Отопитель, кондиционер, вентиляция. Heater, Air Conditioner and Ventilation

Отопитель, кондиционер, вентиляция. Heater, Air Conditioner and Ventilation

55-1

HEATER,

AIR CONDITIONER

AND VENTILATION

MANUAL AIR CONDITIONER . . . . . . . .

3

GENERAL INFORMATION . . . . . . . . . . . . . . . .

3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . .

3

SERVICE SPECIFICATIONS . . . . . . . . . . . . . .

4

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . .

5

CONTENTS

55109000119

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . .

5

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . .

Sight Glass Refrigerant Level Test

Magnetic Clutch Test

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Receiver Drier Test . . . . . . . . . . . . . . . . . . . . . . . .

Dual Pressure Switch Check . . . . . . . . . . . . . . .

7

7

7

7

8

CONTINUED ON NEXT PAGE

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES

WARNING!

(1) Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative).

(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized

MITSUBISHI dealer.

(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental

Restraint System (SRS) before beginning any service or maintenance of any component of the SRS or any SRS-related component.

NOTE

The SRS includes the following components: SRS-ECU, SRS warning lamp, air bag module, clock spring, side impact sensors and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*).

55-2

Compressor Drive Belt Adjustment

Charging

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Performance Test . . . . . . . . . . . . . . . . . . . . . . . .

Refrigerant Leak Repair . . . . . . . . . . . . . . . . . . .

14

15

8

9

Compressor Noise

Power Relay Check

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Idle-up Operation Check . . . . . . . . . . . . . . . . . .

16

16

18

HEATER CONTROL ASSEMBLY, A/C

SWITCH AND INSIDE/OUTSIDE AIR

CHANGEOVER SWITCH . . . . . . . . . . . . . . .

19

HEATER UNIT*, HEATER CORE AND

BLOWER UNIT . . . . . . . . . . . . . . . . . . . . . . . .

22

RESISTOR, BLOWER FAN AND MOTOR

AND INSIDE/OUTSIDE AIR CHANGEOVER

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . .

25

AIR PURIFIER ASSEMBLY . . . . . . . . . . . . .

27

COMPRESSOR AND TENSION PULLEY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

REFRIGERANT LINE . . . . . . . . . . . . . . . . . .

28

CONDENSER AND CONDENSER FAN

MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . .

33

AUTOMATIC AIR CONDITIONER . . . .

35

GENERAL INFORMATION . . . . . . . . . . . . . .

35

SERVICE SPECIFICATIONS . . . . . . . . . . . .

35

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . .

36

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . .

36

TROUBLESHOOTING . . . . . . . . . . . . . . . . . .

36

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . .

56

AIR CONDITIONER CONTROL PANEL AND

ECU ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

57

DAMPER MOTOR ASSEMBLY AND

POWER TRANSISTOR . . . . . . . . . . . . . . . . .

58

COMPRESSOR AND TENSION PULLEY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61

PHOTO SENSOR . . . . . . . . . . . . . . . . . . . . . .

67

OUTSIDE AIR TEMPERATURE SENSOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68

HEATER WATER TEMPERATURE

SENSOR* . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69

OTHER MAINTENANCE SERVICE POINTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - General Information

55-3

MANUAL AIR CONDITIONER

GENERAL INFORMATION

The heater system uses a two-way-flow full-air-mix system that features high performance and low operating noise, and includes an independent face air blowing function. The A/C system is basically the same as the conventional system, but a new

Items

Heater unit

Heater control assembly

Type

Compressor Model

Dual pressure switch High-pressure switch kPa

Low-pressure switch

Refrigerant and quantity g

55200010190

refrigerant system has been adopted as a response to restrictions on the use of chlorofluorocarbons.

In addition, an air purifier which carries out fine

A/C control has been included.

Specifications

Two-way-flow full-air-mix system

Dial type

Scroll type <MSC90>

ON ® OFF: 2,942, OFF ® ON: 2,353

ON ® OFF: 196, OFF ® ON: 221

R-134a (HFC-134a), Approx. 670- 710

SAFETY PRECAUTIONS

Because R-134a refrigerant is a hydrofluorocarbon

(HFC) which contains hydrogen atoms in place of chlorine atoms, it will not cause damage to the ozone layer.

Refrigerant R-134a is transparent and colourless in both the liquid and vapour state. Since it has a boiling point of - 29.8_C, at atmospheric pressure, it will be a vapour at all normal temperatures and pressures. The vapour is heavier than air, non-flammable, and nonexplosive. The following precautions must be observed when handling

R-134a.

Caution

Wear safety goggles when servicing the refrigeration system.

R-134a evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to freeze anything it contacts. For this reason, extreme care must be taken to prevent any liquid refrigerant from contacting the skin and especially the eyes. Always wear safety goggles when servicing the refrigeration part of the A/C system.

Keep a bottle of sterile mineral oil handy when working on the refrigeration system. Should any liquid refrigerant get into the eyes, use a few drops of mineral oil to wash them out. R-134a is rapidly absorbed by the oil. Next splash the eyes with plenty of cold water. Call your doctor immediately even though irritation has ceased after treatment.

55-4

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

General Information/

Service Specifications/Lubricants

Caution

Do not heat R-134a above 40

_

C

In most instances, moderate heat is required to bring the pressure of the refrigerant in its container above the pressure of the system when charging or adding refrigerant.

A bucket or large pan of hot water not over 40_C is all the heat required for this purpose. Do not heat the refrigerant container with a blow torch or any other means that would raise temperature and pressure above this temperature. Do not weld or steam clean on or near the system components or refrigerant lines.

Caution

Keep R-134a containers upright when charging the system.

SERVICE SPECIFICATIONS

Items

Idle speed r/min

Idle-up speed r/min When load by 4G6

A/C is low

6A1

4D6

When load by 4G6

A/C is high

6A1

4D6

Resistor (for blower motor) W

Air gap (Magnetic clutch) mm

4G6

6A1

4D6

When metering R-134a into the refrigeration system keep the supply tank or cans in an upright position.

If the refrigerant container is on its side or upside down, liquid refrigerant will enter the system and damage the compressor.

Caution

1.

The leak detector for R-134a should be used to check for refrigerant gas leaks.

2.

Do not allow liquid refrigerant to touch bright metal.

Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can severely corrode all metal surfaces.

Standard value

750 ± 50

650 ± 50

800 ± 30

750 ± 50

650 ± 50

850 ± 50

850 ± 50

900 ± 50

850 ± 50

LO: 2.30, ML: 1.10, MH: 0.40

0.40 - 0.65

55200030219

LUBRICANTS

Items

Each connection of refrigerant line

Compressor refrigerant unit lubricant mL

Specified lubricants

SUN PAG 56

SUN PAG 56

Quantity

As required

120

55200040199

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Special Tools/Troubleshooting

SPECIAL TOOLS

Tool Number

MB991367

Name

Special spanner

55-5

55200060133

Use

Removal and installation of armature mounting nut of compressor

MB991386 Pin

TROUBLESHOOTING

TROUBLESHOOTING PROCEDURES

Trouble symptom Problem cause

When the ignition switch is “ON”, the A/C does not operate.

A/C compressor relay is defective

Magnetic clutch is defective

Refrigerant leak or overfilling of refrigerant

Dual pressure switch is defective

A/C switch is defective

Blower switch is defective

Refrigerant temperature switch is defective

Automatic compressor-ECU is defective

When the A/C is operating, temperature inside the passenger compartment doesn’t decrease

(cool air is not emitted).

Engine-ECU is defective

Refrigerant leak

Dual pressure switch is defective

Refrigerant temperature switch is defective

Automatic compressor ECU is defective

Engine-ECU is defective

55200070242

Remedy

Replace the A/C compressor relay

Replace the armature plate, rotor or clutch coil

Replenish the refrigerant, repair the leak or take out some of the refrigerant

Replace the dual pressure switch

Replace the A/C switch

Replace the blower switch

Replace the refrigerant temperature switch

Replace the automatic compressor-ECU

Replace the engine-ECU

Replenish the refrigerant and repair the leak

Replace the dual pressure switch

Replace the refrigerant temperature switch

Replace the automatic compressor-ECU

Replace the engine-ECU -

Reference page

55-17

55-65

55-15

55-28, 29

55-19

55-21

55-65

55-26

-

55-15

55-28, 29

55-65

55-26

55-6

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Troubleshooting

Trouble symptom Problem cause

Blower fan and Blower relay is defective motor doesn’t turn

Blower fan and motor is defective

Blower fan and motor doesn’t stop turning.

Resistor (for blower motor) is defective

Blower switch is defective

Short circuit of the harness between the blower fan and motor and the blower switch

Blower switch is defective

Blower relay is defective

When the A/C is operating condenser fan or radiator fan does not run

Condenser fan motor is defective

Fan control relay is defective

Engine-ECU is defective

Remedy

Replace the blower relay

Replace the blower fan and motor

Replace the resistor

Replace the blower switch

Repair the harness

Reference page

-

55-16

55-23

55-23

55-21

Replace the blower switch

Replace the blower relay

Replace the condenser fan motor

55-21

55-16

55-31

Replace the radiator fan motor -

Replace the fan control relay 55-17

Replace the engine-ECU -

INSPECTION AT THE AUTOMATIC COMPRESSOR-ECU TERMINAL

55201030041

Terminal

No.

1

2

3

4

Check item Checking requirements Normal condition

Input from A/C switch to ECU

Earth

A/C switch: OFF

A/C switch: ON

Output from ECU to A/C compressor A/C compressor relay: OFF relay

A/C compressor relay: ON

Output from ECU to engine-ECU Air thermo sensor detection temperature: 5_C or less

Air thermo sensor detection temperature: 8_C or more

Always

0 V

0V

0 V

Battery voltage

Battery voltage

0 V

Battery voltage

Sight glass

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

55-7

ON-VEHICLE SERVICE

55200840133

SIGHT GLASS REFRIGERANT LEVEL TEST

The sight glass is a refrigerant level indicator. To check the refrigerant level, clean the sight glass and start the vehicle engine. Push the A/C button to operate the compressor, place the blower switch to high and move the temperature control lever to max cool. After operating for a few minutes in this manner, check the sight glass.

1. If the sight glass is clear, the magnetic clutch is engaged, the compressor discharge line is warm and the compressor inlet line is cool; the system has a full charge.

2. If the sight glass is clear, the magnetic clutch is engaged and there is no significant temperature difference between compressor inlet and discharge lines; the system has lost some refrigerant.

3. If the sight glass shows foam or bubbles, the system could be low on charge. The system has to be recharged with refrigerant.

Magnetic clutch connector

MAGNETIC CLUTCH TEST

55200850174

1. Disconnect the connector (1-pin) to the magnetic clutch.

2. Connect battery (+) voltage directly to the connector for the magnetic clutch.

3. If the magnetic clutch is normal, there will be “click”. If the pulley and armature do not make contact (‘click’), there is a malfunction.

RECEIVER DRIER TEST

55200860115

Operate the unit and check the piping temperature by touching the receiver drier outlet and inlet.

If there is a difference in the temperatures, the receiver drier is restricted.

Replace the receiver drier.

55-8

LOW-PRESSURE

SIDE

ON

OFF

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

High/Low pressure side

HIGH-PRESSURE

SIDE

ON

OFF

DUAL PRESSURE SWITCH CHECK

55201040167

1. Remove the dual pressure switch connector and connect the high/low pressure side terminals located on the harness side as shown in the illustration.

2. Install a gauge manifold to the high-pressure side service valve of the refrigerant line. (Refer to Performance Test.)

3. When the high/low pressure sides of the dual pressure switch are at operation pressure (ON) and there is continuity between the respective terminals, then the condition is normal. If there is no continuity, replace the switch.

Items

Low-pressure side kPa

High-pressure side kPa

Switch position

OFF ® ON

221

2,353

ON ® OFF

196

2,942

COMPRESSOR DRIVE BELT ADJUSTMENT

55200100101

Refer to GROUP 11 - On-vehicle Service.

Low-pressure valve

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

High-pressure valve

Gauge manifold

Adapter valve

Charging hose

(yellow)

Charging hose

(blue)

Switch

R-12 connection port

R-134a connection port

Quick joint (for low pressure)

Vacuum pump adaptor

Vacuum pump

Power supply plug

Switch

Low-pressure service valve

A

Sleeve

55-9

CHARGING

55200120176

1. With the handles turned back all the way (valve closed), install the adaptor valve to the low-pressure side of the gauge manifold.

2. Connect the charging hose (blue) to the adaptor valve.

3. Connect the quick joint (for low pressure) to the charging hose (blue).

4. Connect the quick joint (for low pressure) to the low pressure service valve.

NOTE

The low-pressure service valve should be connected to the suction flexible hose.

Caution

(1) Use tools that are suited to R-134a.

(2) To install the quick joint, press section “A” firmly against the service valve until a click is heard.

When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose.

5. Close the high and low-pressure valves of the gauge manifold.

6. Install the vacuum pump adaptor to the vacuum pump.

7. Connect the vacuum pump plug to the vacuum pump adaptor.

8. Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor.

9. Tighten the adaptor valve handle (valve open).

10. Open the low-pressure valve of the gauge manifold.

11. Turn the power switch of the vacuum pump to the ON position.

NOTE

Even if the vacuum pump power switch is turned ON, the vacuum pump will not operate because of the power supply connection in step (7).

55-10

Low-pressure service valve

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump.

Caution

Do not operate the compressor for evacuation.

13. Evacuate to a vacuum reading of 100 kPa or higher (takes approx. 10 minutes).

14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes.

Caution

Do not operate the compressor in the vacuum condition; damage may occur.

15. Carry out a leak test. (Good if the negative pressure does not drop.)

Caution

If the negative pressure drops, increase the tightness of the connections, and then repeat the evacuation procedure from step (12).

Vacuum pump

Adaptor valve

Valve open

Valve close

Charging valve

Service can

16. With the handle turned back all the way (valve open), install the charging valve to the service can.

17. Turn the handle of the adaptor valve back all the way

(valve closed), remove it from the gauge manifold and install the service can.

18. Tighten the handle of the charging valve (valve closed) to puncture the service can.

Service can

(Refrigerant container)

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

Charging valve

Low-pressure service valve

55-11

19. Turn the handle of the charging valve back (valve open) and tighten the handle of the adaptor valve (valve open) to charge the system with refrigerant.

Caution

If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state.

20. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve closed).

21. Check for gas leaks using a leak detector.

If a gas leak is detected, re-tighten the connections, and then repeat the charging procedure from evacuation in step (12).

Caution

The leak detector for R-134a should be used.

22. Start the engine.

23. Operate the A/C and set to the lowest temperature (MAX.

COOL).

24. Fix the engine speed at 1,500 r/min.

25. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant.

Caution

If the service can is inverted, liquid refrigerant may be drawn into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is charged in gas state.

26. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve closed).

27. Tighten the charging valve handle (valve closed).

Remove the quick joint (for low pressure) from the low-pressure service valve.

NOTE

If the service can is not emptied completely, keep the handles of the charging valve and adaptor valve closed for the next charging.

55-12

Valve open

Valve close

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

Charging valve

Adaptor valve

Charging hose (blue)

Service can

(Refrigerant container)

Quick joint (for low pressure)

CORRECTING LOW REFRIGERANT LEVEL IN CASE

THE SERVICE CAN IS USED.

1. Install the charging valve with the handle turned all the way back (valve open) to the service can.

2. Install the adaptor valve with the handle turned all the way back (valve close) to the charging valve.

3. Connect the charging hose (blue) to the adaptor valve.

4. Connect the charging hose (blue) to the quick joint (for low pressure).

5. Tighten the handle of the charging valve (valve close), and pierce the service can.

6. Turn the handle of the adaptor valve to bleed the air.

Service can

(Refrigerant container)

Quick joint

(for low pressure)

7. Install the quick joint (for low pressure) to the low-pressure service valve.

NOTE

The low-pressure service valve should be connected to the suction flexible hose.

Low-pressure service valve

Charging valve

Low-pressure service valve

8. Start the engine.

9. Operate the air conditioner and set at the lowest temperature (MAX. COOL).

10. Fix the engine speed at 1,500 r/min.

11. Tighten the handle of the adaptor valve (valve open), and replenish refrigerant while checking the quantity through the sight glass.

Caution

If the service can is inverted, liquid refrigerant may be draw into the compressor damaging it by liquid compression. Keep the service can upright to ensure that refrigerant is changed in gas state.

12. After replenishing is completed, turn the handle of the adaptor valve all the way back (valve close), and remove the quick joint.

NOTE

When there is remainder of refrigerant in the service can, keep it for next use with the charge value and the valve of the adaptor valve being closed.

Oil

Charging hose (blue)

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

Sleeve

Quick joint

Low-pressure service valve

A

Adaptor valve

55-13

DISCHARGING SYSTEM

1. Run the engine at an engine speed of 1,200 - 1,500 r/min for approximately 5 minutes with the A/C operating to return to the oil.

NOTE

Returning the oil will be more effective if it is done while driving.

2. Stop the engine.

3. Connect the charging hose (blue) to the adaptor valve with its handle turned back all the way (valve closed).

4. Connect the quick joint to the charging hose (blue).

5. Install the quick joint to the low-pressure service valve.

NOTE

The low-pressure service valve should be connected to the suction flexible hose.

Caution

To connect the quick joint, press section “A” firmly against the service valve until a click is heard.

When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose.

6. Place the adaptor valve inside the container and discharge the refrigerant by opening the handle gradually so that oil does not gush out.

NOTE

Any oil remaining in the container should be returned to the A/C system.

REFILLING OF OIL IN THE A/C SYSTEM

Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature.

When a compressor is installed at the factory, it contains

120 mL of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant.

Some of this oil will be trapped and retained in various parts of the system.

When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component.

Compressor oil: SUN PAG 56

Quantity

Condenser: 15 mL

Evaporator: 60 mL

Suction hose: 10 mL

Receiver: 10 mL

55-14

Low-pressure valve

Gauge manifold

Charging hose (red)

Charging hose (blue)

A

Adaptor valve (for low pressure)

Lowpressure service valve

Sleeve

Highpressure service valve

Adaptor valve

(for high pressure)

Thermometer

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

High-pressure valve

PERFORMANCE TEST

55200140189

1. The vehicles to be tested should be in a place that is not in direct sunlight.

2. Close the high and low-pressure valve of the gauge manifold.

3. Connect the charging hose (blue) to the low-pressure valve and connect the charging hose (red) to the high-pressure valve of the gauge manifold.

4. Install the quick joint (for low pressure) to the charging hose (blue), and connect the quick joint (for high pressure) to the charging hose (red).

5. Connect the quick joint (for low pressure) to the low-pressure service valve and connect the quick joint

(for high pressure) to the high-pressure service valve.

NOTE

The high-pressure service valve is on liquid pipe B and the low-pressure service valve is on the suction flexible hose.

Caution

To connect the quick joint, press section “A” firmly against the service valve until a click is heard.

When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose.

6. Start the engine.

7. Set the controls to the A/C as follows:

A/C switch: A/C - ON position

Mode selection: Face position

Temperature control: Max. cooling position

Air selection: Recirculation position

Blower switch: HI (Fast) position

8. Adjust engine speed to 1,000 r/min with A/C clutch engaged.

9. Engine should be warmed up with doors and windows closed.

10. Insert a thermometer in the left center A/C outlet and operate the engine for 20 minutes.

11. Note the discharge air temperature.

NOTE

If the clutch cycles, take the reading before the clutch disengages.

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

55-15

Performance Temperature Chart

Garage ambient temperature _C

Discharge air temperature _C

Compressor high pressure kPa

Compressor low pressure kPa

20

2.5- 4.5

765- 960

40- 135

REFRIGERANT LEAK REPAIR

55200150045

LOST CHARGE

If the system has lost all charge due to a leak:

1. Evacuate the system. (See procedure.)

2. Charge the system with approximately one pound of refrigerant.

3. Check for leaks.

4. Discharge the system.

5. Repair leaks.

6. Replace receiver drier.

Caution

Replacement filter-drier units must be sealed while in storage. The drier used in these units will saturate water quickly upon exposure to the atmosphere.

When installing a drier, have all tools and supplies ready for quick reassembly to avoid keeping the system open any longer than necessary.

7. Evacuate and charge system.

LOW CHARGE

If the system has not lost all of its refrigerant charge; locate and repair all leaks. If it is necessary to increase the system pressure to find the leak

(because of an especially low charge) add refrigerant. If it is possible to repair the leak without discharging the refrigerant system, use the procedure for correcting low refrigerant level.

25

2.5- 4.5

765- 960

40- 135

35

4.0- 6.5

1,325- 1,420

80- 175

40

6.5- 9.0

1,570- 1,765

155- 255

HANDLING TUBING AND FITTINGS

Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the capacity of the entire system. High pressures are produced in the system when it is operating.

Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and moisture can enter the system when it is opened for repair or replacement of lines or components. The following precautions must be observed. The system must be completely discharged before opening any fitting of connection in the refrigeration system. Open fittings with caution even after the system has been discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure to bleed off very slowly.

Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing.

A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of the hose.

Sharper bends will reduce the flow of refrigerant.

The flexible hose lines should be routed so that they are at least 80 mm from the exhaust manifold.

It is good practice to inspect all flexible hose lines at least once a year to make sure they are in good condition and properly routed.

Unified plumbing connections with O-rings, these

O-rings are not reusable.

55-16

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

COMPRESSOR NOISE

55200870033

You must first know the conditions when the noise occurs. These conditions are: weather, vehicle speed, in gear or neutral, engine temperature or any other special conditions.

Noises that develop during A/C operation can often be misleading. For example: what sounds like a failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a loose clutch assembly. Verify accessory drive belt tension (power steering or alternator).

Improper accessory drive belt tension can cause a misleading noise when the compressor is engaged and little or no noise when the compressor is disengaged.

Drive belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension, belts can develop unusual noises that are often mistaken for mechanical problems within the compressor.

ADJUSTMENT

1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on and off several times to clearly identify compressor noise. To duplicate high ambient conditions (high head pressure), restrict air flow through condenser. Install manifold gauge set to make sure discharge pressure doesn’t exceed 2,070 kPa.

2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor drive belt.

Check to assure clutch coil is tight (no rotation or wobble).

3. Check refrigerant hoses for rubbing or interference that can cause unusual noises.

4. Check refrigerant charge. (See “Charging

System”.)

5. Recheck compressor noise as in Step 1.

6. If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1.

7. If noise continues, replace compressor and repeat Step 1.

Blower relay

POWER RELAY CHECK

BLOWER RELAY

Battery voltage Terminal No.

1 3

Power is not supplied

Power is supplied

2

55200880210

5

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

A/C compressor relay

A/C COMPRESSOR RELAY

Battery voltage Terminal No.

1 3

Power is not supplied

Power is supplied

FAN CONTROL RELAY

Refer to GROUP 14 - Radiator.

4

55-17

5

55-18

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - On-vehicle Service

IDLE-UP OPERATION CHECK

55200160208

1. Before inspection and adjustment, set vehicle in the following condition:

D Engine coolant temperature: 80 - 90_C

D Lights, electric cooling fan and accessories: Set to

OFF

D Transmission: Neutral (N or P for vehicles with A/T)

D Steering wheel: Straightforward

2. Check whether or not the idle speed is the standard value.

Standard value:

<4G6> 750

±

50 r/min

<6A1> 650

±

50 r/min

<4D6> 800

±

30 r/min

3. When the A/C is running after turning the A/C switch to ON, and the blower switch to the MH or HI position, check to be sure that the idle speed is at the standard value.

Standard value:

Engine

4G6

6A1

4D6

Idle speed r/min

When load by A/C is low

750 ± 50

650 ± 50

850 ± 50

When load by A/C is high

850 ± 50

900 ± 50

850 ± 50

NOTE

(1) The engine-ECU determine whether the load by A/C is low or high according to the output signal from the automatic compressor-ECU <manual A/C> or the

A/C-ECU <automatic A/C>.

(2) There is no necessity to make an adjustment, because the idle speed is automatically adjusted by the ISC system. If, however, there occurs a deviation from the standard value for some reason, check the ISC system. (Refer to GROUP 13A - On-vehicle Service.)

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Heater Control Assembly, A/C Switch and

Inside/Outside Air Changeover Switch

55-19

HEATER CONTROL ASSEMBLY, A/C SWITCH AND

INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Center Console Panel, Side Cover Removal and

Installation (Refer to GROUP 52A - Instrument Panel.)

55201240017

D Radio, Tape Player Removal and Installation (Refer to GROUP 54.)

6

4

3

5

2

Removal steps

"

B

A 1. Air mix damper cable connection

"

A

A 2. Air outlet changeover damper cable connection

3. Rear window defogger switch

1

Air outlet changeover damper lever

DEF position

Air mix damper lever

4. A/C switch

5. Inside/outside air changeover switch

6. Heater control assembly

INSTALLATION SERVICE POINTS

"

A

A

AIR OUTLET CHANGEOVER DAMPER CABLE

CONNECTION

1. Set the air outlet changeover control knob on the heater control assembly to the DEF position.

2. Set the air outlet changeover damper lever of the heater unit to the DEF position (turn clockwise the damper lever until it stops), and then connect the to cable to the lever.

"

B

A

AIR MIX DAMPER CABLE CONNECTION

1. Set the temperature control knob on the heater control assembly to the MAX HOT position.

2. Set the air mix damper lever of the heater unit to the

MAX HOT position (turn clockwise the damper lever until it stops), and then connect the cable to the lever.

MAX HOT position

55-20

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Heater Control Assembly, A/C Switch and

Inside/Outside Air Changeover Switch

INSPECTION

BLOWER SWITCH CONTINUITY CHECK

Switch position Terminal No.

1 2 3 4 5

OFF

D (LO)

D

(ML)

D

(MH)

D

(HI)

6

55201250010

7 8

FRESH position

RECIRC position

INSIDE/OUTSIDE AIR CHANGEOVER SWITCH

CONTINUITY CHECK

Switch position

RECIRC

Terminal No.

1 ILL 2 3 IND 4 5

FRESH

6

OFF position

ON position

A/C SWITCH CONTINUITY CHECK

Switch position

OFF

ON

Terminal No.

1 ILL 2 IND 4 5 7

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Heater Control Assembly, A/C Switch and

Inside/Outside Air Changeover Switch

55-21

HEATER CONTROL ASSEMBLY

DISASSEMBLY AND REASSEMBLY

55100130077

8

2

7

6

1

5

4

3

A

A

"

A

A

"

Disassembly steps

1. Knob assembly

2. Bulb harness

3. Air outlet changeover damper cable

4. Air mix damper cable

Flat-tipped screwdriver

Claw part

5. Heater control panel

6. Nut

7. Blower switch

8. Control base assembly

DISASSEMBLY SERVICE POINT

A

A

"

AIR OUTLET CHANGEOVER DAMPER

CABLE/AIR MIX DAMPER CABLE REMOVAL

Insert a flat-tipped screwdriver into the control base clip from inner side, and then remove the cable by lifting the claw part of the clip.

55-22

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Heater Unit, Heater Core, and Blower Unit

HEATER UNIT, HEATER CORE, AND BLOWER UNIT

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Under Cover Removal and Installation (Refer to

P.55-33.)

D Instrument Panel removal and Installation (Refer to GROUP 52A.)

55201270016

Caution: SRS

When removing and installing the heater unit from vehicles equipped with SRS, do not let it bump against the SRS-ECU or the components.

1

Vehicles with automatic A/C

3

2

5

2

6

4

A

A

"

Heater unit

Heater unit and heater core removal steps

D Center reinforcement (Refer to

GROUP 52A - Instrument panel.)

D Center duct assembly and foot distribution duct (Refer to P.55-33.)

D Draining and refilling engine coolant

(Refer to GROUP 14 - On-vehicle service.)

1. Heater hose connection

2. Evaporator mounting bolt and nut

3. Heater unit

4. Heater core

Blower unit removal steps

2. Evaporator mounting bolt and nut

5. Clip

6. Blower unit

REMOVAL SERVICE POINT

A

A

"

HEATER UNIT REMOVAL

After sliding the cooling unit towards you slightly, remove the heater unit.

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Resistor, Blower Fan and Motor, and

Inside/Outside Air Changeover Damper Motor

55-23

RESISTOR, BLOWER FAN AND MOTOR, AND INSIDE/OUTSIDE

AIR CHANGEOVER DAMPER MOTOR

55100500014

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

Glove Box Removal and Installation (Refer to GROUP

52A - Instrument Panel.)

3

Resistor removal steps

D Under cover (Refer to P.55-33.)

1. Resistor

Blower fan and motor removal steps

D Under cover (Refer to P.55-33.)

2. Blower fan and motor

1

2

Inside/outside air changeover damper motor removal

3. Inside/outside air changeover damper motor

INSPECTION

55100510017

BLOWER FAN AND MOTOR CHECK

When battery voltage is applied between the terminals, check that the motor operates. Also, check that there is no abnormal noise.

55-24

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Resistor, Blower Fan and Motor, and

Inside/Outside Air Changeover Damper Motor

RESISTOR CHECK

Use a circuit tester to measure the resistance between the terminals as indicated below. Check that the measured value is at the standard value.

Standard value:

Measurement terminal Standard value W

Between terminals 3 and 2 (LO) 2.30

Between terminals 3 and 4 (ML) 1.10

Between terminals 3 and 1 (MH) 0.40

INSIDE/OUTSIDE CHANGEOVER DAMPER MOTOR

CHECK

Lever operation Battery connection terminal

1 2

Moves to the outside air position

Moves to the inside air position

Caution

Cut off the battery voltage when the damper is in the inside air position or outside air position.

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Evaporator

EVAPORATOR

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Discharging and Charging of Refrigerant (Refer to

P.55-9.)

D Glove Box, Side Cover and Glove Box Frame Removal and Installation (Refer to GROUP 52A - Instrument

Panel.)

55-25

55200360165

D Under Cover Removal and Installation (Refer to

P.55-33.)

Piping connection

1

3

Compressor oil: SUN PAG 56

3

2

4

5

6

A

A

"

A

A

"

Removal steps

1. Suction hose connection

2. Discharge pipe connection

3. O-ring

4. Drain hose

5. Plate

"

A

A 6. Evaporator

REMOVAL SERVICE POINT

A

A

"

SUCTION HOSE, DISCHARGE PIPE

DISCONNECTION

Plug the disconnected hose and the evaporator nipple not to let foreign matter get into them.

Caution

Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

INSTALLATION SERVICE POINT

"

A

A

EVAPORATOR INSTALLATION

When replacing the evaporator, refill it with a specified amount of compressor oil and install it (to the vehicle).

Compressor oil: SUN PAG 56

Quantity: 60 mL

55-26

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Evaporator

DISASSEMBLY AND REASSEMBLY

3

2

7

6

1

8

4

7

Compressor oil: SUN PAG 56

55200380154

7

6

A

A

"

Disassembly steps

1. Clip

2. Evaporator case (upper)

3. Automatic compressor-ECU

<Manual A/C>

4. Air thermo sensor <Automatic A/C>

5

5. Evaporator case (lower)

6. Expansion valve

7. O-ring

8. Evaporator

DISASSEMBLY SERVICE POINT

A

A

"

CLIP REMOVAL

Remove the clips with a flat-tipped screwdriver covered with a shop towel to prevent damage to case surfaces.

Clip

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER>

-

Evaporator/Air Purifier Assembly/

Compressor and Tension Pulley

Resistance kW

20

15

10

5

0

-10 0 10 20 30

Temperature _C

40

55-27

INSPECTION

55200390058

AIR THERMO SENSOR

When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph.

NOTE

The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.

AIR PURIFIER ASSEMBLY

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Glove Box, Side Cover and Glove Box Frame Removal and Installation (Refer to GROUP 52A - Instrument

Panel.)

55500100032

D Under Cover Removal and Installation (Refer to

P.55-33.)

Air purifier assembly

COMPRESSOR AND TENSION PULLEY

Refer to P.55-61.

55200410266

55-28

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line

REFRIGERANT LINE

REMOVAL AND INSTALLATION

<L.H. DRIVE VEHICLES>

Pre-removal and Post-installation Operation

D Discharging and Changing of Refrigerant (Refer to

P.55-9.)

D Reserve Tank Removal and Installation (Refer to

GROUP 14 - Radiator.)

55200640269

D Oil Reservoir Removal and Installation (Refer to

GROUP 37A - Power Steering Hoses.)

Piping connection

4

2

10

Compressor oil: SUN PAG 56

10

6

10

10

5

7

8

9

10

3

2

10

1

10

A

A

"

A

A

"

A

A

"

A

A

"

Removal steps

1. Suction pipe

2. Clamp and bracket

3. Suction flexible hose

4. Liquid pipe A

5. Liquid pipe B

6. Dual pressure switch

7. Receiver bracket assembly

A

A

" "

A

A 8. Receiver assembly

9. Discharge flexible hose

A

A

"

10. O-ring

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line

<R.H. DRIVE VEHICLES>

Pre-removal and Post-installation Operation

D Discharging and Changing of Refrigerant (Refer to

P.55-9.)

D Canister Removal and Installation (Refer to GROUP

17.)

55-29

D Reserve Tank Removal and Installation (Refer to

GROUP 14 - Radiator.)

D Oil Reservoir Removal and Installation (Refer to

GROUP 37A - Power Steering Hoses.)

Piping connection

11

Compressor oil:

SUN PAG 56

5

11

7

9

11

6

11

8

10

11

3

4

11

1

2

11

A

A

"

A

A

"

A

A

"

A

A

"

Removal steps

1. Clamp

2. Suction pipe

3. Clamp and bracket

4. Suction flexible hose

5. Liquid pipe B

6. Liquid pipe A

A

A

"

7. Dual pressure switch

8. Receiver bracket assembly

A

A

" "

A

A 9. Receiver assembly

10. Discharge flexible hose

11. O-ring

55-30

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Refrigerant Line

REMOVAL SERVICE POINT

A

A

"

HOSE/PIPE/RECEIVER ASSEMBLY

DISCONNECTION

Plug the disconnected hose, the receiver, the evaporator and the compressor nipple not to let foreign matter get into them.

Caution

Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

INSTALLATION SERVICE POINT

"

A

A

SUCTION HOSE/RECEIVER ASSEMBLY

INSTALLATION

When replacing the suction hose or receiver assembly, refill them with a specified amount of compressor oil, and then install them.

Compressor oil: SUN PAG 56

Quantity:

Suction hose: 10 mL

Receiver assembly: 10 mL

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor

CONDENSER AND CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION

55-31

55200670244

Piping connection

5

O-ring

Compressor oil: SUN PAG 56

6

2

1

4

3

Condenser fan motor removal steps

1. Condenser fan motor and shroud assembly

2. Condenser fan

3. Shroud

4. Condenser fan motor

A

A

"

Condenser removal steps

D Discharging and charging of refrigerant (Refer to P.55-9.)

D Air cleaner

D Engine coolant draining and supplying

(Refer to GROUP 14 - On-vehicle service.)

D Radiator (Refer to GROUP 14.)

5. Discharge flexible hose and liquid pipe A connection

"

A

A 6. Condenser

REMOVAL SERVICE POINT

A

A

"

DISCHARGE FLEXIBLE HOSE AND LIQUID PIPE

A CONNECTION

Plug the disconnected pipe, hose and the condenser nipple not to let foreign matter get into them.

Caution

Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

55-32

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Condenser and Condenser Fan Motor

INSTALLATION SERVICE POINT

"

A

A

CONDENSER INSTALLATION

When replacing the condenser, refill it with a specified amount of compressor oil and install it. (to the vehicle).

Compressor oil: SUN PAG 56

Quantity: 15 mL

INSPECTION

55200680148

CONDENSER FAN MOTOR CHECK

Check to be sure that the condenser fan motor operates when battery voltage is applied to terminal 1 and terminal

2 earthed.

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Ventilators

VENTILATORS

REMOVAL AND INSTALLATION

<Automatic A/C>

3

2

5

55-33

55300160119

2

4

9

6

1

7

8

Under cover removal

1. Under cover

Defroster nozzle and distribution duct removal steps

D Floor console assembly (Refer to

GROUP 52A.)

D Instrument panel (Refer to GROUP

52A.)

2. Side defroster duct

3. Defroster nozzle assembly

4. Distribution duct assembly

5. Defroster garnish and photo sensor

6. Center duct assembly

Rear heater duct and foot distribution duct removal steps

D Front seat (Refer to GROUP 52A.)

D Floor console assembly (Refer to

GROUP 52A.)

D Instrument panel and center reinforcement (Refer to GROUP 52A.)

7. Rear heater duct (R.H.)

8. Rear heater duct (L.H.)

9. Foot distribution duct

NOTE

For the center air outlet assembly and the side air outlet assembly, refer to GROUP 52A - Instrument panel.

55-34

HEATER, AIR CONDITIONER AND VEN-

TILATION <MANUAL AIR CONDITIONER> - Ventilators

<Wagon>

<Sedan>

10

Rear ventilation duct assembly removal steps

D Rear bumper (Refer to GROUP 51.)

10. Rear ventilation duct assembly

NOTE

For the front deck garnish, refer to GROUP 51 - Windshield wiper and washer.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

General Information/

Service Specifications

55-35

AUTOMATIC AIR CONDITIONER

GENERAL INFORMATION

The heater system uses a two-way-flow full-air-mix system that features high performance and low operating noise, and includes an independent face-directed air flow function.

An air purifier which carries out fine A/C control has been included.

Items

Heater unit

Heater control assembly

Type

Compressor Model

Dual pressure switch High-pressure switch kPa

Low-pressure switch

Refrigerant and quantity g

55400010080

The A/C system is basically the same as the manual air conditioner in which a new refrigerant system has been adopted. However, an A/C control panel with a reduced number of buttons and more compact arrangement of necessary functions owing to more functions being assigned to each button has been adopted.

Specifications

Two-way-flow full-air-mix system

Push button type

Scroll type <MSC 90>

ON ® OFF: 2,942, OFF ® ON: 2,353

ON ® OFF: 196, OFF ® ON: 221

R-134a (HFC-134a), Approx. 670 - 710

SERVICE SPECIFICATIONS

Items

Idle speed r/min

Idle-up speed r/min

4G6

6A1

4D6

When load by A/C is low

4G6

6A1

4D6

When load by A/C is high

4G6

6A1

4D6

Air mix damper motor potenMAX. HOT position tiometer resistance kW

MAX. COOL position

Outlet air changeover damp-

DEF position er motor potentiometer resistance kW FACE position

Air gap (Magnetic clutch) mm

Standard value

750 ± 50

650 ± 50

800 ± 30

750 ± 50

650 ± 50

850 ± 50

850 ± 50

900 ± 50

850 ± 50

Approx. 4.8

Approx. 0.2

Approx. 4.8

Approx. 0.2

0.40 - 0.65

55400030086

55-36

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Lubricants/Special Tools/

Troubleshooting

LUBRICANTS

Items

Each connection of refrigerant line

Specified lubricants

SUN PAG 56

Compressor refrigerant unit lubricant mL SUN PAG 56

SPECIAL TOOLS

Tool Number

MB991502

Name

MUT-II sub-assembly

Quantity

As required

120

55400040072

Use

Inspection of automatic air conditioner

55400060061

MB991529 Diagnosis code check harness

Inspection of automatic air conditioner using a voltmeter

NOTE

Other special tools are the same as for the manual A/C.

TROUBLESHOOTING

55400470055

STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING

Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

DIAGNOSIS FUNCTION

55400480072

DIAGNOSIS CODES CHECK

Connect the MUT-II to the diagnosis connector (16-pin) under the instrument under cover, then check diagnosis codes.

(Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.)

ERASING DIAGNOSIS CODES

Refer to GROUP 00 - How to Use Troubleshooting/Inspection Service Points.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

INSPECTION CHART FOR DIAGNOSIS CODES

Code No.

Diagnosis item

22

31

32

41

42

11

12

13

14

15

16

21

Inside air temperature sensor system (open circuit)

Inside air temperature sensor system (short circuit)

Outside air temperature sensor system (open circuit)

Outside air temperature sensor system (short circuit)

Heater water temperature sensor system (open circuit)

Heater water temperature sensor system (short circuit)

Air thermo sensor system (open circuit)

Air thermo sensor system (short circuit)

Potentiometer system of air mix damper motor assembly

Potentiometer system of air outlet changeover damper motor assembly

Drive system of air mix damper motor assembly

Drive system of air outlet changeover damper motor assembly

INSPECTION PROCEDURES FOR DIAGNOSIS CODES

Code No.11 or 12 Inside air temperature sensor system

This diagnosis code is output if the inside air temperature sensor inside the

A/C-ECU is defective.

Probable cause

D Malfunction of the A/C-ECU

Replace the A/C-ECU.

55-37

55400490051

55-40

55-41

55-42

55-43

55-43

Reference page

55-37

55-37

55-38

55-38

55-39

55-39

55-40

55-38

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Code No.13 Outside air temperature sensor system (open circuit)

This diagnosis code is output if there is a defective connector connection, or if there is an open circuit in the harness.

Probable cause

D Malfunction of connector

D Malfunction of harness

D Malfunction of the outside air temperature sensor

D Malfunction of the A/C-ECU

Outside air temperature sensor check (Refer to P.55-68.)

OK

Measure at the outside air temperature sensor connector A-21.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (1) and body earth

OK:

5 V

NG

NG

OK

Replace

Check the following connectors:

C-05, C-64 <L.H. drive vehicles>, C-116 <L.H. drive vehicles>,

C-99 <R.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the outside air temperature sensor and the A/C-ECU.

OK

NG

Repair

Replace the A/C-ECU.

NG

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (7) and body earth

OK:

2.3 - 2.9 V

OK

Check the following connectors:

C-05, C-116 <L.H. drive vehicles>, C-99 <R.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the outside air temperature sensor and the A/C-ECU, and repair if necessary.

NG

Check the following connector:

C-05

OK

Check the trouble symptom.

NG

Repair

Replace the A/C-ECU.

Code No.14 Outside air temperature sensor system (short circuit)

This diagnosis code is output if there is a short circuit in the outside air temperature sensor input circuit.

Probable cause

D Malfunction of harness

D Malfunction of connector

D Malfunction of the outside air temperature sensor

D Malfunction of the A/C-ECU

NG

Outside air temperature sensor check (Refer to P.55-68.)

OK

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (7) and body earth

OK:

2.3 - 2.9 V

OK

Replace the A/C-ECU.

NG

Replace

Check the harness between the outside air temperature sensor and the A/C-ECU, and repair if necessary.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-39

Code No.15 Heater water temperature sensor system

(open circuit)

This diagnosis code is output if there is a defective connector connection, or if there is an open circuit in the harness.

Probable cause

D Malfunction of connector

D Malfunction of harness

D Malfunction of the heater water temperature sensor

D Malfunction of the A/C-ECU

Heater water temperature sensor check (Refer to P.55-70.)

OK

Measure at the heater water temperature sensor connector C-70.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (1) and body earth

OK:

5 V

OK

NG

NG

Replace

Check the following connectors:

C-05, C-64 <L.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the heater water temperature sensor and the A/C-ECU.

OK NG

Repair

Replace the A/C-ECU.

NG

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (4) and body earth

OK:

2.3 - 2.9 V

OK

Check the following connector:

C-70

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the heater water temperature sensor and the A/C-ECU, and repair if necessary.

NG

Check the following connector:

C-05

OK

Check the trouble symptom.

NG

Repair

Replace the A/C-ECU.

Code No.16 Heater water temperature sensor system

(short circuit)

This diagnosis code is output if there is a short circuit in the heater water temperature sensor input circuit.

Probable cause

D Malfunction of harness

D Malfunction of connector

D Malfunction of the heater water temperature sensor

D Malfunction of the A/C-ECU

NG

Heater water temperature sensor check (Refer to P.55-70.)

OK

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (4) and body earth

OK:

2.3 - 2.9 V

OK

Replace the A/C-ECU.

NG

Replace

Check the harness between the heater water temperature sensor and the A/C-ECU, and repair if necessary.

55-40

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Code No.21 Air thermo sensor system (open circuit)

This diagnosis code is output if there is a defective connector connection, or if there is an open circuit in the harness.

Probable cause

D Malfunction of connector

D Malfunction of harness

D Malfunction of the air thermo sensor

D Malfunction of the A/C-ECU

Air thermo sensor check (Refer to P.55-26.)

OK

Measure at the air thermo sensor connector C-73.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (2) and body earth

OK:

5 V

OK

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (8) and body earth

OK:

2.3 - 2.9 V

OK

NG

NG

NG

Replace

Check the following connectors:

C-05, C-64 <L.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the air thermo sensor and the A/C-ECU.

OK NG

Repair

Replace the A/C-ECU.

Check the following connector:

C-73

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the air thermo sensor and the A/C-ECU, and repair if necessary.

Check the following connector:

C-05

OK

Check the trouble symptom.

NG

NG

Code No.22 Air thermo sensor system (short circuit)

This diagnosis code is output if there is a short circuit in the air thermo sensor input circuit.

Repair

Replace the A/C-ECU.

Probable cause

D Malfunction of harness

D Malfunction of connector

D Malfunction of the air thermo sensor

D Malfunction of the A/C-ECU

Air thermo sensor check (Refer to P.55-26.)

OK

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Voltage between terminal (8) and body earth

OK:

2.3 - 2.9 V

OK

Replace the A/C-ECU.

NG

NG

Replace

Check the harness between the air thermo sensor and the A/C-ECU, and repair if necessary.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-41

Code No.31 Potentiometer system of air mix damper motor assembly

This diagnosis code is output if there is an open or short circuit in the potentiometer input circuit, or if there is an open circuit in the power circuit or earth circuit.

Probable cause

D Malfunction of the air mix damper motor assembly

D Malfunction of connector

D Malfunction of harness

D Malfunction of the A/C-ECU

Air mix damper motor potentiometer check (Refer to P.55-59.)

OK

Measure at the air mix damper motor potentiometer connector C-79.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (6) and body earth

OK:

5 V

OK

NG

NG

Replace

Check the following connectors:

C-05, C-64 <L.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the air mix damper motor potentiometer and the A/C-ECU.

OK NG

Repair

Replace the A/C-ECU.

NG

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Air mix damper position: MAX.HOT

D Voltage between terminal (5) and body earth

OK:

4.7 - 5.0 V

OK

Check the following connector:

C-79

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the air mix damper motor potentiometer and the A/C-ECU, and repair if necessary.

NG

Check the following connector:

C-05

OK

Check the trouble symptom.

NG

Repair

Replace the A/C-ECU.

55-42

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Code No.32 Potentiometer system of air outlet changeover damper motor assembly

This diagnosis code is output if there is an open or short circuit in the potentiometer input circuit, or if there is an open circuit in the power circuit or earth circuit.

Probable cause

D Malfunction of the air outlet changeover damper motor assembly

D Malfunction of connector

D Malfunction of the A/C-ECU

D Malfunction of harness

Air outlet changeover damper motor potentiometer check (Refer to P.55-60.)

OK

Measure at the air outlet changeover damper motor potentiometer connector C-17.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (2) and body earth

OK:

5 V

OK

NG

NG

Replace

Check the following connectors:

C-05, C-64 <L.H. drive vehicles>

OK NG

Repair

Check the trouble symptom.

NG

Check the harness between the air outlet changeover damper motor potentiometer and the A/C-ECU.

OK

NG

Repair

Replace the A/C-ECU.

NG

Measure at the A/C-ECU connector C-05.

D Connect the connector.

D Air outlet changeover damper position: DEF

D Voltage between terminal (6) and body earth

OK:

4.8 - 5.2 V

OK

Check the following connector:

C-17

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the air outlet changeover damper motor potentiometer and the A/C-ECU, and repair if necessary.

NG

Check the following connector:

C-05

OK

Check the trouble symptom.

NG

Repair

Replace the A/C-ECU.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-43

Code No.41 Drive system of air mix damper motor assembly

This diagnosis code is output if the motor drive circuit is defective.

Probable cause

D Malfunction of the air mix damper motor assembly

D Malfunction of connector

D Malfunction of harness

D Malfunction of the A/C-ECU

NG

Air mix damper motor check (Refer to P.55-59.)

OK

Check the following connectors:

C-07, C-79

OK

Check the trouble symptom.

NG

NG

Replace

Repair

Check the harness between the air mix damper motor and the

A/C-ECU.

OK

NG

Repair

Replace the A/C-ECU.

Code No.42 Drive system of air outlet changeover damper motor assembly

This diagnosis code is output if the motor drive circuit is defective.

Probable cause

D Malfunction of the air outlet changeover damper motor assembly

D Malfunction of connector

D Malfunction of harness

D Malfunction of the A/C-ECU

Air outlet changeover damper motor check (Refer to P.55-60.)

OK

Check the following connectors:

C-17, C-07

OK

Check the trouble symptom.

NG

NG

NG

Replace

Repair

Check the harness between the air outlet changeover damper motor and the A/C-ECU.

OK

NG

Repair

Replace the A/C-ECU.

55-44

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

INSPECTION CHART FOR TROUBLE SYMPTOMS

Trouble symptom

Communication with the MUT-II is not possible.

Air conditioner does not operate.

A/C graphic display on control panel is blank.

Temperature cannot be set.

A/C outlet air temperature does not increase.

A/C outlet air temperature does not decrease.

Blower does not operate.

Blower air amount cannot be changed.

Air outlet port cannot be changed.

Inside/outside air changeover is not possible.

Defroster function does not operate.

Rear defogger does not operate.

A/C-ECU power supply circuit check

A/C compressor control circuit check

Radiator fan does not operate.

Condenser fan does not operate.

11

12

13

14

15

16

7

8

9

10

4

5

6

2

3

Inspection procedure No.

1

55400500068

Reference page

55-45

55-46

55-47

55-47

55-47

55-47

55-48

55-49

55-49

55-50

55-51

55-51

55-52

55-53

Refer to GROUP

14 Troubleshooting.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS

Inspection procedure 1

Communication with the MUT-II is not possible.

If communication with all other systems is not possible, there is a high possibility that there is a malfunction of the diagnosis line. If communication with only the

A/C is not possible, the cause is probably a malfunction of the diagnosis line or of the A/C-ECU power supply system (earth).

Probable cause

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Is communication between MUT-II and other system is possible?

YES

NO

OK

Measure at the diagnosis connector

C-20.

D Voltage between terminal (11) and body earth

OK:

Indication fluctuates between 0 V and 12 V.

NG

Measure at the A/C-ECU connector

C-05.

D Connect the connector.

D Voltage between terminal (17) and body earth

OK:

Indication fluctuates between 0 V and 12 V.

OK

NG

Check the MUT-II diagnosis line, and repair if necessary.

Measure at the A/C-ECU connector

C-05.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (18) and body earth

OK:

Battery voltage - 2 V

OK

NG

Check the following connector:

C-05

OK NG

Repair

Check the trouble symptom.

NG

Replace the A/C-ECU.

55-45

Check the following connector:

C-05

OK NG

Repair

Check the trouble symptom.

NG

Check the harness between the diagnosis connector and the A/C-ECU, and repair if necessary.

Check the harness between the diagnosis connector and the A/C-ECU.

NG

NG

NG

Check the following connectors:

C-05, C-20

OK

Check the trouble symptom.

NG

Measure at the A/C-ECU connector

C-07.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (28) and body earth

OK:

Battery voltage

OK

NG

Measure at the A/C-ECU connector

C-07.

D Disconnect the connector, and measure at the harness side connector.

D Continuity between terminales

(27), (35) and body earth

OK:

Continuity

OK

Replace the A/C-ECU.

NG

Repair

Repair

Check the following connectors:

C-132, C-63 <L.H. drive vehicles>, C-61

<R.H. drive vehicles>

OK

Check the trouble symptom.

NG

NG

Check the following connectors:

C-07, C-62 <L.H. drive vehicles>

OK

Check the trouble symptom.

NG

NG

Repair

Check the harness between the junction block and the A/C-ECU, and repair if necessary.

Repair

Check the harness between the

A/C-ECU and the body earth, and repair if necessary.

55-46

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 2

Air conditioner does not operate.

If the A/C does not operate when the A/C switch is on and the temperature setting is at 17_C, the cause is probably insufficient refrigerant, or a malfunction of the blower or of the magnet clutch power supply.

Probable cause

D Malfunction of blower

D Insufficient refrigerant

D Malfunction of magnetic clutch

D Malfunction of air thermo sensor

D Malfunction of A/C compressor relay

D Malfunction of refrigerant temperature switch

D Malfunction of dual pressure switch

D Malfunction of connector or harness

D Malfunction of engine-ECU

D Malfunction of A/C-ECU

Does the blower operate?

YES

A/C system refrigerant pressure check (Refer to P.55-14.)

OK

NO

NG

MUT-II DIAGNOSIS CODE

Is any of the codes 11, 21 and 22 output?

NO

D Magnetic clutch check (Refer to P.55-7.)

D A/C compressor relay check (Refer to P.55-17.)

D Refrigerant temperature switch check (Refer to P.55-65.)

D Dual pressure switch check (Refer to P.55-8.)

OK

Measure at the A/C compressor relay connector B-28X.

D Disconnect the connector, and measure at the harness side connector.

(1) Continuity between terminal (4) and body earth

OK:

Continuity

(2) Voltage between terminal (5) and body earth

OK:

Battery voltage

(1) NG

YES

NG

OK

(2) NG

Check the following connectors:

B-28X, B-30, B-75

OK

Check the trouble symptom.

NG

Check the harness between the magnetic clutch and the A/C compressor relay, and repair if necessary.

NG

Inspection procedure 7 (Refer to P.55-48.)

Refill the specified amount of refrigerant. (Refer to P.55-9.)

INSPECTION CHART FOR DIAGNOSIS CODES (Refer to

P.55-37.)

Replace

Inspection procedure 14 (Refer to P.55-53.)

Check the following connector:

B-28X

OK NG

Repair

Repair

Check the trouble symptom.

NG

Check the harness between the fusible link and the A/C compressor relay, and repair if necessary.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 3

A/C graphic display on control panel is blank.

The cause is probably a malfunction of the A/C-ECU power supply system

(earth).

NO

Does the A/C operate?

YES

Replace the A/C-ECU.

Probable cause

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Inspection procedure 13 (Refer to P.55-52.)

Inspection procedure 4

Temperature cannot be set.

The cause is probably a malfunction of the temperature setting signal input system or output system.

Probable cause

D Malfunction of connector or harness

D Malfunction of A/C-ECU

55-47

Inspection procedure 13 (Refer to P.55-52.)

Inspection procedure 5

A/C outlet air temperature does not increase.

If the outlet air temperature does not increase when the temperature setting is increased, the cause is probably a sensor malfunction or a problem with operation of the air mix damper. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.

Probable cause

D Malfunction of air mix damper motor potentiometer

D Malfunction of air mix damper motor

D Malfunction of air mix damper

D Malfunction of connector or harness

D Malfunction of thermostat

D Malfunction of A/C-ECU

MUT-II DIAGNOSIS CODE

Is any of the codes 11, 12, 31 and 41 output?

NO

Thermostat check (Refer to GROUP 14 - On-vehicle Service.)

OK

Replace the A/C-ECU.

YES

NG

INSPECTION CHART FOR DIAGNOSIS CODES (Refer to

P.55-37.)

Replace

Inspection procedure 6

A/C outlet air temperature does not decrease.

If the outlet air temperature does not decrease when the temperature setting is decreased, the cause is probably a problem in A/C system operation due to a sensor error, or a problem with operation of the air mix damper. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.

Probable cause

D Malfunction of outside air temperature sensor

D Malfunction of air mix damper motor potentiometer

D Malfunction of air mix damper motor

D Malfunction of air thermo sensor

D Malfunction of connector or harness

D Malfunction of air mix damper

D Malfunction of A/C-ECU

Does the A/C operate?

YES

MUT-II DIAGNOSIS CODE

Is any of the codes 11, 12, 13, 14, 21, 22, 31 and 41 output?

NO

Replace the A/C-ECU.

NO

YES

Inspection procedure 2 (Refer to P.55-46.)

INSPECTION CHART FOR DIAGNOSIS CODES (Refer to

P.55-37.)

55-48

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 7

Blower does not operate.

If no air comes out of the blower even though the blower switch is on, the cause is probably a malfunction of the blower motor relay circuit.

Probable cause

D Malfunction of blower motor relay

D Malfunction of blower motor

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Can an operating sound be heard when the blower speed changeover switch is operated?

YES

NO

NG

D Blower relay check (Refer to P.55-16.)

D Blower motor check (Refer to P.55-23.)

OK

Measure at the blower relay connector C-140.

D Disconnect the connector, and measure at the harness side connector.

(1) Continuity between terminal (1) and body earth

OK:

Continuity

(2) Voltage between terminal (3) and body earth (Ignition switch: ON)

OK:

Battery voltage

(3) Voltage between terminal (2) and body earth

OK:

Battery voltage

OK

(1) NG

(2) NG

(3) NG

NG

Measure at the blower motor connector C-09.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (1) and body earth (Ignition switch: ON)

OK:

Battery voltage

OK

Inspection procedure 13 (Refer to P.55-52.)

Replace

Check the harness between the blower relay and the body earth, and repair if necessary.

Check the harness between the blower relay and the ignition switch, and repair if necessary.

Check the harness between the blower relay and the fusible link

No.1, and repair if necessary.

Check the following connector:

C-131

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the blower relay and the blower motor, and repair if necessary.

NG

Check the following connector:

C-09

OK

Check the trouble symptom.

NG

Repair

Check the harness between the blower motor and the A/C-ECU, and repair if necessary.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-49

Inspection procedure 8

Blower air amount cannot be changed.

If the blower does not operate in any mode other than HI setting, the cause is probably a malfunction of the power transistor system.

Probable cause

D Malfunction of power transistor

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Measure at the power transistor connector C-77.

D Blower switch position: LO

D Connect the connector.

(1) Continuity between terminal (1) and body earth

OK:

Continuity

(2) Voltage between terminal (3) and body earth (Ignition switch: ON)

OK:

Battery voltage - 2 V

(3) Voltage between terminal (4) and body earth (Ignition switch: ON)

OK:

Approx. 1.3 V

OK

Check the following connector:

C-77

OK

Check the trouble symptom.

Replace the power transistor.

NG

NG

Repair

(1) NG

(2) NG

(3) NG

NG

Measure at the A/C-ECU connector C-05.

D Blower switch position: LO

D Connect the connector.

(1) Voltage between terminal (1) and body earth (Ignition switch: ON)

OK:

Approx. 7 V

(2) Voltage between terminal (2) and body earth (Ignition switch: ON)

OK:

Approx. 1.3 V

OK

Check the harness between the power transistor and the A/C-ECU.

OK

NG

Replace the power transistor.

Check the harness between the power transistor and the body earth, and repair if necessary.

Check the harness between the power transistor and the blower motor, and repair if necessary.

Check the following connector:

C-05

OK

Check the trouble symptom.

Replace the A/C-ECU.

Repair

Inspection procedure 9

Air outlet port cannot be changed.

The cause is probably a malfunction of the air outlet port changeover signal input system or output system. The MUT-II can be used to check the diagnosis codes in order to check the cause of the problem for each separate system.

Probable cause

NG

NG

Repair

D Malfunction of air outlet changeover damper motor potentiometer

D Malfunction of air outlet changeover damper motor

D Malfunction of air outlet changeover damper

D Malfunction of connector or harness

D Malfunction of A/C-ECU

NO

Can an operating sound be heard when the air outlet port changeover switch is operated?

YES

MUT-II DIAGNOSIS CODE

Is either code 32 or code 42 output?

NO

Air outlet changeover damper check

OK

Replace the A/C-ECU.

YES

NG

Inspection procedure 13 (Refer to P.55-52.)

INSPECTION CHART FOR DIAGNOSIS CODES (Refer to

P.55-37.)

Repair

55-50

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 10

Inside/outside air changeover is not possible.

If inside/outside air changeover is not possible even when the inside/outside air changeover switch is on, the cause is probably a malfunction of the inside/outside air changeover damper motor.

Probable cause

D Malfunction of inside/outside air changeover damper motor

D Malfunction of inside/outside air changeover damper

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Can an operating sound be heard when the inside/outside air changeover switch is operated?

YES

NO

NG

Inside/outside air changeover damper motor check (Refer to

P.55-24.)

OK

NG

Measure at the inside/outside air changeover damper motor connector C-78.

D Disconnect the connector, and measure at the harness side connector.

D Outside air select button: ON

D Voltage between terminal (1) and body earth

OK:

10 V

D Inside air select button: ON

D Voltage between terminal (2) and body earth

OK:

10 V

OK

NG

Check the following connector:

C-78

OK

Check the trouble symptom.

NG

Inside/outside air changeover damper check

OK

Replace the A/C-ECU.

NG

Inspection procedure 13 (Refer to P.55-52.)

Replace

Check the following connector:

C-07

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the inside/outside air changeover damper motor and the A/C-ECU, and repair if necessary.

Repair

OK

NG

Repair

Replace the A/C-ECU.

Repair

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-51

Inspection procedure 11

Defroster function does not operate.

If the defroster function does not operate when the defroster switch is turned on, the cause is probably a malfunction of the A/C or of the air outlet port changeover circuit.

Probable cause

D Malfunction of air conditioner drive system

D Malfunction of air outlet changeover damper drive system

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Can an operating sound be heard when the defroster switch is operated?

YES

NO

NO

Does the A/C operate?

YES

Can the air outlet port be changed over?

YES

NO

NG

Air outlet changeover damper (for defroster) check

OK

Replace the A/C-ECU.

Inspection procedure 12

Rear defogger does not operate.

If the rear defogger does not operate when the rear defogger switch is turned on (timer operates for 20 minutes), the cause is probably a malfunction of the

A/C-ECU power supply system (earth).

Inspection procedure 13 (Refer to P.55-52.)

Inspection procedure 2 (Refer to P.55-46.)

Inspection procedure 9 (Refer to P.55-49.)

Repair

Probable cause

D Malfunction of connector or harness

D Malfunction of A/C-ECU

Can an operating sound be heard when the rear defogger switch is operated?

YES

NO

Replace the A/C-ECU.

Inspection procedure 13 (Refer to P.55-52.)

55-52

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 13

A/C-ECU power supply circuit check

NG

Measure at the A/C-ECU connector C-05.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (3) and body earth

OK:

Battery voltage

OK

Check the following connectors:

C-63, C-132, C-141 <L.H. drive vehicles>, C-62, C-14 <R.H. drive vehicles>

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the A/C-ECU and the fusible link No.2, and repair if necessary.

NG

Measure at the A/C-ECU connector C-07.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (28) and body earth (Ignition switch: ON)

OK:

Battery voltage

OK

Check the following connectors:

C-63 <L.H. drive vehicles>, C-61 <R.H. drive vehicles>, C-132

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the A/C-ECU and the junction block, and repair if necessary.

NG

Measure at the A/C-ECU connector C-07.

D Disconnect the connector, and measure at the harness side connector.

D Continuity between terminal (27) and body earth

OK:

Continuity

D Continuity between terminal (35) and body earth

OK:

Continuity

OK

Check the following connector:

C-07

OK

Check the trouble symptom.

NG

NG

Check the harness between the A/C-ECU and the body earth, and repair if necessary.

Repair

Replace the A/C-ECU.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

Inspection procedure 14

A/C compressor control circuit check

NG

Measure at the A/C-ECU connector C-07.

D Blower switch and A/C switch: ON

D Setting temperature: 17_C

D Connect the connector.

D Voltage between terminal (34) and body earth (Ignition switch: ON)

OK:

Battery voltage

OK

Check the following connector:

C-07

OK

Check the trouble symptom.

NG

Replace the A/C-ECU.

NG

Measure at the A/C compressor relay connector B-28X.

D Blower switch and A/C switch: ON

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (3) and body earth

OK:

Battery voltage

OK

55-53

NG

Repair

Check the following connectors:

C-116, C-67, C-14, C-64, C-07 <L.H. drive vehicles>

C-14, C-66, C-115, C-07 <L.H. drive vehicles>

OK NG

Repair

Check the trouble symptom.

NG

Check the harness between the A/C-ECU and the A/C compressor relay, and repair if necessary.

Measure at the engine-ECU connector C-55 <4D6>, C-34 <4G6>,

C-33 <6A1>.

D Disconnect the connector, and measure at the harness side connector.

D Voltage between terminal (53) and body earth <4D6>

D Voltage between terminal (8) and body earth <4G6, 6A1>

OK:

Battery voltage

OK

NG

Replace the engine-ECU.

Check the following connectors:

B-30, B-28X

OK

NG

Repair

Check the trouble symptom.

NG

Check the harness between the A/C compressor relay and the engine-ECU, and repair if necessary.

55-54

13

15

21

25

31

32

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

DATA LIST REFERENCE TABLE

Item No.

Check item

11 Inside air temperature sensor

Check condition

Ignition switch: ON

Outside air temperature sensor

Ignition switch: ON

Heater water temperature sensor

Ignition switch: ON

Air thermo sensor

Photo sensor

Ignition switch: ON

Ignition switch: ON

Air mix damper mo- Ignition switch: ON Damper position tor potentiometer

MAX. HOT

MAX. COOL

Air outlet change- Ignition switch: ON Damper position over damper motor potentiometer FACE

FOOT

FOOT/DEF.

DEF.

CHECK AT THE A/C-ECU TERMINALS

55400510078

Normal condition

Inside air temperature and temperature displayed on the MUT-II are identical.

Outside air temperature and temperature displayed on the

MUT-II are identical.

Heater core surface temperature and temperature displayed on the MUT-II are identical.

Evaporator surface temperature and temperature displayed on the MUT-II are identical.

Amount of incident light is proportional to voltage displayed on the MUT-II.

Opening degree (%)

Approx. 100

Approx. 0

Opening degree (%)

Approx. 0

Approx. 50

Approx. 75

Approx. 100

55400540077

Terminal

No.

1

Check item

Power MOS FET drain output

Check condition

When blower switch is at OFF

When blower switch is at LO

When blower switch is at HI

Normal condition

System voltage

Approx. 9 V

Almost no voltage (0 V)

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Troubleshootimg

55-55

3

4

17

18

19

20

5

6

7

8

Terminal

No.

2

Check item

9

10

16

21

22

Check condition Normal condition

Power MOS FET gate output

A/C-ECU backup power supply

Heater water temperature sensor input

Air mix damper motor potentiometer input

When sensor section temperature is

25_C (4 kW)

When damper is moved to MAX. HOT position

Air outlet changeover damper motor potentiometer input

When damper is moved to DEF.

position

Outside air temperature sensor input When sensor section temperature is

25_C (4 kW)

Air thermo sensor input When sensor section temperature is

25_C (4 kW)

Photo sensor (-)

When blower switch is at HI

At all times

At luminous intensity of 100,000 lux or more

At luminous intensity of 0 lux

Sensor power supply

Rear defogger input

When blower switch is at OFF

When blower switch is at LO

Diagnosis date output

Diagnosis control input

Photo sensor (+)

Air mix damper motor and air outlet changeover damper motor potentiometers

At all times

When rear defogger switch is ON

When rear defogger switch is OFF

When ignition switch is ON

When ignition switch is ON

At all times

At all times

Air outlet changeover damper motor

(+)

Air mix damper motor (-)

Set to FACE position (OFF after 40 seconds of output)

Set to DEF. position (OFF after 40 seconds of output)

Set the setting temperature to 17_C and set to MAX. COOL position (OFF after 40 seconds of output)

Set the setting temperature to 32_C and set to MAX. HOT position (OFF after 40 seconds of output)

0 V

Approx. 1.3 V

Approx. 2.5 V

System voltage

2.3 - 2.9 V

4.7 - 5.0 V

4.8 - 5.2 V

2.3 - 2.9 V

2.3 - 2.9 V

-0.1 - 0.2 V

0 V

4.8 - 5.2 V

1.5 V or less

System voltage

0 V « System voltage

Battery voltage - 2 V

0 V

0 V

10 V

0.5 V

10 V

0.5 V

55-56

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Troubleshooting/

On-vehicle Service

27

28

29

30

33

Terminal

No.

23

Check item Check condition Normal condition

24

25

26

34

Inside/outside air changeover damper motor (-)

Air outlet changeover damper motor

(-)

Air mix damper motor (+)

Inside/outside air changeover damper motor (+)

Earth

A/C-ECU power supply

ILL earth (rheostat)

ILL power supply

Engine-ECU output

A/C output

Earth

Set to inside air position (OFF after 40 seconds of output)

Set to outside air position (OFF after

40 seconds of output)

Set to FACE position (OFF after 40 seconds of output)

Set to DEF. position (OFF after 40 seconds of output)

Set the setting temperature to 17_C and set to MAX. COOL position (OFF after 40 seconds of output)

Set the setting temperature to 32_C and set to MAX. HOT position (OFF after 40 seconds of output)

Set to inside air position (OFF after 40 seconds of output)

Set to outside air position (OFF after

40 seconds of output)

At all times

When ignition switch is ON

At all times

When lighting switch is at ON

When air mix damper is at MAX.

COOL position

When air mix damper is at MAX. HOT position

When A/C is OFF

When A/C is ON

At all times

0.5 V

10 V

0.5 V

10 V

0.5 V

10 V

10 V

0.5 V

Continuity

System voltage

Continuity

System voltage

0 V

System voltage

0 V

System voltage

Continuity 35

ON-VEHICLE SERVICE

The service procedures are the same as for the manual air conditioner. (Refer to P.55-7.)

55400080029

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Air Conditioner Control Panel and

ECU Assembly

55-57

AIR CONDITIONER CONTROL PANEL AND ECU ASSEMBLY

55400100084

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Floor Console Panel Removal and Installation

(Refer to GROUP 52A - Floor Console Box.)

3

1

2

Removal steps

1. Center console panel and air conditioner control panel assembly

2. Center console panel

3. Air conditioner control panel and ECU assembly

55-58

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Damper Motor Assembly and

Power Transistor

DAMPER MOTOR ASSEMBLY AND POWER TRANSISTOR

55400580024

REMOVAL AND INSTALLATION

2

3

4

1

Inside/outside air changeover damper motor assembly removal steps

D Glove box (Refer to GROUP 52A -

Instrument Panel.)

1. Inside/outside air changeover damper motor assembly

Outlet air changeover damper motor assembly removal steps

D Lower cover (Refer to GROUP 52A

- Instrument Panel.)

2. Outlet air changeover damper motor assembly

5

Air mix damper motor assembly removal steps

D Glove box, side cover, glove box frame, radio, tape player (Refer to

GROUP 52A - Instrument Panel.)

D Under cover (Refer to P.55-33.)

3. Control relay bracket assembly

4. Air mix damper motor assembly

Power transistor removal steps

D Glove box (Refer to GROUP 52A -

Instrument Panel.)

D Under cover (Refer to P.55-33.)

5. Power transistor

INSPECTION

55400590027

INSIDE/OUTSIDE AIR CHANGEOVER DAMPER MOTOR

ASSEMBLY CHECK

For inspection service points, refer to P.55-24 for heater and manual A/C.

MOTOR

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Damper Motor Assembly and

Power Transistor

Lever

55-59

AIR MIX DAMPER MOTOR ASSEMBLY CHECK

Motor

Check that the lever moves when battery voltage is applied across terminals 1 and 3 of the motor assembly connector.

Check also that the lever moves in the backward direction when polarity is changed.

Caution

1.

Cut off the voltage when the damper is in the MAX.

HOT or MAX. COOL position.

2.

Cut off the voltage if the motor does not turn when battery voltage is applied.

Potentiometer

Connect a circuit tester across terminals 2 and 5 of the motor assembly connector and check that resistance gradually changes as the damper is moved from MAX. HOT to MAX.

COOL position.

Standard value:

MAX. HOT position: Approx. 4.8 k

W

MAX. COOL position: Approx. 0.2 k

W

POTENTIOMETER

55-60

MOTOR

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Damper Motor Assembly and

Power Transistor

Lever

AIR OUTLET CHANGEOVER DAMPER MOTOR

ASSEMBLY CHECK

Motor

Check that the lever moves when battery voltage is applied across terminals 1 and 3 of the motor assembly connector.

Check also that the lever moves in the backward direction when polarity is changed.

Caution

1.

Cut off the voltage when the damper is in the DEF or FACE position.

2.

Cut off the voltage if the motor does not turn when battery voltage is applied.

Potentiometer

Connect a circuit tester across terminals 5 and 6 of the motor assembly connector and check that resistance gradually changes as the damper is moved from DEF. to FACE position.

Standard value:

DEF. position: Approx. 4.8 k

W

FACE position: Approx. 0.2 k

W

POTENTIOMETER

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

55-61

COMPRESSOR AND TENSION PULLEY

REMOVAL AND INSTALLATION

Pre-removal Operation

D Discharging of Refrigerant (Refer to P.55-13.)

Post-installation Operation

D Drive Belt Tension Adjustment

(Refer to GROUP 11 - On-vehicle Service.)

D Charging of Refrigerant (Refer to P.55-9.)

55200410273

Piping connection

O-ring

Compressor oil: SUN PAG 56

<6A1>

6

5

2

49 Nm

4

1

3

25 Nm

<4G6>

2

6

1

5

3

A

A

"

Removal steps

D Under cover

D Condenser fan motor (Refer to

P.55-31.)

D Drive belt (for alternator) <6A1> (Refer to GROUP 11 - Crankshaft Pulley.)

1. Drive belt

A

B

"

2. Tension pulley

3. Hose connections

4. Power steering oil pressure switch harness <6A1>

A

C

" "

A

A 5. Compressor

6. Compressor bracket

55-62

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

<4D6>

39 Nm

Piping connection

7

O-ring

Compressor oil: SUN PAG 56

6

3

8

25 Nm

2

20 - 25 Nm

5

4

1

A

A

"

Removal steps

D Under cover

D Condenser fan motor (Refer to

P.55-31.)

1. Drive belt (for compressor)

2. Tension pulley

3. Tension pulley bracket

A

B

"

4. Hose connections

A

C

" "

A

A 5. Compressor

6. Drive belt (for power steering oil pump)

7. Power steering oil pump

8. Compressor bracket

<4G6>

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

Bolt “B”

55-63

REMOVAL SERVICE POINTS

A

A

"

DRIVE BELT REMOVAL

1. Loosen the nut “A” for holding.

2. Loosen the bolt “B” <4G6 and 6A1> or nut “B” <4D6> for adjustment.

3. Remove the drive belt.

Nut “A”

<6A1>

<4D6>

Nut “A”

Bolt “B”

Nut “A”

Nut “B”

A

B

"

HOSE DISCONNECTION

Plug the disconnected hose and the compressor nipple not to let foreign matter get into them.

Caution

Seal the hoses completely, otherwise the compressor oil and receiver will absorb water vapour easily.

A

C

"

COMPRESSOR REMOVAL

When doing this work, be careful not to spill the compressor oil.

55-64

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

INSTALLATION SERVICE POINT

"

A

A

COMPRESSOR INSTALLATION

If a new compressor is installed, first adjust the amount of oil according to the procedures described below, and then install the compressor.

1. Measure the amount (X mL) of oil within the removed compressor.

2. Drain (from the new compressor) the amount of oil calculated according to the following formula, and then install the new compressor.

New compressor oil amount

120 mL - X mL = Y mL

NOTE

(1) Y mL indicates the amount of oil in the refrigerant line, the condenser, the evaporator etc.

(2) When replacing the following parts at the same times as the compressor, subtract the rated oil amount of the each part from Y mL and discharge from the new compressor.

Quantity

Evaporator: 60 mL

Condenser: 15 mL

Suction hose: 10 mL

Receiver: 10 mL

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

Refrigerant temperature switch

55-65

INSPECTION

55200930083

REFRIGERANT TEMPERATURE SWITCH SIMPLE

CHECK

When the A/C is off, check that there is continuity between the refrigerant temperature switch terminals. If no, replace the refrigerant temperature switch.

COMPRESSOR MAGNETIC CLUTCH OPERATION

CHECK

55200850181

Connect the battery (+) terminal to the compressor side terminal, and earth the battery (-) terminal to the body of the compressor. The condition is normal if the sound of the magnetic clutch (click) can be heard.

MAGNETIC CLUTCH AND REFRIGERANT TEMPERATURE SWITCH

DISASSEMBLY AND REASSEMBLY

<4G6>

2

1

4

6

7

8

9

5

10

55200460216

3

<6A1, 4D6>

8

7

6

3

4

Magnetic clutch disassembly steps

1. Bolt <4G6>

2. Pulley <4G6>

"

E

A D Air gap adjustment

A

A

" "

D

A 3. Nut

"

C

A 4. Armature plate

5. Shims

"

B

A 6. Snap ring

9

5

7. Rotor

8. Snap ring

"

A

A 9. Clutch coil

Refrigerant temperature switch removal

10. Refrigerant temperature switch

55-66

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Compressor and Tension Pulley

MB991386

DISASSEMBLY SERVICE POINT

A

A

"

NUT REMOVAL

MB991367

Snap ring Rotor

Clutch coil projection

REASSEMBLY SERVICE POINTS

"

A

A

CLUTCH COIL INSTALLATION

When installing the clutch coil to the A/C compressor body, install so that the pin hole of the A/C compressor body and the clutch coil projection are aligned.

Compressor body pin hole

Clutch coil

"

B

A

SNAP RING INSTALLATION

Install the snap ring so that the tapered surface is at the outer side.

Tapered part

Armature plate

Serration notch

"

C

A

ARMATURE PLATE INSTALLATION

Align the mating mark of the crankshaft spline and the mating mark of the armature plate, and then fit them together.

"

D

A

NUT INSTALLATION

Use the special tool to hold the magnet clutch, and tighten the nut in the same manner as removal.

Matching mark

Crankshaft

Thickness gauge

"

E

A

AIR GAP ADJUSTMENT

Check whether or not the air gap of the clutch is within the standard value.

Standard value: 0.40 - 0.65 mm

NOTE

If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Photo Sensor

PHOTO SENSOR

REMOVAL AND INSTALLATION

1

55-67

55400310067

A

A

"

Removal step

1. Photo sensor

Flat-tipped screwdriver

Photo sensor

REMOVAL SERVICE POINT

A

A

"

PHOTO SENSOR REMOVAL

Use a flat-tipped screwdriver (width: 3 mm or less) to remove the photo sensor.

INSPECTION

55400320046

If the blower speed drops when the receiver section of the photo sensor is covered with your hand, then the photo sensor is normal. If the speed does not drop, replace the photo sensor.

55-68

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Outside Air Temperature Sensor

OUTSIDE AIR TEMPERATURE SENSOR

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Front Bumper Removal and Installation (Refer to

GROUP 51.)

55400340042

Outside air temperature sensor

Resistance kW

20

15

10

5

0

-10 0 10 20 30

Temperature _C

40

INSPECTION

55400350021

When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph.

NOTE

The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER> - Heater Water Temperature Sensor

55-69

HEATER WATER TEMPERATURE SENSOR

REMOVAL AND INSTALLATION

Pre-removal and Post-installation Operation

D Lower Cover and Side Cover Removal and

Installation (Refer to GROUP 52A - Instrument

Panel.)

D Engine-ECU, A/T-ECU and A/T Control Relay

Removal and Installation (Refer to GROUP 52B

- SRS-ECU.)

55400450080

Caution: SRS

When removing and installing the engine-ECU,

A/T-ECU, A/T control relay and clip from vehicles equipped with SRS, do not let them bump against the SRS-ECU.

1

2

Removal steps

A

A

" "

A

A 1. Heater water temperature sensor clip

A

A

" "

A

A 2. Heater water temperature sensor

Foot distribution duct

Heater unit

Heater water temperature sensor clip

REMOVAL SERVICE POINT

A

A

"

HEATER WATER TEMPERATURE SENSOR CLIP

AND HEATER WATER TEMPERATURE SENSOR

REMOVAL

Pull out the heater water temperature sensor clip which is at the bottom of the heater unit, and then remove the heater water temperature sensor from the heater unit.

INSTALLATION SERVICE POINT

"

A

A

HEATER WATER TEMPERATURE SENSOR AND

HEATER WATER TEMPERATURE SENSOR CLIP

INSTALLATION

Insert the heater water temperature sensor into its mounting hole at the bottom of the heater unit, and then fix it by inserting the heater water temperature sensor clip.

55-70

HEATER, AIR CONDITIONER AND VENTILA-

TION <AUTOMATIC AIR CONDITIONER>

-

Heater Water Temperature Sensor/

Other Maintenance Service Points

Resistance kW

20

15

10

5

0

-10 0 10 20 30

Temperature _C

40

INSPECTION

55400460021

When the resistance value between the sensor terminals is measured under two or more temperature conditions, the resistance value should be close to the values shown in the graph.

NOTE

The temperature conditions when testing should not exceed the range of the characteristic curve in the graph.

OTHER MAINTENANCE SERVICE POINTS

The following maintenance service points are the same as for the manual A/C.

Items

GENERAL INFORMATIONS

ON-VEHICLE SERVICE

Safety Precautions

Sight Glass Refrigerant Level Test

Magnetic Clutch Test

Receiver Drier Test

Dual Pressure Switch Check

Compressor Drive Belt Adjustment

Charging

Performance Test

Refrigerant Leak Repair

Compressor Noise

Power Relay Check

Idle-up Operation Check

HEATER UNIT, HEATER CORE, AND BLOWER UNIT

BLOWER FAN AND MOTOR

EVAPORATOR

AIR PURIFIER ASSEMBLY

REFRIGERANT LINE

CONDENSER AND CONDENSER FAN MOTOR

VENTILATORS

55400400078

55-16

55-18

55-22

55-23

55-25

55-27

55-28

55-31

55-33

Reference page

55-3

55-7

55-7

55-7

55-8

55-8

55-9

55-14

55-15

55-16

RJST612005 - 1218

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement