AC HVAC System

AC HVAC System
HVAC SYSTEM
(HEATER, VENTILATOR, AND A/C)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
1. General Description
A: SPECIFICATION
1. HEATER SYSTEM
Item
Specification
5.0 kW (4,299 kcal/h, 17,059
BTU/h) or more
Heating capacity
290 m3 (10,243 cu ft)/h
Air flow rate
Max air flow rate
480
Heater core size
(height × length × width)
Type
Blower motor
Fan type and size
(diameter × width)
m3
(16,954 cu ft)/h
257.5 × 118.5 × 27 mm
(10.1 × 4.67 × 1.06 in)
Magnet motor 250 W or less
Sirocco fan type
150 × 75 mm (5.91 × 2.95 in)
Condition
• Mode selector switch: HEAT
• Temperature control switch: FULL HOT
• Temperature difference between hot water
and inlet air: 65°C (149°F)
• How water flow rate: 360 2
(95.1 US gal, 79.2 Imp gal)/h
Heat mode (FRESH), FULL HOT at 12.5 V
• Temperature control switch: FULL COLD
• Blower fan speed:
Auto A/C: 7th position
• Mode selector lever: RECIRC
—
12 V
—
2. A/C SYSTEM
Item
Specification
Reheat air-mix type
5.0 kW [at 480 m3 (16,954 cu ft)/h]
(4,299 kcal/h, 17,059 BTU/h)
HFC-134a (CH2FCF3)
[0.5r0.03 kg (1.1r0.07 lb)]
Rotary, constant volume (DVK-10R)
Type of air conditioner
Cooling capacity
Refrigerant
Type
Compressor
Magnet clutch
Condenser
Receiver drier
Expansion valve
Evaporator
Discharge
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
105 cc (6.41 cu in)/rev
7,700 rpm
Dry, single-disc type
38.8 W
V-belt 4 PK
100 mm (3.9 in)
Pulley ratio
Type
Core face area
1.32
Sub cool type
0.188 m2 (2.002 sq ft)
Core thickness
Radiation area
Effective inner capacity
Type
Type
Dimensions (W × H × T)
Blower fan
Fan type
Outer diameter × width
Power consumption
Condenser fan (Sub fan)
Motor type
Power consumption
Fan outer diameter
AC-2
16 mm (0.63 in)
4.5 m2 (48.44 sq ft)
177 cm3 (10.8 cu in)
Block
Double tank
290.1 × 172 × 39 mm
(11.42 × 6.77 × 1.54 in)
Sirocco fan
150 × 75 mm (5.91 × 2.95 in)
250 W
Magnet
120 W
318.5 mm (12.5 in)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Item
Radiator fan (Main fan)
Motor type
Power consumption
Fan outer diameter
Idling speed (A/C ON, sub fan ON)
MPFI model
Low pressure switch
operating pressure
Triple switch
High pressure switch
(Pressure switch) operating pressure
Middle-pressure switch
operating pressure
Specification
Magnet
120 W
318.5 mm (12.5 in)
800r50 rpm
177r25 kPa
(1.80r0.25 kgf/cm2, 25.7r3.6 psi)
206r30 kPa
(2.10r0.31 kgf/cm2, 29.9r4.3 psi)
ON o OFF
OFF o ON
2,940r200 kPa
(29.98r2.04 kgf/cm2, 426.3r29 psi)
2,350r200 kPa
(24.00r2.04 kgf/cm2, 340.7r29.0 psi)
ON o OFF
OFF o ON
1,470r120 kPa
(14.99r1.22 kgf/cm2, 213.15r17.4 psi)
1,770r100 kPa
(18.05r1.02 kgf/cm2, 256.65r14.5 psi)
ON o OFF
OFF o ON
(3)
(1)
Thermo-control amplifier working temperature
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 1.5r0.3°C (34.7r0.5°F)
(4) 1.0r0.5°C (33.8r0.9°F)
AC-3
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
B: COMPONENT
1. HEATER COOLING UNIT
(8)
T1
(25)
(28)
(2)
(3)
(7)
T3
(1)
(4)
(5)
(6)
(31) (30)
(5)
(24)
(27)
(9)
(14)
(29)
(27)
T2
(22)
(10)
T3
(26)
(16)
(11)
(17)
(12)
(23)
(21)
(15)
(19)
(13)
(18)
(20)
AC-01766
(1)
(2)
Expansion valve
Gasket
(13)
(14)
Drain hose
Mode actuator
(25)
(26)
Aspirator
Air mix actuator
(3)
Grommet
(15)
Heater core pipe
(27)
O-ring
(4)
(5)
(6)
Case
O-ring
Evaporator pipe
(16)
(17)
(18)
Heater pipe cover
Heater core cover
O-ring
(28)
(29)
(30)
Mode main lever
Vent door link
Defroster door link
(7)
(8)
(9)
(10)
(11)
Evaporator
Lining
Evaporator sensor
Evaporator pipe cover
Evaporator cover
(19)
(20)
(21)
(22)
(23)
Clamp
Heater core
Pipe clamp
Foot duct (LH)
Foot duct (RH)
(31)
Mode link
(12)
Power transistor
(24)
Heater case
AC-4
Tightening torque:N·m (kgf-m, ft-lb)
T1: 5.0 (0.5, 3.7)
T2: 6.68 (0.7, 4.9)
T3: 7.5 (0.76, 5.5)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
2. BLOWER MOTOR UNIT
(3)
(9)
(8)
(1)
(2)
(11)
T
T
(7)
T
(10)
(4)
(6)
(5)
AC-01768
(1)
(2)
(3)
Lining
Upper case
Intake door actuator
(6)
(7)
(8)
Hose
Lower case
Lining
(4)
(5)
Filter
Blower motor ASSY
(9)
(10)
Intake door link
Relay bracket
AC-5
(11)
Relay holder bracket
Tightening torque:N·m (kgf-m, ft-lb)
T: 7.5 (0.76, 5.5)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
3. CONTROL MODULE
(7)
T
(6)
(3)
(5)
(2)
(4)
(1)
AC-01838
(1)
(2)
FRESH/RECIRC switch
Rear defogger switch
(5)
(6)
Mode control dial
Temperature adjustment dial
(3)
(4)
A/C switch
(7)
Control case
Fan speed control dial
AC-6
Tightening torque:N·m (kgf-m, ft-lb)
T: 2 (0.2, 1.48)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
4. AIR CONDITIONING UNIT
T1
(5)
T1
T2
(5)
(5)
(3)
(7)
(4)
T2
(1)
(5)
(2)
(5)
(6)
(5)
T1
T1
AC-01844
(1)
(2)
(3)
Condenser
Hose (High pressure)
Hose (Low pressure)
(4)
Compressor
(5)
(6)
(7)
O-ring
Clamp
Pipe
Tightening torque:N·m (kgf-m, ft-lb)
T1: 7.5 (0.76, 5.5)
T2: 10 (1.0, 7.4)
AC-7
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. COMPRESSOR
T2
(1)
T2
(2)
T2
T1
T2
(3)
(4)
T1
AC-01828
(1)
(2)
Compressor bracket
Compressor
(3)
V-belt
(4)
Compressor bracket
Tightening torque:N·m (kgf-m, ft-lb)
T1: 26.5 (2.7, 19.5)
T2: 36 (3.7, 26.6)
AC-8
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
6. HEATER DUCT
(1)
(3)
(2)
(5)
(6)
(4)
(7)
(8)
AC-01803
(1)
(2)
(3)
Front defroster nozzle
Side defroster duct
Side ventilation duct (LH)
(4)
(5)
(6)
Side ventilation duct (RH)
Center ventilation duct (A)
Center ventilation duct (B)
AC-9
(7)
(8)
Rear heater duct (LH)
Rear heater duct (RH)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
C: CAUTION
4. HANDLING OF REFRIGERANT
1. HFC-134A A/C SYSTEM
• The refrigerant boils at approx. –30°C (–22°F).
When handling it, be sure to wear protective goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.
If the refrigerant gets into your eye, avoid rubbing
your eyes with your hands. Wash your eye with
plenty of water, and receive medical treatment from
an eye doctor.
• Do not heat a service can. If a service can is directly heated, or put into boiling water, the inside
pressure will become extremely high. This may
cause the can to explode. If a service can must be
warmed up, use warm water of 40°C (104°F) or less.
• Do not drop or impact a service can. (Observe
the precautions and operation procedure described
on the refrigerant can.)
• When the engine is running, do not open the
high-pressure valve of the manifold gauge. High
pressure gas may backflow, causing the can to explode.
• Provide good ventilation and do not work in a
closed area.
• In order to prevent global warming, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and recycle the
gas.
• The cooling system components for the HFC134a system such as the refrigerant and compressor oil are different from the conventional CFC-12
system components and they are incompatible with
each other.
• Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle.
Before maintenance, check which A/C system is installed to the vehicle.
(A)
AC-01771
2. COMPRESSOR OIL
• HFC-134a compressor oil has no compatibility
with that of CFC-12 system.
• Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR
(ZXL200PG).
• Do not mix multiple compressor oils.
If CFC-12 compressor oil is used in the HFC-134a
A/C system, the compressor may become stuck
due to poor lubrication, or the refrigerant may leak
due to swelling of rubber parts.
On the other hand, if HFC-134a compressor oil is
used in a CFC-12 A/C system, the durability of the
A/C system will be lowered.
• HFC-134a compressor oil is very hygroscopic.
When replacing or installing/removing A/C parts,
immediately isolate the oil from atmosphere using a
plug or tape. In order to avoid moisture, store the oil
in a container with its cap tightly closed.
(A)
(C)
(B)
(D)
(F)
(E)
3. REFRIGERANT
• CFC-12 refrigerant cannot be used in a HFC134a A/C system. HFC-134a refrigerant, also cannot be used in a CFC-12 A/C system.
• If an incorrect or no refrigerant is used, it will result in poor lubrication and the compressor itself
may be damaged.
AC-00007
(A) Goggles
(B)
(C)
(D)
(E)
Gloves
Avoid open flame
No direct heat on container
Do not discharge
(F) Loosen
AC-10
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. O-RING CONNECTIONS
• Always use a new O-ring.
• In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform work without
using gloves or waste cloths.
• Apply compressor oil to O-rings to avoid sticking,
before installation.
• Use a torque wrench to tighten the O-ring fittings.
Over-tightening will result in damage of the O-ring
and deformation of the pipe end.
• If the work is interrupted before completing pipe
connections, recap the pipes, components and fittings with a plug or tape to prevent foreign matter
from entering.
• Use compressor oil specified in the service manual to lubricate the O-rings.
Apply oil to the top and sides of O-rings before installation.
Apply compressor oil to grooves of the pipe.
AC-00010
• After tightening, use a clean cloth to remove excess compressor oil from the connections and any
oil which may have run on the vehicle body or other
parts.
• If any leakage is suspected after tightening, do
not tighten the connections further, but disconnect
the connections, remove the O-rings, and check
the O-rings, threads, and connections.
(A)
AC-00008
D: PREPARATION TOOL
(A) Seal
• Visually check the surfaces and mating surfaces
of O-rings, threads and connecting points. If a failure is found, replace the applicable parts.
• Install the O-rings straight against the curb of the
pipe.
(A)
(B)
(D)
(C)
CAUTION:
When working on vehicles with a HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compressor oil is mixed, it will result in poor lubrication
and the compressor itself may be damaged.
In order to prevent the mixing HFC-134a and
CFC-12 parts and fluids, the type of tools,
screw types, and replacement valves are different. The gas leak detectors for the HFC-134a
and CFC-12 systems must also not be interchanged.
Tool & screw type
Valve type
(C)
AC-00009
(A) O-ring
(B) OK
(C) NG
(D) Curb
AC-11
HFC-134a
CFC-12
Millimeter size
Quick joint type
Inch size
Screw-in type
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Illustration
Name and Function
WRENCH
Various WRENCHES will be required to service an A/C system. 7 —
40 N·m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be
needed to hold the tube and hose fittings.
AC-00213
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply compressor
oil to the various parts. It can be available at a hardware or drug store.
AC-00012
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) is available either from a
refrigerant supplier or an automotive equipment supplier.
AC-00013
Refrigerant recovery system
A REFRIGERANT RECOVERY SYSTEM is used for the recovery and
recycling of an A/C system refrigerant after contaminants and moisture
have been removed from the refrigerant.
AC-00014
Syringe
A graduated plastic SYRINGE will be needed to add oil into the system
again. A syringe can be available at a pharmacy or drug store.
AC-00015
AC-12
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Illustration
Name and Function
Vacuum pump
A VACUUM PUMP is necessary (for a good working condition), and is
available either at a refrigerant supplier or an automotive equipment
supplier.
AC-00016
Can tap
A CAN TAP for the 397 g (14 oz.) can is available at an automotive
equipment supplier.
AC-00017
Thermometer
A Pocket THERMOMETER is available either at a industrial hardware
store or a refrigerant supplier.
AC-00018
Electronic leak detector
An ELECTRONIC LEAK DETECTOR is available at either a specialty
tool supplier or an A/C equipment supplier.
AC-00019
Weight scale
A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.
AC-00020
AC-13
Refrigerant Pressure with Manifold Gauge Set
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
2. Refrigerant Pressure with Manifold Gauge Set
A: PROCEDURE
1) Place the vehicle in the shade and windless condition.
2) Open the front hood.
3) Connect the manifold gauge set.
4) Open the front windows and close all doors.
5) Increase the engine to 1,500 rpm.
6) Turn the A/C switch to ON.
7) Turn the temperature control switch to MAX COOL.
8) Put in RECIRC position.
9) Turn the blower control switch to HI.
10) Read the gauge.
Standard:
Low pressure: 127 — 196 kPa (1.3 — 2.0 kg/cm2, 18 — 28 psi)
High pressure: 1,471 — 1,667 kPa (15 — 17 kg/cm2, 213 — 242 psi)
Ambient temperature: 30 — 35°C (86 — 95°F)
B: INSPECTION
Symptom
•
•
•
•
•
•
•
Repair order
• Replace the fan motor.
• Clean the condenser fin.
• Discharge refrigerant.
• Replace the receiver dryer.
• After evacuating again, charge an
appropriate amount of refrigerant.
Defective compressor
• Replace the compressor.
Not enough refrigerant
• Check for leaks.
Clogged expansion valve
• Replace the expansion valve.
Expansion valve frozen temporarily by moisture. • Fully evacuate the expansion valve.
Defective compressor
• Replace the compressor.
Defective expansion valve
• Replace the expansion valve.
Too much refrigerant
• Discharge refrigerant.
•
•
•
•
Not enough refrigerant
• Check for leaks.
Clogged expansion valve
• Replace the expansion valve.
Expansion valve frozen temporarily by moisture. • Replace the receiver dryer.
Saturated receiver dryer
•
•
•
High pressure side is unusually high.
•
•
High pressure side is unusually low.
Low pressure side is unusually high.
Low pressure side is unusually low.
Probable cause
Defective condenser fan motor
Clogged condenser fin
Too much refrigerant
Air inside the system
Defective receiver dryer
AC-14
Refrigerant Recovery Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
3. Refrigerant Recovery
Procedure
4) Install the low/high pressure hoses to the low/
high pressure side service ports of the vehicle respectively.
A: PROCEDURE
CAUTION:
• During operation, be sure to wear protective
goggles and protective gloves.
• Connect the refrigerant recovery system with
the manifold gauge set to drain the refrigerant
from the A/C system and recycle the gas.
• When recycling the drained refrigerant, keep
service cans on hand. Because the recovery
rate with the recovery system is approx. 90%,
service cans are necessary to charge the refrigerant.
• Follow the detailed operation procedure described in the operation manual attached to the
refrigerant recovery system.
1) Perform compressor oil return operation. <Ref.
to AC-20, PROCEDURE, Compressor Oil.>
2) Stop the engine.
3) Make sure the valves on the low/high pressure
sides of the manifold gauge set are fully closed.
(1)
(2)
(3)
AC-00147
L
(1) Low pressure side service port
(2) High pressure side service port
H
(3) Close
5) Connect the center hose to the refrigerant recovery system.
6) Follow the operation manual to activate the refrigerant recovery system.
(3)
(1)
(4)
(2)
(6)
(5)
(3)
(1)
(2)
AC-00146
L: Low pressure gauge
H: High pressure gauge
(1) Low pressure valve
(2) Vacuum pump valve
(3)
(4)
(5)
(6)
High pressure valve
For low pressure
For vacuum pump
For high pressure
AC-15
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
4. Refrigerant Charging
Procedure
2) Attach the low pressure side and high pressure
side hoses to the service port of the vehicle.
A: PROCEDURE
CAUTION:
• While working, make sure to wear protective
goggles and gloves.
• Air in the cycle can cause insufficient air conditioning, and water in the cycle can cause
clogging in the cycle (icing) and rust. To remove this air and water content, use a vacuum
pump to perform evacuation of the system before filling with refrigerant. By making the inside of the cycle a vacuum, the water content
will evaporate even at atmospheric temperatures, and can be removed.
1) Close the all valves of the manifold gauge.
(1)
(2)
(3)
L
H
AC-00147
(3)
(1)
(1) Low pressure side service port
(2) High pressure side service port
(3) Close
(4)
(2)
CAUTION:
Confirm that the connection is secure.
3) Connect the center manifold hose of the manifold gauge to the vacuum pump.
4) Operate the vacuum pump and open the low
pressure and high pressure side valves. Next, open
the center manifold hose valve, and begin evacuation.
(6)
(5)
(3)
(1)
(2)
AC-00146
L: Low pressure gauge
H: High pressure gauge
(1) Low pressure valve
(2)
(3)
(4)
(5)
(6)
(2)
Vacuum pump valve
High pressure valve
For low pressure
For vacuum pump
For high pressure
(1)
AC-00148
(1) Vacuum pump
(2) Open
CAUTION:
Make sure to perform evacuation using a vacuum pump.
AC-16
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5) Perform evacuation for 5 minutes or more, and
when the low pressure gauge needle reaches
–100.0 kPa (–750 mmHg, –29.5 inHg) or higher,
close the center manifold hose valve, and stop the
vacuum pump.
6) Leave alone for 5 to 10 minutes after closing the
low pressure side and high pressure side valves,
and check whether there is any change in the low
pressure gauge needle indication. If there is a
change, this indicates a leak. Check the pipe and
hose connections, and check the location with the
problem. In this case, repeat again from step 1).
7) If there is no leakage, continue evacuation for an
additional 20 to 30 minutes.
8) Close all valves, and stop the vacuum pump.
9) Follow the can tap operation manual, and attach
the refrigerant can.
(1)
13) Loosen the center hose connection on the
manifold gauge for a few seconds (if there is a
purge valve on the manifold gauge push this instead) to allow the air in the center manifold hose to
escape using the refrigerant pressure.
AC-00216
14) Open the high pressure side and low pressure
side valves of the manifold gauge to fill with refrigerant.
(2)
(1)
(2)
AC-00214
(1) Tap valve
(2) To the center manifold hose
AC-00217
10) Disconnect the center manifold hose from the
vacuum pump, and connect the hose to the tap
valve.
11) When a 13.6 kg (30 lb) refrigerant container is
used, measure the amount of refrigerant with a refrigerant charging scale, and connect with the center manifold hose.
(1)
(2)
AC-00215
(1) Refrigerant can (HFC-134a)
(2) Weight scale
12) Open the valve on the HFC-134a source.
(1) Open
(2) Open
CAUTION:
When filling with the engine running, do not
open the high pressure side valve. Always fill
from the low pressure side.
15) When the gauge needle indicates approximately 200 kPa (1,500 mmHg, 59.1 inHg), close all
valves.
16) Using a leak tester, check for refrigerant leaks
in the system.
17) After checking that there is no refrigerant leaks,
fill with refrigerant up to the specified amount.
18) If the HFC-134a supply container becomes
empty, close all valves, and close the can tap valve
to replace the empty container. After replacing with
a new HFC-134a supply container, perform air
purge, and resume the filling operation.
19) If the refrigerant filling efficiency drops, close all
valves.
20) Check that both the low pressure and high
pressure valves are closed. Start the engine with
the A/C switch OFF.
21) To prevent damage to the compressor, push
the A/C switch ON-OFF quickly a few times.
AC-17
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
22) Set up the vehicle to the following status:
CAUTION:
When filling with the engine running, do not
open the high pressure side valve.
Always fill from the low pressure side valve.
• A/C switch ON
• Engine running at 1,500 rpm
• Blower speed setting to “HI”
• Temperature setting to “MAX COOL”
• Air inlet setting to “RECIRC”
• Window open
23) Open the low pressure side valve and fill with
refrigerant up to the specified amount.
24) After filling with refrigerant, close all valves and
disconnect the hose from the service port.
25) Attach the cap of the service port.
AC-18
Refrigerant Leak Check
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. Refrigerant Leak Check
A: INSPECTION
1) Operate the A/C system for approx. 10 minutes,
and check that the high-side pressure shows at
least 690 kPa (7.03 kgf/cm2, 100 psi). Then stop
the engine to start the leak test.
2) Starting from the connection between high-pressure pipe and evaporator, check the system for
leaks along the high-pressure side through the
compressor. The following items must be checked
thoroughly.
3) Check the joint and seam between pressure
switch (triple pressure switch) and high-pressure
pipe.
4) Check the connections between condenser and
pipes, and welded joints on the condenser.
The leak tester may detect the oil on the condenser
fins as a leak.
5) Check the joint between compressor and hoses.
6) Check the machined area of the compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Shaft seals may show a slight amount of leakage,
about 3 g (0.1 oz) per year. This is not a problem.
8) Starting from the connection between low-pressure pipe and evaporator, check the system for
leakage along the low-pressure side through the
compressor. The following items must be checked
thoroughly.
• Connection between 2 parts
• Connection between pipe and plate
9) Visually check the rubber area of the flexible
hose for cracks.
Check the entire length of the flexible hose, especially the connection with the metal hose end.
CAUTION:
Carefully check the external surface of hoses
and tubes at approx. 25 mm (0.98 in) per second.
(A)
AC-00036
(A) Flexible hose
10) Disconnect the drain hose from the heater case,
and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
11) Turn the ignition key to the ON position, and
run the blower at high speed for approx. 1 minute.
Stop the blower and check the ventilation grille on
the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds,
then stop it. Check the grille at that position for at
least 10 seconds.
AC-00037
AC-00035
12) Check the valve in the service port.
13) Visually check the rubber seal in the service
port cap.
AC-00038
AC-19
Compressor Oil
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
6. Compressor Oil
A: PROCEDURE
NOTE:
Before making repairs, perform the oil return operation to return the compressor oil in circulation with
the refrigerant to the compressor.
1) Increase the engine to 1,500 rpm.
2) Turn the A/C switch to ON.
3) Turn the temperature control switch to MAX
COOL.
4) Put in RECIRC position.
5) Turn the blower control switch to HI.
6) Leave in this condition for 10 minutes.
B: REPLACEMENT
NOTE:
• If a component has been replaced, add an appropriate amount of compressor oil (same as the
amount of remaining oil in removed component).
• When replacing the compressor, the new compressor will already have the specified amount of
oil in it. Adjust the oil amount (so that the amount
remains the same as that of the removed compressor) and install the new compressor.
• Since the hygroscopicity of compressor oil is
high, perform this series of works quickly.
AC-20
Blower Motor Unit Assembly
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
7. Blower Motor Unit Assembly
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Remove the instrument panel lower. <Ref. to EI46, INSTRUMENT PANEL LOWER, REMOVAL,
Center Console.>
3) Remove the protect cover of ECM.
AC-01772
4) Disconnect the connectors of the intake door actuator and blower motor.
5) Remove the relay holder.
6) Loosen the bolt and nut to remove blower motor
unit assembly.
AC-01773
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to “COMPONENT” of “General Description”. <Ref. to AC-4, HEATER COOLING
UNIT, COMPONENT, General Description.>
<Ref. to AC-5, BLOWER MOTOR UNIT, COMPONENT, General Description.>
AC-21
Blower Motor
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
8. Blower Motor
A: REMOVAL
1) Disconnect the battery ground cable from the
battery.
2) Disconnect the connector of the blower motor.
3) Turn up the floor mat near the blower motor.
4) Loosen the screw to remove the blower motor.
AC-01804
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
Connect the battery positive (+) terminal to terminal
No. 2 of blower motor connector, and negative
(–) terminal to terminal No. 1. Check the blower
motor for smooth rotation.
2
1
AC-01805
AC-22
Power Transistor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
9. Power Transistor
(Auto A/C Model)
A: REMOVAL
1) Remove the instrument panel lower. <Ref. to EI46, INSTRUMENT PANEL LOWER, REMOVAL,
Center Console.>
2) Disconnect the power transistor connector.
3) Remove the two screws and remove the power
transistor.
AC-01806
B: INSTALLATION
Install in the reverse order of removal.
AC-23
Heater Core
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
10.Heater Core
6) Remove the heater core.
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
2) Remove the screws and detach the heater pipe
cover.
AC-01780
B: INSTALLATION
Install in the reverse order of removal.
AC-01778
CAUTION:
Replace O-rings and pipe clamps with new
parts and install securely.
3) Remove the screws and detach the clamp.
AC-01732
4) Remove the pipe clamp and detach the pipe.
AC-01733
5) Remove the heater core cover.
AC-01779
AC-24
Control Unit (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
11.Control Unit (Auto A/C Model)
A: REMOVAL
1) Disconnect the battery ground cable from the
battery.
2) Remove the ornament panel. <Ref. to EI-45,
ORNAMENT PANEL, REMOVAL, Center Console.>
3) Remove the screw and claw and disconnect the
connector to detach the control unit from the ornament panel RH.
AC-01738
B: INSTALLATION
Install in the reverse order of removal.
AC-25
Compressor
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
12.Compressor
9) Remove the bolts and remove the compressor
bracket.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.3 — 0.6 mm (0.0118 — 0.0236 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
terminal of the compressor connector.
3) Check the magnet clutch engagement.
If there is a malfunction, replace the compressor.
B: REMOVAL
1) Perform compressor oil return operation. <Ref.
to AC-20, PROCEDURE, Compressor Oil.>
2) Turn the A/C switch to OFF and stop the engine.
3) Using the refrigerant recovery system, drain the
refrigerant. <Ref. to AC-15, PROCEDURE, Refrigerant Recovery Procedure.>
4) Disconnect the ground cable from the battery.
5) Remove the V-belts. <Ref. to ME(STI)-38, REMOVAL, V-belt.>
6) Remove the generator. <Ref. to SC(STI)-13,
REMOVAL, Generator.>
7) Remove the bolt and remove the low-pressure
hose and high-pressure hose.
AC-01740
10) Remove the bolts, then remove the bracket
from the compressor.
AC-01741
C: INSTALLATION
AC-01739
8) Disconnect the compressor harness from the
body harness.
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hoses with new parts, then apply compressor oil.
3) After replacing the compressor, adjust the
amount of compressor oil. <Ref. to AC-20, PROCEDURE, Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-16, PROCEDURE, Refrigerant Charging Procedure.>
Tightening torque:
Refer to “COMPONENT” of “General Description”. <Ref. to AC-7, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
<Ref. to AC-8, COMPRESSOR, COMPONENT,
General Description.>
AC-26
Condenser
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
13.Condenser
B: INSTALLATION
A: REMOVAL
1) Install in the reverse order of removal.
1) Using the refrigerant recovery system, drain the
refrigerant. <Ref. to AC-15, PROCEDURE, Refrigerant Recovery Procedure.>
2) Disconnect the ground cable from the battery.
3) Disconnect the high pressure hose and pipe
from the condenser.
CAUTION:
Replace the O-rings on hoses or pipes with new
parts, and then apply compressor oil. Confirm
that lower guide (A) of condenser fits into holes
on radiator panel.
(A)
AC-00631
2) Charge with refrigerant. <Ref. to AC-16, PROCEDURE, Refrigerant Charging Procedure.>
AC-01793
4) Remove the radiator brackets.
Tightening torque:
Refer to “COMPONENT” of “General Description”. <Ref. to AC-7, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
<Ref. to CO(STI)-5, RADIATOR AND RADIATOR FAN, COMPONENT, General Description.>
C: INSPECTION
AC-01742
5) Remove the front bumper. <Ref. to EI-26, REMOVAL, Front Bumper.>
6) Remove two bolts. While lifting the condenser,
pull out through space between the radiator and the
radiator panel.
1) Check to see that the condenser fins are not
clogged with debris or insects. Blow with compressed air or flush fins with water as needed.
2) Inspect for oil leakage from the condenser. If a
failure is found, replace the condenser with a new
part.
AC-01743
CAUTION:
• Be careful not to damage the condenser fins.
If a damaged fin is found, repair it using a thin
screwdriver.
• When replacing the condenser, add an appropriate amount of compressor oil to the compressor. <Ref. to AC-20, REPLACEMENT, Compressor
Oil.>
AC-27
Heater and Cooling Unit
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
14.Heater and Cooling Unit
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Using the refrigerant recovery system, drain the
refrigerant. <Ref. to AC-15, PROCEDURE, Refrigerant Recovery Procedure.>
3) Drain coolant from the radiator.
4) Remove the bolts securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
AC-00921
5) Remove the instrument panel. <Ref. to EI-47,
REMOVAL, Instrument Panel Assembly.>
6) Remove the blower motor unit assembly. <Ref.
to AC-21, REMOVAL, Blower Motor Unit Assembly.>
7) Disconnect the connectors of the actuator, thermo sensor, and power transistor.
8) Remove the bolt and nuts and remove the heater and cooling unit.
AC-01596
B: INSTALLATION
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-16, PROCEDURE, Refrigerant Charging Procedure.>
Tightening torque:
Refer to “COMPONENT” of “General Description”. <Ref. to AC-4, HEATER COOLING
UNIT, COMPONENT, General Description.>
AC-28
Evaporator
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
15.Evaporator
6) Remove the evaporator.
A: REMOVAL
1) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-15, PROCEDURE,
Refrigerant Recovery Procedure.>
2) Remove the heater and cooling unit. <Ref. to
AC-28, REMOVAL, Heater and Cooling Unit.>
3) Remove the screws and detach the cover.
AC-01784
CAUTION:
If the evaporator is replaced, add an appropriate amount of compressor oil to evaporator.
<Ref. to AC-20, REPLACEMENT, Compressor
Oil.>
B: INSTALLATION
AC-01781
4) Remove the bolt and detach the pipe.
Install in the reverse order of removal.
CAUTION:
• Make sure that the water seal gasket on the
cover attachment area is securely attached.
• Install the sensor at the position shown in the
figure below.
(1)
(3)
AC-01782
5) Remove the screws and detach the cover.
(4)
(2)
(1)
(3)
AC-01783
(2)
AC-01807
(1) 148 mm (5.83 in) from the upper end of the fin
(2) The 6th column fin from the left end
(3) Sensor
(4) Evaporator
AC-29
Hose and Tube
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
16.Hose and Tube
B: INSTALLATION
A: REMOVAL
CAUTION:
• When disconnecting or connecting the hoses, do not apply excessive force. After installing, check that no torsion or excessive tension
applied to the hoses.
• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-16, PROCEDURE, Refrigerant Charging Procedure.>
CAUTION:
• When disconnecting/connecting hoses, do
not apply an excessive force to them. After installing, check that no torsion or excessive tension applied to the hoses.
• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.
1) Disconnect the ground cable from the battery.
2) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-15, PROCEDURE,
Refrigerant Recovery Procedure.>
3) Remove the evaporator unit mounting bolt (A)
and low-pressure hose bracket bolt (B).
4) Remove the low-pressure hose attaching bolts
(C).
5) Disconnect the low-pressure hose from evaporator unit.
6) Disconnect the low-pressure hose from compressor.
7) Remove the low-pressure hose from vehicle.
8) Remove the high-pressure hose attaching bolt
(D).
9) Disconnect the high-pressure hose from compressor.
10) Disconnect the high-pressure hose from condenser.
11) Remove the high-pressure hose from vehicle.
12) Remove the high-pressure tube attaching bolt
(E).
13) Remove the high-pressure tube from vehicle.
Tightening torque:
Refer to “COMPONENT” of “General Description”. <Ref. to AC-7, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
C: INSPECTION
Check the hoses for cracks, damage and expansion. If any fault is found, replace with new parts.
(A)
(B)
(C)
(D)
(D)
(E)
AC-01808
AC-30
Relay and Fuse
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
17.Relay and Fuse
B: INSPECTION
A: LOCATION
(1)
(2)
(4)
(3)
(E)
(1)
(A)
(2)
(1)
(3)
(4)
(B)
(D)
(C)
AC-00641
(2)
(3) — (4): Continuity exists
(1) — (2): Continuity does not exist
AC-01570
(1) Joint box
(2) Main fuse box
Main fan relay 1
(A)
Main fan relay 2
Sub fan relay
A/C relay
A/C Fuse
(B)
(C)
(D)
(E)
While applying battery voltage to the terminal between (3) and (4), check for continuity between (1)
and (2).
If no continuity exists, replace the relay with a new
part.
AC-31
Pressure Switch (Triple Pressure Switch)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
18.Pressure Switch (Triple Pressure Switch)
A: INSPECTION
1) Connect the manifold gauge to the service valve on the high-pressure side.
2) Disconnect the pressure switch harness connector.
3) Start the air conditioner, and check the operating pressure of switch by turning the compressor (magnet
clutch) to ON/OFF. Operation of each switch is as follows.
(10)
(5)
(4)
(1)
(11)
(10)
(6)
(7)
(2)
(11)
(10)
(9)
(3)
(8)
(11)
(12)
(13)
(13)
(14)
(15)
AC-01433
(1)
(2)
(3)
(4)
High pressure switch
Middle pressure switch
Low pressure switch
2,350r200 kPa
(24.00r2.04 kg/cm2, 340.7r29.0 psi)
(5)
2,940r200 kPa
(29.98r2.04 kg/cm2, 426.3r29.0 psi)
(6)
1,770r100 kPa
(18.05r1.02 kg/cm2,
256.65r14.5 psi)
1,470r120 kPa
(14.99r1.22 kg/cm2,
213.15r17.4 psi)
(10)
ON
(11)
(12)
OFF
Operative range of compressor
(8)
206r30 kPa
(2.10r0.31 kg/cm2, 29.9r4.3 psi)
(13)
(14)
Inoperative range of compressor
Low pressure
(9)
177r25 kPa
(1.80r0.25 kg/cm2, 25.7r3.6 psi)
(15)
High pressure
(7)
NOTE:
• High pressure switch turns the compressor (magnet clutch) to OFF when the refrigerant pressure becomes extremely high to prevent the evaporator, air conditioner piping and expansion valve from getting
damaged or frozen, etc.
• Middle pressure switch effectively controls the radiator fan output by judging high load/low load in normal
range.
• Low pressure switch turns the compressor (magnet clutch) to OFF, judging as low refrigerant level when
the refrigerant pressure becomes extremely low, to prevent the possible seizure if the compressor rotates.
AC-32
Ambient Sensor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
19.Ambient Sensor
(Auto A/C Model)
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Disconnect the ambient sensor connector.
3) Remove the ambient sensor from the radiator
lower panel.
AC-01749
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC(diag)-29, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>
AC-33
Sunload Sensor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
20.Sunload Sensor
(Auto A/C Model)
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Remove the audio. <Ref. to ET-6, REMOVAL,
Audio.>
3) Push out the sunlight sensor from the back side
of the instrument panel.
AC-01845
4) Disconnect the connector, and remove the sunlight sensor.
CAUTION:
Be careful not to damage the interior trims
when removing the sensor.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC(diag)-35, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>
AC-34
In-vehicle Sensor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
21.In-vehicle Sensor
(Auto A/C Model)
A: REMOVAL
1) Disconnect the ground cable from the battery.
2) Remove the instrument panel lower. <Ref. to EI46, INSTRUMENT PANEL LOWER, REMOVAL,
Center Console.>
3) Disconnect the connector and aspirator hose,
remove the screw and remove the in-vehicle sensor from the instrument panel.
AC-01811
CAUTION:
Be careful not to damage the sensors and interior trims when removing.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC(diag)-31, IN-VEHICLE SENSOR, Diagnostic Procedure for Sensors.>
AC-35
Air Vent Grille
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
22.Air Vent Grille
A: REMOVAL
1. CENTER GRILLE
1) Insert the plastic remover into the slit on the bottom of the center panel, to lift the panel.
2) Detach the claw and plastic hook, and remove
the center panel.
EI-02011
3) Remove the air vent center grille from the center
panel.
2. SIDE GRILLE
1) Remove the ornament panel. <Ref. to EI-45, ORNAMENT PANEL, REMOVAL, Center Console.>
2) Remove the claws, and remove the air vent side
grille.
AC-01753
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
1) Check that the direction and amount of air can
be adjusted smoothly.
2) Check that the adjustment can be maintained in
each position.
AC-36
Heater Duct
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
23.Heater Duct
A: REMOVAL
1. REAR HEATER DUCT
1) Remove the heater cooling unit. <Ref. to AC-28,
REMOVAL, Heater and Cooling Unit.>
2) Remove the front seats. <Ref. to SE-6, REMOVAL, Front Seat.>
3) Remove the front side sill cover.
4) Pull off the floor mat to remove the rear center
heater duct (A) and rear heater duct LH, RH (B).
(A)
(B)
AC-00794
B: INSTALLATION
Install in the reverse order of removal.
AC-37
Heater Vent Duct
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
24.Heater Vent Duct
A: REMOVAL
1) Remove the instrument panel. <Ref. to EI-47,
REMOVAL, Instrument Panel Assembly.>
2) Remove the screws, and then remove the heater
vent duct.
AC-01755
B: INSTALLATION
Install in the reverse order of removal.
AC-38
A/C Filter
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
25.A/C Filter
A: REPLACEMENT
1) Remove the glove box damper.
EI-01887
2) Disengage the stopper section and pull the glove
box lid to remove it.
EI-01831
3) Pinch the claw to unlock and remove the A/C filter.
AC-01789
4) Install in the reverse order of removal.
AC-39
General Diagnostic Table
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
26.General Diagnostic Table
A: INSPECTION
Symptoms
Blower motor
Does not operate.
Noise
Does not operate.
Repair order
Fuse
Blower motor relay
Blower motor
Blower switch
Wiring harness
Blower motor
Refrigerant
Fuse
Air conditioning relay
Magnet clutch
Compressor
Pressure switch
A/C switch
Blower switch
Wiring harness
Compressor
Noise
V-belt
Magnet clutch
Compressor
Refrigerant
V-belt
Magnet clutch
Compressor
Pressure switch
Aspirator hose
Cold air not emitted.
Blower fan relay
Blower motor
A/C switch
Blower switch
Control module
Expansion valve
Evaporator
Air mix actuator
Wiring harness
Heater duct
Heater vent duct
Engine coolant
Warm air not emitted.
Temperature of air from vents does not change.
Unable to switch blow vents.
Aspirator hose
Air mix actuator
Blower switch
Heater core
Engine coolant
Air mix actuator
Temperature control switch
Wiring harness
Mode actuator
Mode switch
Wiring harness
AC-40
General Diagnostic Table
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Symptoms
Unable to switch suction vents.
Repair order
FRESH/RECIRC select switch
Intake door actuator
Wiring harness
AC-41
General Diagnostic Table
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
AC-42
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