out. HEATER RADIATOR INSPECTION INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. HEATER RADIATOR INSTALLATION 1. INSTALL HEATER RADIATOR (a) Insert the heater radiator to the heater unit. (b) Install the 2 plates with the 2 screws. 2. INSTALL HEATER UNIT (See page AC-33 ) -AIR CONDITIONING SYSTEM HEATER RADIATOR AC-45
  46. 46. BLOWER MOTOR MOTOR REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. MOTOR INSTALLATION 1. INSTALL BLOWER MOTOR (a) Install the blower motor with the 3 screws. (b) Connect the connector to blower motor. 2. INSTALL A/C AMPLIFIER Install A/C amplifier with the 3 screws. 3. CONNECT NEGATIVE (-) CABLE TO BATTERY MOTOR INSPECTION INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, then check that the motor operation is smooth. 3. REMOVE BLOWER MOTOR (a) Disconnect the connector from the blower motor. (b) Remove the 3 screws and the blower motor. 2. REMOVE A/C AMPLIFIER Remove the 3 screws and the A/C amplifier with the connector connected. -AIR CONDITIONING SYSTEM BLOWER MOTOR AC-46
  47. 47. CONDENSER FAN REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE FOLLOWING COMPONENTS • Front grille • Hood lock • Center brace 3. REMOVE CONDENSER FAN (a) Disconnect the connector from fan motor. (b) Remove the 2 bolts and the condenser fan. CONDENSER FAN INSTALLATION 1. INSTALL CONDENSER FAN (a) Install the condenser fan with the 2 bolts. (b) Connect the connector to the fan motor. 2. INSTALL FOLLOWING PARTS • Center brace • Hood lock • Front grille 3. CONNECT NEGATIVE (-) CABLE TO BATTERY CONDENSER FAN ON-VEHICLE INSPECTION INSPECT CONDENSER FAN MOTOR (a) Using the wire harness, apply battery positive voltage to the connector. (b) Confirm smooth rotation of the motor within the spe- cified current flow. Standard current: 9.5 ±1.5 A If current is not as specified, replace the motor. -AIR CONDITIONING SYSTEM CONDENSER FAN AC-47
  48. 48. EXPANSION VALVE ON-VEHICLE INSPECTION 1. CHECK QUANTITY OF GAS DURING REFRIGERA- TION CYCLE 2. INSTALL MANIFOLD GAUGE SET 3. RUN ENGINE Run the engine at 2,000 RPM for at least 5 minutes. Then check that the high pressure reading is 1,275 - 1,471 kPa (13 - 15 kgf/cm2, 185 - 213 psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm2, 0 psi), otherwise it is OK. HINT: When the low pressure drops to 0 kPa (0 kgf/ cm2, 0 psi), feel the receiver’s IN and OUT sides for no temperature difference. EXPANSION VALVE REMOVAL AND INSTALLATION See item of cooling unit. -AIR CONDITIONING SYSTEM EXPANSION VALVE AC-48
  49. 49. 2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY BLOWING AIR INTO PIPES (a) Connect the VSV terminals to the battery terminals as illustrated. (b) Blow into pipe ”A” and check that air comes out of pipe ”B”. (c) Disconnect the battery. (d) Blow into pipe ”A” and check that air does not come out pipe ’B’. If a problem is found, replace the VSV. 3. CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity between each terminal and the VSV body. If there is continuity, replace the VSV. VSV INSPECTION 1. DISCONNECT VACUUM HOSES AND CONNECTOR FROM VSV VACUUM SWITCHING VALVE (VSV) VACUUM HOSE CIRCUIT -AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV) AC-49
  50. 50. 4. CHECK FOR OPEN CIRCUIT Using an ohmmeter, the resistance between the 2 terminals. Resistance: 30 - 34 W at 20 C (68 F) If the resistance is not within specification, replace the VSV. -AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV) AC-50
  51. 51. BLOWER RESISTOR BLOWER RESISTOR REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE BLOWER RESISTOR (a) Disconnect the connector from the blower resistor. (b) Remove the 2 screws and the blower resistor. BLOWER RESISTOR INSTALLATION 1. INSTALL BLOWER RESISTOR (a) Install the blower resistor with the 2 screws. (b) Connect the connector to the blower resistor. 2. CONNECT NEGATIVE (-) CABLE TO BATTERY BLOWER RESISTOR INSPECTION INSPECT BLOWER RESISTOR Continuity If continuity is not as specified, replace the blower resistor. Condition Terminal Constant -AIR CONDITIONING SYSTEM BLOWER RESISTOR AC-51
  52. 52. HEATER MAIN RELAY RELAY REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 3. DISCONNECT HEATER MAIN RELAY FROM A/C RELAY BLOCK RELAY INSTALLATION 1. CONNECT HEATER MAIN RELAY TO A/C RELAY BLOCK 2. INSTALL INSTRUMENT LOWER FINISH PANEL 3. CONNECT NEGATIVE (-) CABLE TO BATTERY RELAY INSPECTION INSPECT HEATER MAIN RELAY Continuity If continuity is not as specified, replace the relay. Tester connection to terminal number Apply B + between terminals 1 and 3. Specified value 1-3 2-4 Continuity Continuity Condition Constant 4-5 -AIR CONDITIONING SYSTEM HEATER MAIN RELAY AC-52
  53. 53. MAGNETIC CLUTCH RELAY RELAY REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 3. REMOVE MAGNETIC CLUTCH RELAY Remove a screw and disconnect the relay from the connector. RELAY INSTALLATION 1. INSTALL MAGNETIC CLUTCH RELAY Connect the relay to the connector and install it to the cooling unit with the screw. 2. INSTALL INSTRUMENT LOWER FINISH PANEL 3. CONNECT NEGATIVE (-) CABLE TO BATTERY RELAY INSPECTION INSPECT MAGNETIC CLUTCH RELAY Continuity If continuity is not as specified, replace the relay. Tester connection to terminal number Apply B+ between terminals 1 and 3. Specified value Continuity Continuity Condition Constant 1-3 2-4 -AIR CONDITIONING SYSTEM MAGNETIC CLUTCH RELAY AC-53
  54. 54. CONDENSER FAN RELAY NO.2 AND NO.3 (USA) RELAYS REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 FROM RELAY BLOCK NO. 2 RELAYS INSPECTION 1. INSPECT CONDENSER FAN RELAY NO. 2 Check the relay the same way as for the heater main relay. 2. INSPECT CONDENSER FAN RELAY NO. 3 Check the relay the same way as for the magnetic clutch relay. RELAYS INSTALLATION 1. CONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 TO RELAY BLOCK NO. 2 2. CONNECT NEGATIVE (-) CABLE TO BATTERY -AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N0.3 (USA) AC-54
  55. 55. CONDENSER FAN RELAY NO.2 AND NO.3 (Canada) RELAYS REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 FROM RELAY BLOCK NO. 5 RELAYS INSPECTION 1. INSPECT CONDENSER FAN RELAY NO.2 Continuity If continuity is not as specified, replace the relay. 2. INSPECT CONDENSER FAN RELAY NO.3 Continuity If continuity is not as specified, replace the relay. Tester connection to terminal number Tester connection to terminal number Apply B + between terminals 1 and 2. Apply B+ between terminals 1 and 2. Specified value Specified value 1-2 3-4 Continuity Continuity Continuity Continuity Condition Condition Constant Constant 1-2 3-5 3-5 -AIR CONDITIONING SYSTEM CONDENSER FAN RELAY NO.2 AND NO.3 (Canada) AC-55
  56. 56. RELAYS INSTALLATION 1. CONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 TO RELAY BLOCK NO.5 2. CONNECT NEGATIVE (-) CABLE TO BATTERY -AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N 0.3(Canada) AC-56
  57. 57. THERMISTOR INSPECTION INSPECT THERMISTOR RESISTANCE (a) Measure the resistance between terminals at 25 C (77 F). Resistance: 1,500 W at 25°C (77°F) (b) Place the thermistor in cold water. While varying the temperature of the water, measure the resistance at the connector and at the same time, measure the temperature of the water with a thermometer. (c) Compare the 2 readings on the chart. If the resistance valve is not as specified, replace the thermistor. THERMISTOR THERMISTOR REMOVAL AND INSTALLATION See item of cooling unit. -AIR CONDITIONING SYSTEM THERMISTOR AC-57
  58. 58. REVOLUTION DETECTING SENSOR (w Power Steering) SENSOR INSPECTION MEASURE SENSOR RESISTANCE Measure the resistance between terminals 3 and 4. Standard resistance: 240 ± 80 at 20°C (68°F) If resistance value is not as specified, replace the sensor. SENSOR REMOVAL 1. REMOVE COMPRESSOR (See page AC-35 ) 2. REMOVE REVOLUTION DETECTING SENSOR (a) Remove the bolt. (b) Remove the revolution detecting sensor. SENSOR INSTALLATION 1. INSTALL REVOLUTION DETECTING SENSOR Using a torque wrench, tighten the bolt. Torque: 11 N .m (110 kgf-cm, 8 ft-lbf) 2. INSTALL COMPRESSOR (See page AC-40 ) -AIR CONDITIONING SYSTEM REVOLUTION DETECTING SENSOR (w Power Steering) AC-58
  59. 59. REFRIGERANT TEMPERATURE SWITCH SWITCH REMOVAL AND INSTALLATION See ”Discharge Valve Removal or Installation” on page AC-35 or 40. SWITCH INSPECTION INSPECT REFRIGERANT TEMPERATURE SWITCH Check refrigerant temperature switch operation. If operation is not as specified, replace the switch. HINT: After inspection, throughly clean the switch before assembly. Oil Temperature 120°C (248°F) 180°C (356°F) Specified Value No continuity Continuity -AIR CONDITIONING SYSTEM REFRIGERANT TEMPERATURE SWITCH AC-59
  60. 60. SWITCHES REMOVAL 1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT NEGATIVE (-) CABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 3. REMOVE TRIPLE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the triple pres- sure switch. SWITCHES INSTALLATION 1. INSTALL TRIPLE PRESSURE SWITCH TO LIQUID TUBE Tighten the triple pressure switch then connect the connector to it. Torque: 10 N-m (100 kgf-cm, 7 ft-lbf) 2. CONNECT NEGATIVE (-) CABLE TO BATTERY 3. EVACUATE AIR FROM REFRIGERATION SYSTEM 4. CHARGE SYSTEM WITH REFRIGERANT AND IN- SPECT FOR LEAKAGE OF REFRIGERANT Specified amount: 700 ± 50 g (24.69 ± 1.76 oz.) 4. INSPECT TRIPLE PRESSURE SWITCH (Magnetic Clutch Control) (a) Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2. (b) Check continuity between terminals when refrigerant pressure is changed, as shown. If operation is not as specified, replace the pressure switch. TRIPLE PRESSURE SWITCH ON-VEHICLE INSPECTION 1. DISCONNECT CONNECTOR FROM TRIPLE PRES- SURE SWITCH 2. INSTALL MANIFOLD GAUGE SET 3. RUN ENGINE AT APPROX. 2,000 RPM -AIR CONDITIONING SYSTEM TRIPLE PRESSURE SWITCH AC-60
  61. 61. BLOWER SPEED CONTROL SWITCH SWITCH REMOVAL 1. DISCONNECT NEGATIVE (-) GABLE FROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE A/C CONTROL PANEL (See page BO-47 ) 3. REMOVE AUDIO AND ASH TRAY (See page BO-46 ) 4. REMOVE BLOWER SPEED CONTROL SWITCH (a) Remove the illumination light from the A/C control assembly. (b) Using a screwdriver, pry loose the clip and push out the blower speed control switch to rear of the A/C control assembly. (c) Disconnect the connector from the blower speed con- trol switch. SWITCH INSPECTION INSPECT BLOWER SPEED CONTROL SWITCH Continuity If continuity is not as specified, replace the blower speed control switch. Switch position IlluminationTerminal OFF -AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH AC-61
  62. 62. SWITCH INSTALLATION 1. INSTALL BLOWER SPEED CONTROL SWITCH (a) Connect the connector to the blower speed control switch. (b) Install the illumination light to the A/C control assem- bly. (c) Install the blower speed control switch to the A/C control assembly. 2. INSTALL AUDIO AND ASH TRAY 3. INSTALL A/C CONTROL PANEL 4. CONNECT NEGATIVE (-) CABLE TO BATTERY -AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH AC-62
  63. 63. AIR CONDITIONING SWITCH SWITCH REMOVAL 1. DISCONNECT NEGATIVE (-) CABLE PROM BAT- TERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is discon- nected from the battery. 2. REMOVE A/C SWITCH Using a screwdriver, pry loose the clips and remove the A/C switch. HINT: Tape the screwdriver tip before use. SWITCH INSTALLATION 1. INSTALL A/C SWITCH Push in the A/C switch to the A/C control assembly. 2. CONNECT NEGATIVE (-) CABLE TO BATTERY If continuity is not as specified, check the bulb or replace the switch. SWITCH INSPECTION INSPECT A/C SWITCH Continuity Tester connection to terminal number Illumination circuit A/C Switch OFF A/C Switch ON Specified value 4-5 4-6 No continuity Continuity Continuity Condition 1-3 -AIR CONDITIONING SYSTEM AIR CONDITIONING SWITCH AC-63
  64. 64. AIR CONDITIONING CONTROL ASSEMBLY ON-VEHICLE INSPECTION INSPECT A/C CONTROL LEVERS OPERATION Move the control levers left and right and check for stiffness and binding through the full range of the levers. 3. ADJUST AIR MIX DAMPER CONTROL CABLE Set the air mix damper on ”COOL” position, install the control cable and lock the clamp. 1. ADJUST AIR INLET DAMPER CONTROL CABLE Set the air inlet damper on ”RECIRC” position, install the control cable and lock clamp. 2. ADJUST MODE DAMPER CONTROL CABLE Set the air inlet damper on ”FACE” position, install the control cable and lock the clamp. A/C CONTROL CABLES ADJUSTMENT -AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY AC-64
  65. 65. A/C CONTROL ASSEMBLY INSTALLATION 1. INSTALL A/C CONTROL ASSEMBLY (a) Install the blower switch to the A/C control assembly. (b) Wire the control cables, as shown the illustration. (c) Connect the control cables to the heater unit and blower unit. HINT: For installing the control cables, refer to ”Ad- justment of A/C Control Cables”. 2. INSTALL SAFETY PAD A/C CONTROL ASSEMBLY REMOVAL 1. REMOVE SAFETY PAD See ”Instrument Panel” on BO section. 2. REMOVE A/C CONTROL ASSEMBLY (a) Disconnect the control cables from the heater unit and the blower unit. (b) Remove the blower switch and remove the A/C con- trol assembly. -AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY AC-65
  66. 66. AMPLIFIER INSPECTION INSPECT A/C AMPLIFIER CONNECTOR ON WIRE HARNESS SIDE Test conditions: • Ignition switch ON • Temperature control lever to MAX COOL • Blower switch ON w/o Power Steering AIR CONDITIONING AMPLIFIER AMPLIFIER REMOVAL REMOVE A/C AMPLIFIER (a) Disconnect the connector from the amplifier. (b) Remove the 3 screws and the amplifier. Tester connection to terminal number Tester connection to terminal number Tester connection to terminal number Tester connection to terminal number Approx. 1.5 kW at 25°C (77°F) w/ Power Steering Specified value (Resistance) Specified value (Continuity) Specified value (Voltage) Specified value (Voltage) Battery positive voltage Battery positive voltage Battery positive voltage Battery positive voltage Approx. 10 to 14 V Approx. 10 to 14 V Blower switch OFF Blower switch OFF Blower switch ON Blower switch ON A/C switch OFF A/C switch OFF Stop the engine Start the engine Stop the engine Start the engine A/C switch ON A/C switch ON Approx. 240W 12 - Ground 8 - Ground 8 - Ground 8 - Ground 8 - Ground 1 - Ground 1 - Ground 7 - Ground 7 - Ground 7 - Ground 1 - Ground 1 - Ground 7 - Ground No voltage No voltage No voltage No voltage No voltage No voltage Continuity Continuity Condition Condition Condition Condition Constant Constant Constant Constant 9-13 2- 13 5 -7 -AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER AC-66
  67. 67. If continuity is not as specified, replace the A/C ampli- fier. Tester connection to terminal number Tester connection to terminal number Specified value (Continuity) Specified value (Resistance) 12 - Ground Continuity Continuity Condition Condition Constant Constant Constant2 - 12 5-7 Approx. 1.5 kW at 25°C (77°F) -AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER AC-67
  68. 68. SERVICE SPECIFICATIONS SERVICE DATA TORQUE SPECIFICATIONS 0.5 ± 0.15 mm (0.02 ± 0.0059 in.) Compressor x Compressor bracket Refrigerant charge volume 700 ± 50 g (24.69 ± 1.76 oz.) Compressor x Discharge hose Compressor x Suction hose Cooling unit x Suction tube Cooling unit x Liquid tube Magnetic clutch clearance Condenser x Liquid tube Receiver x Liquid tube Drive belt tension 1,450 ± 50 RPMIdle-up speed Part tightened 160 ± 25 lbf 100 ± 20 lbf 48 in.-lbf Used belt 48 in.-lbf New belt kgf-cm ft-lbf 250 330 140 100 100 N-m 5.5 5.5 -AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONS AC-68

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