Workshop Manual L200

Workshop Manual L200
55-2
Vacuum Actuator Check <Diesel-powered
Vehicles> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Idle-up Solenoid Valve Check <Diesel-powered
Vehicles> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lever Position Switch Check <Diesel-powered
Vehicles (A/T)> . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HEATER CONTROL ASSEMBLY AND A/C
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HEATER UNIT AND HEATER CORE* . . . . 24
BLOWER ASSEMBLY AND RESISTOR
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EVAPORATOR <VEHICLES WITH A/C>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COMPRESSOR AND TENSION
PULLEY* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CONDENSER AND CONDENSER FAN
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REFRIGERANT LINE* . . . . . . . . . . . . . . . . . . . 35
ENGINE COOLANT TEMPERATURE
SWITCH <Diesel-powered Vehicles> . . . . 37
IDLE-UP SYSTEM <Diesel-powered
Vehicles> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LEVER POSITION SWITCH
<Diesel-powered Vehicles (A/T)> . . . . . . . . 40
VENTILATORS* . . . . . . . . . . . . . . . . . . . . . . . . . 41
HEATER, AIR CONDITIONER
– General Information
AND VENTILATION
55-3
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 and a cool air bypass function.
Items
Heater unit
55200010121
The A/C system is basically the same as the
conventional system, but a new refrigerant system
has been adopted as a response to restrictions
on the use of chlorofluorocarbons.
Specifications
Type
Two-way-flow full-air-mix system
Heater control assembly
Dial type
Compressor
Model
Inclined-plate type <DKS-15CH>
Dual pressure switch
kPa
High-pressure switch
ON OFF: 2,648, OFF ON: 2,059
Low-pressure switch
ON OFF: 177, OFF ON: 186
Refrigerant and quantity g
R-134a (HFC-134a), Approx. 550 – 600
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
refrigeration system.
when
servicing
the
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 VENTILATION
–
General Information/Service Specifications/
Lubricants/Sealant
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.
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.
Caution
Keep R-134a containers upright when charging
the system.
SERVICE SPECIFICATIONS
55200030141
Items
Idle speed r/min
Standard value
4G6
750 ± 100
4D5
750 ± 100
Idle up speed r/min
900 ± 50
Resistor (for blower motor) <L.H. drive vehicles> Ω
LO: 2.21, ML: 0.97, MH: 0.35
Resistor (for blower motor) <R.H. drive vehicles> Ω
LO: 2.81, ML: 1.28, MH: 0.33
Air gap (Magnetic clutch) mm
0.3 – 0.6
Engine coolant temperature switch (for A/C cut-off)
<4D5> C_
ON (continuity)
108 or less
OFF (no continuity)
115 or more
Engine coolant temperature switch (for condenser
fan) <4D5> C_
ON (continuity)
102 or more
OFF (no continuity)
97 or less
LUBRICANTS
55200040137
Items
Specified lubricants
Quantity
Each connection of refrigerant line
ZXL100PG
As required
Compressor refrigerant unit lubricant m
ZXL100PG
180
SEALANT
55200050048
Item
Specified sealant
Remark
Engine coolant temperature switch threaded
part
3M Nut Locking Part No. 4171 or equivalent
Drying sealant
HEATER, AIR CONDITIONER
– Special Tool/Troubleshooting
AND VENTILATION
55-5
SPECIAL TOOL
Tool
55100060017
Number
Name
Use
MB990784
Ornament remover
Meter bezel assembly removal
TROUBLESHOOTING
55200070150
TROUBLESHOOTING PROCEDURES
Trouble symptom
Problem cause
Remedy
Reference
page
When the ignition
switch is “ON”,
“ON”
the A/C does not
t
operate.
A/C compressor relay is defective
Replace A/C compressor relay
55-16
Magnetic clutch is defective
Replace the A/C compressor
55-6, 30
Refrigerant leak or overfilling of refrigerant
Replenish the refrigerant, repair the leak or take out some of
the refrigerant
55-6, 14
Dual pressure switch is defective
Replace the dual pressure
switch
55-7, 35
A/C switch is defective
Replace the A/C switch
55-21, 23
Blower switch is defective
Replace the blower switch
55-21, 23
Thermostat is defective
Replace the Thermostat
55-29
Engine coolant temperature switch (for A/C
cut-off) is defective <Diesel-powered vehicles>
Replace the engine coolant
temperature switch
55-37, 38
Engine-ECU is defective <Petrol-powered
vehicles>
Replace the engine-ECU
–
Refrigerant leak
Replenish the refrigerant and
repair the leak
55-14
Dual pressure switch is defective
Replace the dual pressure
switch
55-7, 35
Thermostat is defective
Replace the Thermostat
55-29
When the A/C is
operating, temperature inside
the
passenger
compartment
doesn’t decrease
(
(cool
l air
i iis nott
emitted).
55-6
HEATER, AIR CONDITIONER
AND VENTILATION
– Troubleshooting/On-vehicle Service
Trouble symptom
Problem cause
Remedy
Reference
page
Blower fan and
motor
doesn’t
turn
Blower relay is defective
Replace the blower relay
55-15
Blower fan and motor is defective
Replace the blower fan and
motor
55-26, 27
Blower resistor is defective
Replace the blower resistor
55-26, 27
Blower switch is defective
Replace the blower switch
55-21, 23
Blower fan and
motor
doesn’t
stop turning
turning.
Short circuit of the harness between the blower
fan and motor and the blower switch
Repair the harness
–
Blower switch is defective
Replace the blower switch
55-21, 23
When the A/C is
operating
condenser fan does
not turn.
Condenser fan motor is defective
Replace the condenser fan
motor
55-33, 34
Condenser fan relay is defective
Replace the condenser fan
relay
55-16
ON-VEHICLE SERVICE
Sight glass
55200840096
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.
HEATER, AIR CONDITIONER
AND VENTILATION
55-7
– On-vehicle Service
MAGNETIC CLUTCH TEST
55200850099
1. Disconnect the connector (1P) 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
55200860078
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.
High/Lowpressure side
LOW-PRESSURE
SIDE
HIGH-PRESSURE
SIDE
ON
ON
OFF
OFF
DUAL PRESSURE SWITCH CHECK
55201040129
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.
Unit: kPa
Items
Switch position
OFF ON
ON OFF
Low-pressure
side
186
177
High-pressure
side
2,059
2,648
COMPRESSOR DRIVE BELT ADJUSTMENT
55200100101
Refer to GROUP 11 – On-vehicle Service.
HEATER, AIR CONDITIONER
AND VENTILATION
55-8
– On-vehicle Service
CHARGING
High-pressure
side
Low-pressure
valve
Gauge manifold
Charging hose
(yellow)
Adapter
valve
Charging hose
(blue)
Switch
R-12
connection
port
Vacuum
pump
Quick
joint (for adaptor
low
pressure)
Vacuum
pump
R-134a
connection
port
Power supply
plug
Switch
Low-pressure
service valve
A
Sleeve
55200120121
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 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).
HEATER, AIR CONDITIONER
AND VENTILATION
– On-vehicle Service
55-9
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).
Low-pressure
service valve
Vacuum pump
Valve open
Valve close
Charge valve
Adaptor valve
Service can
16. With the handle turned back all the way (valve open),
install the charging valve to the service van.
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.
55-10
HEATER, AIR CONDITIONER
AND VENTILATION
Charging valve
– On-vehicle Service
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).
Service can
(Refrigerant container)
Low-pressure
service valve
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.
HEATER, AIR CONDITIONER
AND VENTILATION
Valve open
Charge valve
Valve close
Adaptor valve
Charging hose (blue)
Service can
(Refrigerant
container)
Quick joint (for low-pressure)
– On-vehicle Service
55-11
CORRECTING LOW REFRIGERANT LEVEL IN CASE
THE SERVICE CAN IS USED.
1. Install the charge 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 charge valve (valve close),
and pierce the service can.
6. Turn the handle of the adaptor valve to bleed the air.
7. Install the quick joint (for low-pressure) to the low-pressure
service valve.
Quick joint
(for low pressure)
NOTE
The low-pressure service valve should be connected to
the suction hose.
Low-pressure
service valve
Charging 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.
Service can
(Refrigerant container)
12. After replenishing is completed, turn the handle of the
adaptor valve all the way back (valve close), and remove
the quick joint.
Low-pressure
service valve
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.
55-12
HEATER, AIR CONDITIONER
AND VENTILATION
– On-vehicle Service
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.
A
Sleeve
Charging hose (blue)
Quick joint
Low-pressure
service valve
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 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.
Adaptor valve
NOTE
Any oil remaining in the container should be returned
to the A/C system.
Oil
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
180 m 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: ZXL100PG
Quantity
Condenser: 30 m
Evaporator: 50 m
Suction hose: 10 m
Receiver: 10 m
HEATER, AIR CONDITIONER
AND VENTILATION
– On-vehicle Service
PERFORMANCE TEST
Low-pressure valve
High-pressure valve
Gauge manifold
Charging
hose (red)
Charging
hose (blue)
A
Adaptor
valve (for low
pressure)
Sleeve
Adaptor valve
(for high pressure)
Lowpressure
service
valve
Highpressure
service
valve
Thermometer
55-13
55200140127
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 discharge hose
and the low-pressure service valve is on the suction 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.
55-14
HEATER, AIR CONDITIONER
AND VENTILATION
– On-vehicle Service
Performance Temperature Chart
Garage ambient temperature _C
20
25
35
40
Discharge air temperature _C
3.6 – 9.5
4.0 – 11.0
7.0 – 9.0
11.0 – 13.8
Compressor high pressure kPa
1,120
1,236
1,814
2,050
Compressor low pressure kPa
115
131
152
175
REFRIGERANT LEAK REPAIR
55200150083
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.
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.
HEATER, AIR CONDITIONER
AND VENTILATION
COMPRESSOR NOISE
55200870095
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.
55-15
– On-vehicle Service
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.
POWER RELAY CONTINUITY CHECK
55200880142
BLOWER RELAY
Battery voltage
Terminal No.
1
Power is not supplied
Power is supplied
Blower relay
3
2
5
55-16
HEATER, AIR CONDITIONER
AND VENTILATION
Condenser fan
control relay
Condenser fan relay
– On-vehicle Service
A/C COMPRESSOR RELAY, CONDENSER FAN RELAY,
CONDENSER FAN CONTROL RELAY
Battery voltage
A/C compressor
relay
Terminal No.
2
4
1
3
Power is not supplied
Power is supplied
IDLE-UP OPERATION CHECK
55200160147
<Petrol-powered vehicles>
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 idling speed is the standard
value.
Standard value: 750 ± 100 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: 900 ± 50 r/min
NOTE
There is no necessity to make an adjustment, because
the idling 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 VENTILATION
– On-vehicle Service
55-17
<Diesel-powered vehicles>
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: Straight forward
2. Check whether or not the idling speed is the standard
value.
Standard value: 750 ± 100 r/min
3. If there is a deviation of the idling speed from the standard
value, adjust the idling speed. (Refer to GROUP 11 –
On-vehicle Service.)
4. Check to be sure that the idling speed becomes the
standard value when the A/C switch is switched ON and
the A/C is activated.
Standard value: 900 ± 50 r/min
Fuel-injection
lever
Rod
A
Adjusting
screw
B
Cap
Adjuster
Holding nut
Approx. 1 mm
5. If there is a deviation of the idling speed from the standard
value, adjust the idling speed by the following the
procedures.
(1) Loosen nuts (A) and (B).
(2) Adjust, by using the adjuster, so that the end of the
vacuum actuator’s rod is at the position indicated
in the illustration.
(3) Securely tighten nuts (A) and (B).
(4) After activating the vacuum actuator, check to be
sure that the rod and the lever do not contact when
the activation is cancelled.
(5) Remove the cap and loosen the nut for holding.
(6) Adjust to the specified r/min by turning the adjusting
screw.
(7) Securely tighten the holding nut, and then attach the
cap.
HEATER, AIR CONDITIONER
AND VENTILATION
55-18
– On-vehicle Service
VACUUM ACTUATOR CHECK <Diesel-powered
Vehicles>
55200890039
<Vehicles without ABS>
Vacuum hose
(yellow stripe)
1. Pull off the vacuum hose (yellow stripe) connected to
the vacuum actuator.
Vacuum actuator
<Vehicles with ABS>
Vacuum hose
(Yellow stripe)
Vacuum actuator
2. Connect a manual vacuum pump to the nipple of the
vacuum actuator.
3. Check to be sure that the vacuum actuator rod starts
to contact when 8 kPa of negative pressure is applied,
and that the rod contracts to its full stroke when 12 kPa
of negative pressure is applied.
4. Disconnect the manual vacuum pump from the vacuum
actuator, and connect the vacuum hose (yellow stripe)
to the vacuum actuator.
5. Start the engine and let it run at idle. Then cover the
end of the vacuum hose (yellow stripe) with a finger and
check the negative pressure when the A/C switch is turned
on and off.
A/C switch
Negative pressure at hose
end
OFF
No
ON
Yes
Caution
Be careful, when connecting the vacuum hose not
to damage it.
HEATER, AIR CONDITIONER
AND VENTILATION
Vacuum hose
(white stripes)
– On-vehicle Service
55-19
IDLE-UP SOLENOID VALVE CHECK
<Diesel-powered Vehicles>
55201120014
1. Disconnect the vacuum hoses (white stripes, yellow
stripes) from the solenoid valve.
2. Disconnect the harness connector.
Idle-up solenoid
valve
Vacuum hose
(yellow stripes)
Nipple A
3. Connect a manual vacuum pump to the nipple A.
Nipple B
Nipple A Nipple
B
4. Check air-tightness by applying a vacuum with voltage
applied directly from the battery to the solenoid valve
terminal and without applying voltage.
Battery voltage
Nipple B
Vacuum
condition
Applied
Open
Vacuum leaks
from nipple B
Blocked with
finger *1
Vacuum is
maintained
Open
Vacuum is
maintained
i t i d
Not applied
Blocked with
finger *2
NOTE
In case of mark *1, a vacuum can be felt but in case
of mark *2, a vacuum can not be felt.
5. Measure the resistance of the solenoid valve.
Standard value: Approx. 40 Ω
6. When disconnecting the vacuum hose, always make a
mark so that the hose can be reconnected at original
position.
HEATER, AIR CONDITIONER
AND VENTILATION
55-20
– On-vehicle Service
LEVER POSITION SWITCH CHECK
<Diesel-powered Vehicles (A/T)>
55200800018
1. Before inspection, set the vehicle to the following
condition.
D Ignition switch: ON (Do not start the engine)
D Blower switch: ON (LO, HL, HM or HI position)
D A/C switch: ON
2. When the vehicle is at full acceleration (accelerator pedal
depression amount is approximately 90% ± 7%), check
that the magnetic clutch turns OFF for a period of
approximately 7 seconds.
3. If there is a malfunction, adjust the installation position
of the lever position switch by the following procedure.
(1) Check that the idle speed is at the standard value,
and adjust it if necessary.
Standard value: 750 ± 100 r/min
(2) Adjust the accelerator cable.
(3) Depress the accelerator pedal fully to fully open the
throttle lever of the fuel injection pump.
Caution
When fully opening the throttle lever of the fuel
injection pump, always open it by the accelerator
pedal, not from the injection pump side.
(4) Adjust the stroke of the lever position switch rod by
moving the lever position switch so that the rod is
pushed down 4 ± 1 mm from the free position.
Lever
position
switch
Throttle lever
Rod
4 ± 1 mm
Free condition
HEATER, AIR CONDITIONER
– Heater Control Assembly and A/C Switch
AND VENTILATION
55-21
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55200240049
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Front Floor Console Assembly Removal
Installation (Refer to GROUP 52A.)
and
D
Driver Side Under Cover, Meter Bezel Assembly,
Glove Box Assembly, Centre Under Cover Removal
and Installation (Refer to GROUP 52A – Instrument
Panel.)
(Contact surface)
1
5
3
4
Removal steps
1. Foot duct
AA" "AA 2. Heater control assembly
3. A/C switch
2
4. Knob
5. Blower switch
REMOVAL SERVICE POINT
AA" HEATER CONTROL ASSEMBLY REMOVAL
1. Remove the heater control assembly mounting screws.
2. Bend the bosses, which are inserted into the centre
reinforcement.
3. Remove the heater control assembly.
NOTE
This service point is first removal of heater control panel.
HEATER, AIR CONDITIONER
– Heater Control Assembly and A/C Switch
AND VENTILATION
55-22
INSTALLATION SERVICE POINT
Air outlet changeover damper link
Link pin
Face position
Defroster position
2. Follow the steps below to instal the air mix damper lever
cable.
(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 as shown in the illustration,
and then connect the cable to the lever pin.
(3) Push the outer cable in the direction of the arrow
so that there is no looseness, and then secure it
with clip.
Max. cool position
Air mix damper
lever
Lever pin
Max. hot position
<L.H. drive vehicles>
Inside/outside
air changeover
damper link
Link pin
Inside recirculation
Outside air induction
position
position
<R.H. drive vehicles>
Inside/outside
air changeover
damper link
Link pin
Inside recirculation
position
"AA HEATER CONTROL ASSEMBLY INSTALLATION
1. Follow the steps below to install the air outlet changeover
damper link cable.
(1) Set the air outlet changeover control knob on the
heater control assembly to the defroster position.
(2) Set the air outlet changeover damper link of the heater
unit to the defroster position as shown in the
illustration, and then connect the cable to the link
pin.
(3) Push the outer cable in the direction of the arrow
so that there is no looseness, and then secure it
with clip.
Outside air
induction position
3. Follow the steps below to install the inside/outside air
changeover damper link cable.
(1) Set the inside/outside air changeover control knob
on the heater control assembly to the inside
recirculation position.
(2) Set the inside/outside air changeover damper link
of the blower assembly to the inside recirculation
position as shown in the illustration, and then connect
the cable to the link pin.
(3) Push the outer cable in the direction of the arrow
so that there is no looseness, and then secure it
with clip.
4. After installation, ensure that each damper operates
smoothly by operating the heater control assembly knob.
HEATER, AIR CONDITIONER
– Heater Control Assembly and A/C Switch
AND VENTILATION
OFF
55-23
INSPECTION
55200220074
A/C SWITCH CONTINUITY CHECK
Switch
position
iti
ON
Terminal No.
1
4
IND
5
3
ILL
6
OFF
ON
BLOWER SWITCH CONTINUITY CHECK
Lever
position
iti
OFF
LO
ML
MH
HI
55200900060
Terminal No.
1
ILL
5
2
3
6
7
8
9
10
HEATER, AIR CONDITIONER
– Heater Unit and Heater Core
AND VENTILATION
55-24
HEATER UNIT AND HEATER CORE
55100190136
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Refrigerant Discharging and Charging <Vehicles
with A/C> (Refer to P. 55-8.)
D Engine Coolant Draining and Refilling (Refer to
GROUP 14 – On-vehicle Service.)
D Instrument Panel Removal and Installation
(Refer to GROUP 52A.)
D Joint Duct Removal and Installation
<Vehicles without A/C> (Refer to P.55-26.)
Caution: SRS
When removing and installing the heater unit
from vehicles equipped with SRS, do not let it
bump against the SRS diagnostic unit or the
components.
Piping
connection
5
Compressor oil: ZXL 100PG
6
2
4
5
3
8
7
9
1
AA"
Removal steps
1. Center reinforcement
2. Center ventilation duct
3. Drain hose <Vehicles with A/C>
4. Suction pipe or hose and discharge
pipe connection <Vehicles with
A/C>
5.
6.
"AA 7.
8.
9.
O-ring
Heater hose connection
Evaporator <Vehicles with A/C>
Heater unit
Heater core
HEATER, AIR CONDITIONER
– Heater Unit and Heater Core
AND VENTILATION
55-25
REMOVAL SERVICE POINTS
AA" SUCTION PIPE OR 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 vapor easily.
INSTALLATION SERVICE POINT
"AA EVAPORATOR INSTALLATION
When replacing the evaporator, refill with a specified amount
of compressor oil and install it (to the vehicle).
Compressor oil: ZXL 100PG
Quantity: 50 m
HEATER, AIR CONDITIONER
AND VENTILATION
55-26
– Blower Assembly and Resistor
BLOWER ASSEMBLY AND RESISTOR
55100280147
REMOVAL AND INSTALLATION
<Vehicles with A/C>
6
7
8
<Vehicles without A/C>
3
2
4
5
NOTE
: metal clip position
Resistor, blower fan and motor
removal steps
1. Under cover
2. Glove box assembly
3. Resistor
4. Blower fan and motor
3
1
Blower case removal steps
D Instrument panel (Refer to GROUP
52A.)
5. Joint duct <Vehicles without A/C>
6. Evaporator <Vehicles with A/C>
(Refer to P. 55-28.)
"AA 7. Inside/outside air changeover
damper cable connection
8. Blower case assembly
HEATER, AIR CONDITIONER
AND VENTILATION
<L.H. drive vehicles>
Inside/outside air
changeover
damper link
Link pin
Inside recirculation
position
Outside air
induction position
<R.H. drive vehicles>
Inside/outside air
changeover damper link
– Blower Assembly and Resistor
55-27
INSTALLATION SERVICE POINT
"AA INSIDE/OUTSIDE AIR CHANGEOVER DAMPER
CABLE INSTALLATION
1. Set the inside/outside air changeover control knob on
the heater control assembly to the inside recirculation
position.
2. Set the inside/outside air changeover damper link of the
blower assembly to the inside recirculation position as
shown in the illustration, and then connect the cable to
the link pin.
3. Push the outer cable in the direction of the arrow so
that there is no looseness, and then secure it with clip.
Link pin
Inside recirculation
position
Outside air
induction position
INSPECTION
55100290072
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.
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:
<L.H. drive vehicles>
Measurement terminal
Standard value Ω
Between terminals 3 and 2 (LO)
2.21
Between terminals 3 and 4 (ML)
0.97
Between terminals 3 and 1 (MH)
0.35
<R.H. drive vehicles>
Measurement terminal
Standard value Ω
Between terminals 3 and 2 (LO)
2.81
Between terminals 3 and 4 (ML)
1.28
Between terminals 3 and 1 (MH)
0.33
55-28
HEATER, AIR CONDITIONER
AND VENTILATION
– Evaporator <Vehicles with A/C>
EVAPORATOR <VEHICLES WITH A/C>
55200360110
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Refrigerant Discharging and Charging (Refer to P.
55-8.)
D
Under Cover, Glove Box Assembly Removal and
Installation (Refer to GROUP 52A – Instrument Panel.)
2
Piping
connection
3
1
4
3
Compressor oil: ZXL 100PG
6
5
AA"
AA"
Removal steps
1. Suction pipe or hose connection
2. Discharge pipe connection
3. O-ring
4. Drain hose
5. Center frame B
"AA 6. Evaporator
REMOVAL SERVICE POINT
AA" SUCTION PIPE OR 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
"AA EVAPORATOR INSTALLATION
When replacing the evaporator, refill it with a specified amount
of compressor oil and install it (to the vehicle).
Compressor oil: ZXL 100PG
Quantity: 50 m
HEATER, AIR CONDITIONER
AND VENTILATION
55-29
– Evaporator <Vehicles with A/C>
DISASSEMBLY AND REASSEMBLY
9
55200380109
8
2
1
<Diesel-powered
vehicles (A/T)>
5
4
4
3
9
8
10
Compressor oil: ZXL 100PG
<Petrol-powered
vehicles and
diesel-powered
vehicles (M/T)>
9
7
6
Disassembly steps
1. Clip
2. Evaporator cover (upper)
3. Lining, upper
4. Thermostat
5. Compressor-ECU <Diesel-powered
vehicles (A/T)>
INSPECTION
Thermostat
6.
7.
8.
9.
10.
Evaporator cover (lower)
Lining, lower
Expansion valve
O-ring
Evaporator
55200370038
THERMOSTAT, AIR THERMO SENSOR CHECK
1. Apply battery voltage between the thermostat terminals
shown in the illustration, and connect a test lamp to
terminal (3).
2. Blow cool air onto the air thermo sensor and check that
the test lamp switches off when the cool air temperature
becomes approximately 3 _C or less.
Air thermo sensor
COMPRESSOR-ECU SIMPLE TEST <Diesel-powered
Vehicles (A/T)>
1. Check to be sure that thermostat has no defect.
2. Apply battery voltage between the connecters shown in
the illustration, and connect a test lamp to terminal (6).
3. Check that the test lamp illuminates for 7 seconds only
when terminal (3) is earthed.
HEATER, AIR CONDITIONER
– Compressor and Tension Pulley
AND VENTILATION
55-30
COMPRESSOR AND TENSION PULLEY
55200410174
REMOVAL AND INSTALLATION
Pre-removal Operation
D Refrigerant Discharging (Refer to P. 55-12.)
D Battery Removal
Post-installation Operation
D Drive Belt Tension Adjustment
(Refer to GROUP 11 – On-vehicle Service.)
D Battery Installation
D Refrigerant Charging (Refer to P. 55-8.)
CAUTION: SRS
When removing and installing the compressor
from vehicles equipped with SRS, do not let it
bump against the front impact sensor (L.H.).
<4G63, 4G64>
8
45 Nm
3
2
6
4
7
22 Nm
<4D56>
1
8
5
45 Nm
2
9
Hose connection
4
6
7
4
Compressor oil: ZXL 100PG
3
22 Nm
22 Nm
45 Nm
5
1
Removal steps
1. Drive belt
2. Suction hose connection
3. Discharge hose connection
4. O-ring
AC" "AA 5. Compressor
AA"
AB"
AB"
6.
7.
8.
9.
Tension pulley
Earth cable connection
Compressor bracket
Tension pulley bracket assembly
<4D56>
HEATER, AIR CONDITIONER
– Compressor and Tension Pulley
AND VENTILATION
<4G6>
B
A
55-31
REMOVAL SERVICE POINTS
AA" DRIVE BELT REMOVAL
1. Loosen the nut “A” for holding.
2. Loosen the bolt “B” for adjustment.
3. Remove the drive belt.
AB" SUCTION HOSE, DISCHARGE HOSE
DISCONNECTION
Plug the disconnected hose and the compressor nipple not
to let foreign matter get into them.
<4D5>
B
A
Caution
Seal the hoses completely, otherwise the compressor
oil and receiver will absorb water vapour easily.
AC" COMPRESSOR REMOVAL
When doing this work, be careful not to spill the compressor
oil.
INSTALLATION SERVICE POINT
"AA 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 m) 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
180 m – X m = Y m
NOTE
(1) Y m 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 m and discharge from the
new compressor.
Quantity
Evaporator: 50 m
Condenser: 30 m
Suction hose: 10 m
Receiver: 10 m
55-32
Magnetic clutch
connector
HEATER, AIR CONDITIONER
– Compressor and Tension Pulley
AND VENTILATION
INSPECTION
COMPRESSOR MAGNETIC CLUTCH OPERATION
CHECK
55200850105
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.
COMPRESSOR MAGNETIC CLUTCH AIR GAP CHECK
55201110011
Check whether or not the air gap of the clutch is within the
standard value.
Standard value: 0.3 – 0.6 mm
Thickness gauge
HEATER, AIR CONDITIONER
– Condenser and Condenser Fan Motor
AND VENTILATION
CONDENSER AND CONDENSER FAN MOTOR
55-33
55200670138
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Radiator Grille Removal and Installation (Refer to
GROUP 51.)
D Front Bumper Removal and Installation (Refer to
GROUP 51.)
D
Hood Latch Removal and Installation (Refer to
GROUP 42 – Hood.)
10
Piping connection
8
10
7
11
1
10
Compressor oil:
12 ZXL 100PG
*
10
10
3
5
4
10
6
9
2
NOTE
*: L.H. drive vehicles
Condenser fan motor removal
steps
1. Hood lock stay
2. Condenser fan motor and shroud
assembly
3. Net
4. Condenser fan
5. Condenser fan motor
6. Shroud
Condenser removal steps
D Refrigerant Discharging and Charging
(Refer to P.55-8.)
D Engine oil cooler <Diesel-powered
vehicles> (Refer to GROUP 12.)
1. Hood lock stay
2. Condenser fan motor and shroud
assembly
7. Cable protector
AA"
8. Discharge pipe B <L.H. drive vehicles>
AA"
9. Discharge hose, discharge pipe A
and condenser connection
10. O-ring
11. Bumper Support (R.H.) <L.H. drive
vehicles>
"AA 12. Condenser
55-34
HEATER, AIR CONDITIONER
– Condenser and Condenser Fan Motor
AND VENTILATION
REMOVAL SERVICE POINTS
AA" DISCHARGE PIPE “B”/DISCHARGE PIPE
“A”/DISCHARGE HOSE DISCONNECTION
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.
INSTALLATION SERVICE POINT
"AA CONDENSER INSTALLATION
When replacing the condenser, refill it with a specified amount
of compressor oil and install it. (to the vehicle).
Compressor oil: ZXL 100PG
Quantity: 30 m
INSPECTION
55200680094
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 VENTILATION
55-35
– Refrigerant Line
REFRIGERANT LINE
55200640146
REMOVAL AND INSTALLATION
<L.H. DRIVE VEHICLES>
Pre-removal and Post-installation Operation
D Refrigerant Discharging and Charging (Refer to P.
55-8.)
D Radiator Grill Removal and Installation (Refer to
GROUP 51.)
D Front Bumper Removal and Installation (Refer to
GROUP 51.)
D Battery Removal and Installation
D Windshield Washer Tank Removal and Installation
(Refer to GROUP 51 – Windshield Wiper and
Washer.)
CAUTION: SRS
When removing and installing the suction pipe
or discharge pipe C from vehicles equipped with
SRS, do not let it bump against the front impact
sensor (R.H.).
10
9
3
2
10
10
8
9 Nm
1
6
10
10
7
5
12
4
10
Piping connection
10
11
10
10
13
Compressor oil: ZXL 100PG
AA" "AA 1. Suction hose
AA"
2. Suction pipe
D Power steering oil reservoir (Refer to
GROUP 37A – Power Steering Hose.)
AA"
3. Suction pipe
AA"
4. Discharge pipe A
AA"
5. Discharge hose
6. Hood latch
7. Hood lock stay
D Engine oil cooler <Diesel-powered
vehicles> (Refer to GROUP 12.)
AA"
8. Discharge pipe B
AA"
9. Discharge pipe C
10. O-ring
AA" "AA 11. Receiver assembly
12. Dual pressure switch
13. Receiver bracket
HEATER, AIR CONDITIONER
– Refrigerant Line
AND VENTILATION
55-36
<R.H. DRIVE VEHICLES>
Pre-removal and Post-installation Operation
D Refrigerant Discharging and Charging
(Refer to P. 55-8.)
D Radiator Grille Removal and Installation
(Refer to GROUP 51.)
D
1
4
8
Front Bumper Removal and Installation
(Refer to GROUP 51.)
8
8
2
3
6
Piping connection
8
5
8
7
AA" "AA 1. Suction hose
AA"
2. Discharge pipe A
AA"
3. Discharge pipe B
AA"
4. Discharge hose
Compressor oil:
ZXL 100PG
AA" "AA 5.
6.
7.
8.
Receiver assembly
Dual pressure switch
Receiver bracket
O-ring
REMOVAL SERVICE POINT
AA" 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.
HEATER, AIR CONDITIONER AND
VENTILATION
–
Refrigerant Line/Engine Coolant Temperature
Switch <Diesel-powered Vehicles>
55-37
INSTALLATION SERVICE POINT
"AA 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: ZXL 100PG
Quantity:
Suction hose: 10 m
Receiver assembly: 10 m
ENGINE COOLANT TEMPERATURE SWITCH
<Diesel-powered Vehicles>
55200730058
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Coolant Refilling (Refer to GROUP 14 – On-vehicle
Service.)
D Intercooler Removal and Installation <Vehicles with
intercooler> (Refer to GROUP 15.)
7.4 Nm
(Threaded portion)
2
1
2
1
34 Nm
Sealant:
3M Nut Locking Part No. 4171 or equivalent
1. Engine coolant temperature switch
(for A/C cut-off)
2. Engine coolant temperature switch
(for condenser fan)
HEATER, AIR CONDITIONER AND
VENTILATION
55-38
–
Engine Coolant Temperature Switch
<Diesel-powered Vehicles>
INSPECTION
Thermometer
Oil
55200740037
ENGINE COOLANT TEMPERATURE SWITCH
CONTINUITY CHECK
1. Dip the engine coolant temperature switch in oil and heat
the oil with a gas burner or similar item.
Caution
Do not heat any more than is necessary.
2. Check the continuity with a circuit tester as the temperature
of the oil changes, and the condition is normal if the
continuity is within the following ranges.
<For A/C cut-off>
Standard value:
B
ON
OFF
Engine coolant
temperature
switch
Temperature
Continuity
For A/C cut-off
Less than 108 _C
(Temperature at point A)
ON
(Continuity)
More than 115 _C
(Temperature at point B)
OFF
(No continuity)
Less than 97 _C
(Temperature at point A)
OFF
(No continuity)
More than 102 _C
(Temperature at point B)
ON
(Continuity)
Oil temp.
A
For condenser
fan
<For condenser fan>
B
ON
OFF
Oil temp.
A
HEATER, AIR CONDITIONER AND
– Idle-up System <Diesel-powered Vehicles>
VENTILATION
55-39
IDLE-UP SYSTEM <Diesel-powered Vehicles>
55200810011
REMOVAL AND INSTALLATION
Pre-removal Operation
D Intercooler Removal <Vehicle with intercooler>
(Refer to GROUP 15.)
Post-installation Operation
D Accelerator Cable Adjustment (Refer to GROUP
17 – On-vehicle Service.)
D Throttle Cable Adjustment <A/T> (Refer to GROUP
23 – On-vehicle Service.)
D Intercooler Installation <Vehicles with intercooler>
(Refer to GROUP 15.)
D Idle-up Operation Check (Refer to P. 55-16.)
5
1
4
3
2
<Vehicles with ABS>
6
8
2
10
9
7
10
Idle-up solenoid valve removal
steps
1. Vacuum hose (white stripe)
connection
2. Vacuum hose (yellow stripe)
connection
3. Idle-up solenoid valve
4. Solenoid valve bracket B
5. Solenoid valve bracket A
Vacuum actuator assembly removal
steps
2. Vacuum hose (yellow stripe)
connection
6. Accelerator cable connection
7. Split pin <A/T>
8. Throttle cable connection <A/T>
9. Vacuum hose (blue stripe)
<Vehicles with ABS>
10. Vacuum actuator assembly
HEATER, AIR CONDITIONER AND
Lever Position Switch
–
VENTILATION
<Diesel-powered Vehicles (A/T)>
55-40
LEVER POSITION SWITCH <Diesel-powered Vehicles (A/T)>
55200790018
REMOVAL AND INSTALLATION
1
"AA 1. Lever-position switch
Throttle lever: Idling position
INSTALLATION SERVICE POINT
"AA LEVER POSITION SWITCH CHECK
1. Check that the idle speed is at the standard value, and
adjust it if necessary.
Standard value: 750 ± 100 r/min
Lever position switch
Throttle lever: Fully opened position
2. Adjust the accelerator cable.
3. Depress the accelerator pedal fully to fully open the throttle
lever of the fuel injection pump.
Caution
When fully opening the throttle lever of the fuel
injection pump, always open it by the accelerator
pedal, not from the injection pump side.
4. Adjust the stroke of the lever position switch rod by moving
the lever position switch so that the rod is pushed down
4 ± 1 mm from the free position.
ON
0.3
OFF
INSPECTION
5.0
1. Connect a circuit tester as shown in the illustration, and
check that there is continuity in the section 0.3 mm from
the full length (full stroke), and that there is no continuity
for the remainder of the stroke (5.0 mm).
2. If there is a defect, replace the component.
5.3
(Full stroke)
mm
55200800025
HEATER, AIR CONDITIONER AND
– Ventilators
VENTILATION
55-41
VENTILATORS
55300160065
REMOVAL AND INSTALLATION
Caution: SRS
When removing and installing the assembly
from vehicles equipped with SRS, do not let it
bump against the SRS diagnosis unit or the
components.
7
8
10
1
1
4
3
9
6
2
NOTE
: Metal clip position
1. Side defroster grille
Air outlet assembly (Driver’s side)
and centre outlet assembly removal
steps
2. Meter bezel assembly
3. Air outlet assembly (Driver’s side)
4. Centre outlet assembly
Foot duct removal steps
D Front floor console assembly (Refer
to GROUP 52A – Floor Console.)
5. Foot duct
5
Defroster nozzle, distribution duct,
air outlet assembly (Passenger’s
side) and centre ventilation duct
removal steps
6. Instrument panel (Refer to GROUP
52A.)
7. Defroster nozzle
8. Distribution duct
9. Air outlet assembly (Passenger’s
side)
10. Centre ventilation duct
HEATER, AIR CONDITIONER AND
– Ventilators
VENTILATION
55-42
<Single cab>
11
11
<Double cab>
11
<Club cab>
12
11
<Single cab>
Air outlet duct assembly removal
steps
D Rear body (Refer to GROUP 42.)
11. Air outlet duct assembly
<Double cab>
Air outlet duct assembly removal
steps
D Rear body (Refer to GROUP 42.)
11. Air outlet duct assembly
12
11
11
<Club cab>
Air outlet duct assembly removal
steps
D Rear body (Refer to GROUP 42.)
11. Air outlet duct assembly
Rear ventilation duct removal steps
D Back panel trim, lower (Refer to
GROUP 52A – Trims.)
D Quarter trim, lower (Refer to GROUP
52A – Trims.)
12. Rear ventilation duct
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