1990 Toyota Supra Factory Repair Manual

1990 Toyota Supra Factory Repair Manual
AC- 1
AIR CONDITIONING
SYSTEM
Page
.................................... AC-2
AIR CONDITIONING SYSTEM CIRCUIT ................. AC-4
SYSTEM COMPONENTS ..................................... AC-8
GENERAL DESCRIPTION ..................................... AC-9
SPECIAL TOOLS AND EQUIPMENT ...................... AC-14
TROUBLESHOOTING .......................................... AC-15
GENERAL INFORMATION
Checking of Refrigeration System w i t h
Manifold Gauge ...........................................
...................................
REFRIGERATION SYSTEM ...................................
Checking of Refrigerant Volume .......................
. Installation of Manifold Gauge Set ....................
COMPRESSOR ...................................................
RECEIVER .........................................................
CONDENSER .....................................................
CONDENSER FAN MOTORS ................................
HEATER BLOWER RESISTOR ...............................
RELAYS ............................................................
PRESSURE SWITCH ...........................................
WATER TEMPERATURE SWITCH .........................
COOLING UNIT ..................................................
Evaporator .....................................................
REFRIGERANT LINES ..........................................
THERMISTOR ....................................................
A/C CONTROL PANEL ASSEMBLY .......................
AMPLIFIERS ......................................................
SENSORS ..........................................................
FUNCTIONAL TEST AND ADJUSTMENT ..............
ON-VEHICLE INSPECTION
AC-2
AIR CONDITIONING SYSTEM - General Information
GENERAL INFORMATION
ELECTRICAL PARTS
Before removing and inspecting the electrical parts, set the
ignition switch t o the LOCK position and disconnect the
negative ( - ) terminal cable from the battery.
CAUTION: Work must not be started until after at least
20 seconds or longer from the time the negative (-1 terminal cable is disconnected.
SRS
AIRBAG SYSTEM
Failure t o carry out service operations in the correct sequence could cause the airbag system t o deploy, possibly
leading t o a serious accident.
When removal or installation of the parts and the yellow
wire harness and connector for the airbag is necessary,
refer t o the precautionary notices in the AB section before
performing the operation.
COOLING SYSTEM
1.
WHEN HANDLING REFRIGERANT (R-12), FOLLOWING
PRECAUTIONS MUST BE OBSERVED;
(a)
Do not handle refrigerant in an enclosed area or near
an open flame.
(b) Always wear eye protection.
(c)
Be careful that liquid refrigerant does not get in your
eyes or on your skin.
If liquid refrigerant gets in your eyes or on your skin;
Do not rub.
Wash the area w i t h lots of cool water.
Apply clean petroleum jelly t o the skin.
Go immediately t o a physician or hospital for professional treatment.
Do not attempt t o treat yourself.
2. WHEN REPLACING PARTS IN REFRIGERANT LINE;
(a)
Discharge the refrigerant in the line slowly before
replacement.
(b)
Insert a plug immediately in disconnected parts t o prevent the entry of moisture and dust.
(c)
DO not leave a new condenser or receiver, etc., lying
around w i t h the plug removed.
AIR CONDITIONING SYSTEM - General Information
AC-3
( d ) Discharge the refrigerant f r o m the charging valve before installing a n e w compressor.
Charging
Valve
If the refrigerant is n o t discharged first, compressor oil will
spray o u t w i t h the refrigerant gas w h e n t h e plug is
removed.
-
(e)
D o n o t use a torch for tube bending or lengthening
operations.
If tubes are heated w i t h a torch, a layer of oxidation forms
inside t h e tube, causing the same kind o f trouble as an accumulation of dust.
3.
Below 4 0 " ~
WHEN HANDLING REFRIGERANT CONTAINER
(SERVICE CAN);
(a) The container m u s t never be heated.
Wrong
(b)
Containers m u s t be kept below 40°C (104OF)
(c)
If warming a service can w i t h h o t water, be careful
t h a t the valve o n t o p of the service can is never immersed i n the water, as the water m a y permeate the
refrigerant cycle.
(d)
Empty service cans m u s t never be re-used.
Correct
4.
WHEN A/C IS ON AND REFRIGERANT GAS IS BEING
REPLENISHED;
(a)
If there is n o t enough refrigerant gas in the refrigera n t cycle, oil lubrication will be insufficient and compressor burnout may occur, so take care t o avoid this.
(b)
If t h e valve o n t h e high pressure side is opened,
refrigerant f l o w s i n the reverse direction and could
cause t h e service can t o rupture, so open and close
t h e valve o n the l o w pressure side only.
(c)
If the service can is inverted and refrigerant is loaded
i n a liquid state, the liquid is compressed and causes
the compressor t o break down, so the refrigerant must
be i n a gaseous state.
(dl
Be careful n o t t o load too much refrigerant gas, as this
causes trouble such as inadequate cooling, poor fuel
economy, engine overheating, etc.
5. WHEN USING GAS-CYLINDER TYPE GAS LEAK TESTER;
(a)
A s a naked flame is used, first make sure t h a t there
are n o flammable substances nearby before using it.
( b ) Be careful, as a poisonous gas is produced w h e n
refrigerant gas comes in contact w i t h heated parts.
AC-4
AIR CONDITIONING SYSTEM - Air Conditioning System Circuit
AIR CONDITIONING SYSTEM CIRCUIT
7M-GTE Engine
AIR CONDITIONING SYSTEM - Air Conditioning System Circuit
@
Fan Motor
Fan Motor
Ambient S e n s o r
No 2
12 HR
27 ST25 S T *
2 2: -4H
SG
1
B FACE
7
WL
19'00T
16
6 DEF
F/C
Panel Assembly
@
@ ~ e l a y Bcx
@ ~ ~ e c l Ci o n n e c t a r
AC-5
AC-6
AIR CONDITIONING SYSTEM - Air Conditioning System Circuit
AIR CONDITIONING SYSTEM CIRCUIT (Cont'd)
7M-GE Engine
AIR CONDITIONING SYSTEM - Air Conditioning System Circuit
AC-7
AIR CONDITIONING SYSTEM - System Components
AC-8
SYSTEM COMPONENTS
1
Cooling Unit
High Pressure Switch
7M-GT-E E/G
Condenser
1
Ambient Sensor
Condenser Fan No. 3
\
"Ited
in-car Sensor
Fitting size
Torque
0.31 in. Tube
135 (10. 13)
0.50 in. Tube
225 (16, 22)
0.62 in. Tube
325 (24,32)
Type
(For Compressor)
(For Condenser)
' - 4 7
Receiver
Solar Sensor
Control Servo Motor
.\
250 (18, 25)
250 (18, 25)
AC1708
AIR CONDITIONING SYSTEM
I
Discharge Port
Suction Port
-
AC-9
General Description
GENERAL DESCRIPTION
REFRIGERATION CYCLE
1.
The compressor discharges high temperature and high pressure refrigerant containing t h e heat absorbed f r o m t h e
evaporator plus the heat created b y the compressor in a
discharge stroke.
2.
This gaseous refrigerant f l o w s into the condenser. In the
condenser, t h e gaseous refrigerant condenses into liquid
refrigerant.
3.
This liquid refrigerant f l o w s into t h e receiver w h i c h stores
and filters the liquid refrigerant till t h e evaporator requires
the refrigerant.
4.
The liquid refrigerant is changed b y the expansion valve into a l o w temperature, l o w pressure liquid
and gaseous mixture.
5.
This cold and foggy refrigerant f l o w s t o the evaporator. Vaporizing the liquid i n t h e evaporator, the
heat f r o m the w a r m air stream passing through t h e evaporator core is transferred t o t h e refrigerant.
All t h e liquid is changed into the gaseous refrigerant in the evaporator and only heat-laden gaseous
refrigerant is d r a w n into t h e compressor. Then t h e process is repeated again.
Blower
%
E V A P O R A T O R . In whlch
released r e f r l g e r a n t expands
and flows through t h e evapor a t o r tubes
It then removes
evaporator cores, causlng a
heat f r o m t h e aw blow~ng
drop In pressure and conse-
across t h e flns and tubes.
quent drop In temperature
and evaporates, causlng
t h e temperature ~ n s ~ dte
he
car t o be gradually lowered
t
J, COMPRESSOR
draws o f f
gaseous refrlgerant from t h e
I
I
evaporator and compresses
~t Thls causes the r e f r ~ g -
(
I\
I
I \
I\
erant gas temperature and
i-
2, RECEIVER
pressure t o rlse rapldly
removes any
t r a c e s of rnolsture and
fllters out d r t In t h e system
f a CONDENSER,
I
-
It also serves as a reservou
through whlch t h e heated refrlgerant
gas glves o f f heat t o t h e englne coollng alr
7
The
r e h g e r a n t gas cools o f f and once agaln becomes a
hquld
J
f o r excess refrlgerant
AIR CONDITIONING SYSTEM - General Description
AC-10
1.
PRINCIPLE OF A/C ELECTRICAL CIRCUIT
Ignition
Switch (ACC)
I
A/C Fuse
1
lqnition
&itch ( l G ON)
A/C Switch
Blower
>Motor
Dual Pressure A/C
Switch
Amolif ier
Battery
T
h
Blower
Switch
Thermistor
@ - - TEMP.
----
2. HOW IS THE MAGNETIC CLUTCH ENERGIZED?
The general process until t h e magnetic clutch is energized is s h o w n below.
8
1 lgnition S w i t c h "ON"
--
2 Blower S w i t c h "ON"
Heater Relay "ON"
(Blower M o t o r "RUN")
($
AIC S w i t c h "ON"
?9
Thermistor supplies temperature signal of evaporator t o AIC amplifier.
AIC Amplifier "ON"
(AIC A m p . Main Power Supply)
4 Dual Pressure S w i t c h "ON":
Refrigerant Condition ( 2 . 1 k g l c m 2 ( 3 0 psi, 2 0 6 kPa) less than 2 7 k g / c m 2 ( 3 8 4 psi, 2 , 6 4 8 kPa))
I
6 VSV "ON"
-
E/G Idle-up
7 Magnetic Clutch Relay "ON"
79
8 Temperature Sensor "ON":
Temperature of Temperature Sensor is less than 1 8 0 ° C ( 3 5 6 ° F ) .
Magnetic Clutch " O N f r
h
10 Revolution Detecting Sensor supplies RPM signal of compressor t o AIC amplifier.
If compressor is n o t locked, magnetic clutch is continuously energized.
AC-11
AIR CONDITIONING SYSTEM - General Description
PRINCIPLE OF AUTOMATIC AIR CONDITIONING SYSTEM
1.
WHAT'S AUTOMATIC AIR CONDITIONING SYSTEM?
Automatic air conditioning system automatically controls the interior room temperature, the blower speed,
the air vent mode, etc, according t o setting temperature of hope. It keeps good air condition at all seasons.
2. HOW FUNCTIONS DOES AUTOMATIC AIR CONDITIONING SYSTEM HAVE?
Automatic air conditioning system has four main functions as follows.
( 1 ) Interior Room Temperature Control System & Blower Speed Control System
- - - - - Max. Cool Position
Block
Water Valve
Water Valve
Diaphram
Heater
Relay
lower Motor
There is water temperature
switch under heater core.
* System Amplifier is built in
AIC panel control assembly.
I
I
AC-12
AIR CONDITIONING SYSTEM - General Description
(;;;)
lnterior Room Temperature Control System & Blower Speed
Control System (Cont'd)
Heater Control
Assembly
I
1-
I
Temp.
1
Resistor
7 1
(a)
lnterior Room Temperature Control System
For example, n o w interior room temperature is rising.
Servo
Amplifier
In-Car
Sensor
Sensor
Sensor
Resistance value of in-car sensor decreases.
Voltage of V i decreases.
System amplifier rotates a motor in air m i x control servo motor
a
Air m i x control servo motor shaft moves t o w a r d s max. cool side.
Resistance value of potentiometer increases.
Voltage of V i increases in original condition.
Air m i x control servo motor shaft stops.
* W h e n air m i x control servo m o t o r shaft moves at m a x . cool position, water valve VSV is o f f . A n d
water valve is close.
( b ) Blower Speed Control System
A s aforeside, according t o moving of air m i x control servo motor, blower speed is controlled.
Warm-up S y s t e m
condition:
Blower S w i t c h
/AUTO\position.
Air M o d e S w i t c h is
v
l
or
position
This system has a function that t h e blower unit b l o w s cold air t o your feet.
Water Temperature Switch
Water Temperature
I
Blower Motor
Less than 20°C (68°F)
20°C ( 6 8 " ~Switch
)
+
OFF
OFF
20°C - 40°C (68" F - 104" F )
20°C (68°F) Switch
~ o ' c ( I o ~ ' F ) switch
+
-+
ON
OFF
Low Only
+
ON
ore than 4 0 ' ~(104°F)
I
40°C (104°F) Switch
1
Automatic Control
I
AIR CONDITIONING SYSTEM - General Description
AC-13
(2) Air V e n t M o d e Control S y s t e m & RECIRCIFRESH Control System
OutsideAir
RECIRC/FRESH
Control Damper
Air Mix Control Damper
Blower Motor
Cool Air By-Pass
Control Damper
Cool Air By-Pass Duct
Air Flow Control Damper
Side Ventilator
Center
Ventilator
\
side Ventilator
~ o h e Ventilator
r
AC1371
(a)
Air V e n t M o d e Control S y s t e m
Air-flow changes as follows.
Air m i x control servo motor shaft moves.
Program s w i t c h is changed.
(Signal is transmitted t o relay b o x )
VENT
BI-LEVEL
h
Relay box rotates a motor in air vent mode control servo
motor.
Servo motor links move.
Each damper moves.
A s aforeside, t h e air f l o w s as s h o w n l e f t illustration.
HEAT
23 Cool Air
*
DEF
Warm Air
AC-14
AIR CONDITIONING SYSTEM
-
General Description, Special Tools and Equipment,
S S M ( S ~ e c i aService
l
Materials)
( b ) RECIRCIFRESH Control S y s t e m
RECIRC and FRESH changes as
follows.
RECIRC/FRESH
Control Dampers
RECIRCIFRESH
:rol Servo
A
n
/
@
RECIRC/FRESH control switch is pushed.
@
System amplifier rotates a motor i n
RECIRCIFRESH control servo motor.
@)
RECIRCIFRESH control dampers moves
as s h o w n left illustration.
SPECIAL TOOLS AND EQUIPMENT
SST NO.
Tool
I
Use
Manifold gauge set
To evacuate and charge system
Ohmmeter
To perform electrical diagnosis
Voltage meter
T o perform electrical diagnosis
Ammeter
T o perform electrical diagnosis
Magnetic clutch stopper
T o remove and install pressure plate
Magnetic clutch remover
T o remove pressure plate
Snap ring pliers (External type)
To remove and install rotor and stator
I
SSM (SPECIAL SERVICE MATERIALS)
I
Part Name
DENSOOIL 6,
SUNlSO No.5GS or qeuivalent
Part No.
07 1 17 - 6 8 0 4 0
Use etc.
Compressor
I
1
I
/ AC-4,6
Fuses
-
Main Relay
AC-4,6
Wiring Connection
AC-4,6
Refrigerant in System
AC-17
3
Heater Relay
AC-3 1
4
Blower Motor
5
Blower Resistor
2
- .-
-- -
AC-30
Water Temp. SW 20°c (68OF)
+AC-32
Water Temp. SW 40°c ( 1 0 4 ~ ~ )
-
Dual Pressure Switch
High Pressure Switch
I Magnetic Clutch
I AC-22
Clutch Relay
A/C Amplifier
I compressor
1 Condenser
I AC-22
Evaporator
Expansion Valve
--
Receiver
/ Thermistor
I Drive Belt
/ AC-37
I AC-20
A/C Switch
AC-38
Blower Switch
Temp. Control System
Air Vent Mode Switch
RECIF RE Control Switch
In-Car Sensor
Ambient Sensor
Solar Sensor
Potentiometer
Program Switch
---
Air Mix Control Servo
Air Vent Mode Control Servo
REC/F RE Control Servo
System Amplifier
Water Valve VSV
Water Valve Diaphram
Water Valve
Leak in System
Excessive Moisture
in System
Air in System
Air or Excessive
Compressor Oil in System
Air Inlet Blocked
Air Leakage from
Cooling Unit or Air Duct
Servo Motor Links
AIR CONDITIONING SYSTEM - Troubleshooting
AC-17
Checking of Refrigeration System with Manifold Gauge
This is a method in which the trouble is located by using a manifold gauge. Read the manifold gauge pressure with the following conditions are established:
(a) Temperature at the air inlet is 3 0 - 35OC (86 - 95OF)
(b) Engine running at 1,500 rpm
(c)
Blower fan speed switch set at high speed
(d) Temperature control lever set at cool side
HINT:
It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.
NORMALLY FUNCTIONING
REFRIGERATION SYSTEM
Gauge reading:
Low pressure side
1 . 5 - 2 . 0 kglcm2
( 2 1 - 2 8 psi, 1 4 7 - 1 9 6 kPa)
High pressure side
1 4 . 5 - 1 5 . 0 kg/cm2
( 2 0 6 - 2 1 3 psi, 1 , 4 2 2 - 1.47 1 kPa)
Each pointer of manifold gauge
point to position A
1
1
Moisture present in refrigeration system
Periodically cools and then fails to cool
Insufficient refrigerant
Insufficient cooling
Poor circulation of refrigerant
Insufficient cooling
1
Refrigerant overcharge or insufficient cooling
of condenser
Does not cool sufficiently
/
Expansion valve improperly mounted, heat
sensing tube defective (opens too wide)
lnsufficient cooling
Air present in refrigeration system
Does not cool sufficiently
7
Refrigerant does not circulate
Does not cool (Cools from time to time in
some cases)
8
l nsufficient compression
Does not cool
2
3
Between
Aand B
c
I
1
1
Position of
Pointers
Condition
Trouble
6
1 1
Low is D
High is [Y
I
F
AC-18
AIR CONDITIONING SYSTEM - Troubleshooting
Checking of Refrigeration System with Manifold Gauge (Cont'd)
Symptom seen in
refrigeration system
No.
Probable cause
During operation, pressure
at low pressure side sometimes becomes a vacuum
and sometimes normal
1
Moisture entered in
refrigeration system
freezes at expansion valve
orifice and temporarily
stops cycle, but normal
state is restored after a
time when the ice melts
Remedy
Diagnosis
(1) Replace receiver and
drier
(2) Remove moisture in
cycle through repeated
vacuum purging
(3) Charge refrigerant t o
proper amount
Drier in oversaturated
state
3.
Moisture in refrigeration
system freezes at expansion valve orifice and
blocks circulation of
refrigerant
I
Gas leakage at some place
in refrigeration system
; Pressure low at both low
1
and high pressure sides
(1) Check with leak de.
tector and repair
Insufficient refrigerant in
system
.1
2
Refrigerant leaking
(2) Charge refrigerant to
proper amount
Refr~gerantflow
obstructed by dirt in
recelver
Receiver clogged
Replace receiver
Unable to develop
sufficient performance
due to excessive
refrigerant in system
Excess refrigerant in
cycle + refrigerant
overcharged
Condenser cooling
insufficient
Condenser cooling
insufficient + condenser
fins clogged or fan motor
faulty
low and high pressure
sides
Trouble in expansion
valve or heat sensing
tube not installed
correctly
Excessive refrigerant in
low pressure piping
Frost or large amount of
dew on piping a t low
pressure side
Refrigerant flow out
Expansion valve opened
too wide
(2) I f (1) is normal, t e s t
expansion valve in unit
(3) Replace if defective
Air entered refrigeration
system
Air present in refrigeration
system
( 1) Replace receiver and
drier
(2) Check compressor oil
to see if dirty or
insufficient
(3) Vacuum purge and
charge new refrigerant
Bubbles seen in sight
I glass
I lnsufficient cooling
performance
--
Pressure low at both low
and high pressure sides
3
I
--
Frost on tubes from
receiver to unit
I
I
Pressure too high a t both
low and high pressure
sides
Pressure too high at both
low and high pressure
sides
HINT: Vent out
refrigerant through
gauge manifold low
pressure side by
gradually opening
valve.
I
I
1 Pressure too high a t both
Clean condenser
Check fan motor
operation
If (1) and (2) are normal, check refrigerant
amount
1
J
lnsufficient vacuum
purging
( 1 ) Check heat sensing
tube installed condition
"Note a t No. 6
These gauge indications are shown when the refrigeration system has been opened and the refrigerant
charged without vacuum purging.
AIR CONDITIONING SYSTEM - Troubleshootina
AC-19
Checking of Refrigeration System with Manifold Gauge (Cont'd)
Symptom seen in
refrigeration system
Probable cause
Vacuum indicated at low
pressure side, very low
pressure indicated at
high pressure side
Refrigerant flow
obstructed by moisture
or dirt in refrigerant
freezing or adhering to
expansion valve orifice
Frost or dew seen on
piping before and after
receiver and drier or
expansion valve
Refrigerant flow
obstructed by gas leakage
from expansion valve
heat sensing tube
Remedy
Diagnosis
Expansion valve orifice
clogged
4
Refrigerant does not flow
Allow t o stand for soml
time and then restart
operation t o determine
if trouble is caused by
moisture or dirt.
If caused by moisture
refer t o procedures Stel
2 on page AC-18.
If caused by dirt, remoj
expansion valve and cle
off dirt by blowing wit1
air. I f unable to removl
dirt, replace valve.
Vacuum purge and chat
new refrigerant to prop
amount.
For gas leakage from ht
sensing tube, replace ex
pansion valve.
Pressure too high at low
pressure side
Pressure too low a t high
pressure side
Internal leak in compres
sor
Compression defective
4
Repair or replace compressor
Valve leaking or broken
sliding parts
(Piston, cylinder, gasket,
etc.) broken
Discharging of Refrigeration System
Evacuating and Charging of
Refrigeration System
(See Air Conditioning Fundamentals and Repairs Pub. No.
36950E3
AIR CONDITIONING SYSTEM - On-Vehicle Inspection
AC-20
ON-VEHICLE INSPECTION
CHECK CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, clean them with pressurized water.
CAUTION:
CORRECT
WRONG
WRONG
Be careful not t o damage the fins.
MAKE SURE THAT DRIVE BELT IS INSTALLED
CORRECTLY
After installing the drive belt, check that i t fits properly in
the ribbed grooves.
CHECK DRIVE BELT TENSION
Nippondenso
Borroughs
Using a belt tension gauge, check the drive belt tension.
Belt tension gauge:
Nippondenso BTG-20(95506-00020) or
No.BT-33-73F
Borroughs
Drive belt tension:
New belt 1 6 0
Used belt 1 0 5
+ 2 0 Ib
+ 1 0 1b
HINT:
"New belt" refers t o a belt which has been used less
than 5 minutes on a running engine.
"Used belt" refers t o a belt which has been used on a
running engine for 5 minutes or more.
START ENGINE
TURN ON A/C SWITCH
Check that the A/C operates at each. position of the blower switch.
CHECK MAGNETIC CLUTCH OPERATION
If magnetic clutch does not engage, check the A/C fuse.
CHECK THAT IDLE INCREASES
When the magnetic clutch engages, engine revolution
should increase.
Standard idle-up rpm:
M I T (N range)
A I T (D range)
7M-GTE EIG
9 0 0 rpm
7 0 0 rpm
7M-GE EIG
9 0 0 rpm
6 5 0 rpm
CHECK CONDENSER FAN MOTOR ROTATES
CHECK AMOUNT OF REFRIGERANT
If you can see bubbles in the sight glass, additional refrigerant is needed. (See page AC-21)
10. IF NO COOLING OR IT IS INSUFFICIENT, INSPECT FOR
LEAKAGE
Using a gas leak detector, inspect each component of the
refrigeration system.
AC-21
AIR CONDITIONING SYSTEM - Refrigeration System
REFRIGERATION SYSTEM
Checking of Refrigerant Volume
1.
RUN ENGINE AT APPROX. 2,000 RPM
2.
OPERATE AIR CONDITIONER AT MAXIMUM COOLING
FOR A FEW MINUTES
3.
CHECK AMOUNT OF REFRIGERANT
Observe the sight glass on the receiver.
Amount of refrigerant
Symptom
l tem
Remedy
Bubbles present in sight glass
Insufficient
Check for leak w i t h gas leak detector
No bubbles present in sight glass
Empty, proper or t o o much
Refer t o items 3 and 4
No temperature difference between
compressor inlet and outlet
Empty or nearly empty
Evacuate and charge system. Then
check for leak with gas leak detector
Temperature between compressor
inlet and outlet is noticeably
different
Proper or too much
Refer to items 5 and 6
Immediately after the air
conditioner is turned off,
refrigerant in sight glass stays
clear
Too much
Discharge the excess refrigerant t o
specified amount
When the air conditioner is turned
off, refrigerant foams and then
stays clear
Proper
Installation of Manifold Gauge Set
i i g h Pressure
2harging Valve
Low Pressure
Charging Valve
/
1.
CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
2.
INSTALL CHARGING HOSES OF GAUGE SET TO CHARGING VALVES
Connect the low pressure hose (Blue) t o the l o w pressure
charging valve and the high pressure hose (Red)t o the high
pressure charging valve. Tighten the hose nuts by hand.
HINT: Do not apply compressor oil t o the seat of the connection.
AC-22
AIR CONDITIONING SYSTEM
-
Compressor
COMPRESSOR
ON-VEHICLE INSPECTION
1.
INSTALL MANIFOLD GAUGE SET
(See page AC-21)
2.
RUN ENGINE AT APPROX. 1 , 5 0 0 RPM
3.
CHECK COMPRESSOR FOR FOLLOWING:
(a)
High pressure gauge reading is not lower and l o w pressure gauge reading is n o t higher than normal.
(b)
Metallic sound
(c)
Leakage f r o m shaft seal
If defects are found, repair the compressor
4.
CHECK MAGNETIC CLUTCH
(a)
Inspect the pressure plate and the rotor for signs of oil.
( b ) Check the clutch bearings for noise and grease
leakage.
(c)
Using an ohmmeter, measure the resistance of the stator coil between the clutch lead wire and ground.
Standard resistance:
2 . 7 - 3 . 1 Q at 2 0 ° C (68OF)
If resistance value is n o t as specified, replace t h e coil.
(d)
Connect the positive ( + ) lead f r o m the battery t o terminal 1, check that the magnetic clutch is energized.
If magnetic clutch is not energized, replace the coil.
NOTICE: Do not short the positive ( + ) lead wire on the
vehicle by applying battery voltage.
AC-23
AIR CONDITIONING SYSTEM - Compressor
I
Compressor
Drive Belt
kg-cm (ft-lb,
Bolt
~4
: S p e c ~ f ~ etorque
d
AC1814
REMOVAL OF COMPRESSOR
RUN ENGINE AT IDLE SPEED WITH AIR CONDITIONING
ON FOR 10 MINUTES
STOP ENGINE
DISCONNECT NEGATIVE AND POSITIVE CABLE FROM
BATTERY
REMOVE BATTERY
DISCONNECT CLUTCH LEAD WIRE FROM WIRING
HARNESS
DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
DISCONNECT TWO HOSES FROM COMPRESSOR
SERVICE VALVES
Cap t h e open fitting immediately t o keep moisture o u t of
the system.
REMOVE COMPRESSOR
(a)
Loosen the drive belt.
(b) Remove the compressor mounting bolts and the compressor.
AC-24
AIR CONDITIONING SYSTEM - Compressor
Bolt
I
Snap Ring
Pressure Plate
+
Non-reusable part
AC1812
DISASSEMBLY OF MAGNETIC CLUTCH
1.
REMOVE PRESSURE PLATE
(a) Using SST and socket, remove the shaft bolt.
SST 071 12-76060
(b)
Install SST t o the pressure plate.
SST 071 12-66040
(c) Using SST and the socket, remove the pressure plate.
SST 071 12-76060
AIR CONDITIONING SYSTEM - Compressor
(dl
2.
AC-25
Remove the shims from the pressure plate.
REMOVE ROTOR
(a)
Using SST, remove the snap ring
SST 07 1 14-84020
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE: Be careful not to damage the pulley when tapping on the rotor.
3.
REMOVE STATOR
(a)
Disconnect the stator lead wire from the compressor
housing.
(b) Using SST, remove the snap ring.
SST 07 1 14-84020
AC-26
AIR CONDITIONING SYSTEM - Compressor
(c)
Remove the stator.
ASSEMBLY OF MAGNETIC CLUTCH
1.
INSTALL STATOR
(a)
Install the stator o n the compressor.
(b)
Using SST, install the n e w snap ring.
SST 07 1 14-84020
(c)
2.
SST
Connect the stator lead wires t o the compressor
housing.
INSTALL ROTOR
(a)
Install the rotor on the compressor shaft.
(b)
Using SST, install the n e w snap ring.
SST 07 1 14-84020
AIR CONDITIONING SYSTEM - Compressor
3.
AC-27
INSTALL PRESSURE PLATE
(a)
Install t h e shims t o the pressure plate.
(b)
Using SST and torque wrench, install the shaft bolt.
SST 07 1 12-76060
Torque:
4.
1 4 0 kg-cm ( 1 0 ft-lb, 1 4 Nmm)
CHECK CLEARANCE OF MAGNETIC CLUTCH
Check the clearance between the pressure plate and rotor
using thickness gauge.
Standard clearance:
0.5
+ 0.15 m m (0.020 + 0.006 in.)
If t h e clearance is n o t w i t h i n tolerance, change the number o f shims t o obtain the standard clearance.
Thickness Gauge
INSTALLATION OF COMPRESSOR
(See page AC-23)
1.
INSTALL COMPRESSOR WlTH FOUR MOUNTING BOLTS
Torque:
2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m)
2.
INSTALL DRIVE BELT
(See steps 2 and 3 on page AC-20)
3.
CONNECT TWO HOSES TO COMPRESSOR SERVICE
VALVES
Torque:
Discharge line
Suction line
2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m)
2 5 0 kg-cm ( 1 8 ft-lb, 2 5 Nmm)
4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS
5.
PLACE BATTERY
6.
CONNECT NEGATIVE CABLE TO BATTERY
7.
EVACUATE AIR FROM AIR CONDITIONING SYSTEM
8. CHARGE AIR CONDITIONING SYSTEM WlTH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount:
6 5 0 - 7 5 0 g (1.4
-
1.7 Ib)
AC-28
AIR CONDITIONING SYSTEM - Receiver. Condenser
RECEIVER
(See page AC-8)
ON-VEHICLE INSPECTION
CHECK SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR
LEAKAGE
Use a gas leak detector. Repair as necessary.
REMOVAL OF RECEIVER
1.
DISCHARGE REFRIGERATION SYSTEM
2.
DISCONNECT TWO LIQUID TUBES FROM RECEIVER
HINT: Cap the open fittings immediately t o keep moisture
out of the system.
3. REMOVE RECEIVER FROM RECEIVER HOLDER
INSTALLATION OF RECEIVER
1.
INSTALL RECEIVER IN RECEIVER HOLDER
HINT: Do not remove the blind plugs until ready for connection.
2. CONNECT TWO LIQUID TUBES TO RECEIVER
Torque:
3.
5 5 kg-cm ( 4 ft-lb, 5 N - m )
IF RECEIVER WAS REPLACED, ADD COMPRESSOR OIL
TO COMPRESSOR
Add 2 0 cc (0.7 fl.oz.1
Compressor oil:
DENSOOIL 6,
SUNlSO No.5GS or equivalent
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5.
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount:
6 5 0 - 7 5 0 g (1.4 - 1.7 Ibl
CONDENSER
(See page AC-8)
ON-VEHICLE INSPECTION
1.
CHECK CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with
compressed air.
NOTICE:
Be careful not t o damage the fins.
If the fins are bent, straighten them with a screwdriver or
pliers.
2.
CHECK CONDENSER FITTINGS FOR LEAKAGE
Repair as necessary.
REMOVAL OF CONDENSER
1.
DISCHARGE REFRIGERATION SYSTEM
AIR CONDITIONING SYSTEM - Condenser
2.
AC-29
REMOVE FOLLOWING COMPONENTS:
(a)
Hood lock brace
(b) Center brace w i t h horn
(c) Washer tank w i t h bracket
(d)
Engine under cover (7M-GTE E/G only)
(e)
Intercooler (7M-GTE E/G only)
(f)
Oilcooler (7M-GTE E/G only)
(g) Condenser fan (7M-GTE E/G and AIT model only)
7M-GT EIG Onlv
\\
3.
DISCONNECT DISCHARGE HOSE AND SUCTION HOSE
4.
DISCONNECT LIQUID TUBE AND SUCTION TUBE
K
HINT: Cap the open fittings immediately t o keep moisture
out of the system.
5.
REMOVE CONDENSER
Remove t w o nuts and t w o bolts.
l nte
INSTALLATION OF CONDENSER
1.
INSTALL CONDENSER
(See page AC-8)
2.
CONNECT DISCHARGE HOSE AND SUCTION HOSE
Torque:
Discharge hose
Suction hose
3.
2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m)
3 2 5 kg-cm ( 2 4 ft-lb, 3 2 N - m )
CONNECT LIQUID TUBE AND SUCTION TUBE
Torque:
Liquid tube
Suction tube
(7M-GT EIG and
4.
1 3 5 kg-cm ( 1 0 ft-lb, 1 3 N - m )
3 2 5 kg-cm ( 2 4 ft-lb, 3 2 N - m )
INSTALL FOLLOWING COMPONENTS:
(a)
Hood lock brace
(b) Center brace w i t h horn
(c) Washer tank w i t h bracket
(d) Engine under cover (7M-GTE E/G only)
(e)
Intercooler (7M-GTE E/G only)
(f)
Oilcoolr (7M-GTE E/G only)
(g) Condenser fan (7M-GTE EIG and AIT model only)
5.
IF CONDENSER WAS REPLACED, ADD COMPRESSOR OIL
TO COMPRESSOR
Add 4 0 - 5 0 cc (1.4 - 1.7 fl.oz.1
Compressor oil:
DENSOOIL 6,
SUNISO No.5GS or equivalent
6.
EVACUATE AIR FROM AIR CONDITIONING SYSTEM
7.
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount:
6 5 0 - 7 5 0 g (1.4 - 1.7 Ib)
AC-30 AIR CONDITIONING SYSTEM - Condenser Fan Motors, Heater Blower Resistor, Relays
CONDENSER FAN MOTORS
INSPECTION OF CONDENSER FAN MOTORS
1.
DISCONNECT NEGATIVE CABLE FROM BATTERY
2. DISCONNECT CONNECTOR OF FAN MOTOR
3.
CHECK FAN MOTOR
(a)
Using t h e wire harness, apply battery voltage ( 1 2V)
t o the connector.
( b ) Confirm smooth rotation of the motor within the specified current f l o w .
7M-GTE E/G and A/T Model Only
Standard current:
Fan motor No.1 and No.2
0.8 A (7M-GTE E/G and M / T model)
8.0
0.7 A
7M-GTE E/G and AIT model or
6.7
(7M-GE EIG model
+
+
Fan motor No.3
6.7
0.7 A
+
1
(7M-GTE E/G and A/T model only)
If defective, replace the motor.
4.
CONNECT CONNECTOR OF FAN MOTOR
5. CONNECT NEGATIVE CABLE TO BATTERY
HEATER BLOWER RESISTOR
INSPECTION OF RESISTOR
INSPECT RESISTOR RESISTANCE
Check t h a t there is continuity between terminals 4 and 6.
If there is n o continuity, replace t h e resistor.
RELAYS
INSPECTION OF RELAYS
1.
REMOVE RELAYS
AIR CONDITIONING SYSTEM - Relays
fl
ci t , !
AC-31
INSPECT RELAY CONTINUITY
(Magnetic Clutch Relay)
Clutch
(Fan Relay No. I )
(Fan Relay No.2 ; 7M-GTE EIG and A / T Model)
: Continuity
Fan Relay No. 1 &
Fan Relay No. 2
I
BE0908
Fan Relay No. 3
Constant
Apply battery voltage t o
terminal 2 and 4
I
I
I+I0
I
I
I
I
(Fan Relay N o . 3 ; 7M-GTE EIG and A / T Model)
\
Terminals
Condition
I
1
\
3
2
4
Constant
Apply battery voltage to
terminal 1 and 2
1
1
1
No continuity
If continuity is n o t as specified, replace the relay
(Heater Relay)
(a)
Check that there is continuity between terminals 1 and
3.
(b)
Check that there is continuity between terminals 2 and
4.
(c)
Check that there is n o continuity between terminals
4 and 5.
If continuity is n o t as specified, replace the relay
Continuity
5
4
3.
INSPECT RELAY OPERATION
(Heater Relay)
(a)
Apply battery voltage t o terminals 1 and 3.
( b ) Check that there is continuity between terminals 4 and
5.
(c)
Check that there is n o continuity between terminals
2 and 4.
If operation is n o t as specified, replace the relay.
AC-32
AIR CONDITIONING SYSTEM - Pressure S w i t c h , W a t e r T e m p e r a t u r e S w i t c h
PRESSURE SWITCH
(See page AC-8)
ON-VEHICLE INSPECTION
1.
DISCONNECT CONNECTOR OF PRESSURE SWITCH
2.
INSPECT PRESSURE SWITCH
(a)
Install t h e m a n i f o l d gauge set. (See page A C - 2 1 )
(b)
Observe t h e gauge reading.
(c)
C h e c k t h e c o n t i n u i t y b e t w e e n t w o terminals o f t h e
pressure s w i t c h s h o w n i n t h e b e l o w .
Dual Pressure Switch
2.1 kg/cm2
(30 psi, 206 kPa)
27 kg/cm2
(384 psi, 2,648 kPa)
(Continuity)
OFF
(NO continuity)
2.35 kglcm2
(33 psi, 230 kPa)
OFF
21.0 kg/cm2
(299 psi, 2,059 kPa)
If defective, replace t h e pressure s w i t c h .
WATER TEMPERATURE SWITCH
HINT: T h e w a t e r t e m p e r a t u r e s w i t c h i s u n d e r t h e heater
radiator.
INSPECTION OF WATER TEMPERATURE
SWITCH NO. 1
'
INSPECT SWITCH CONTINUITY
Heater Unit
15°C ( 5 9 O ~or
) below
-L.J
25°C ( 7 7 " ~or
) more
OFF
35°C
OFF
45°C
ON
45°C (11 3 " ~ or
) more
1
NO
0
-1
I
continuity
0
AIR CONDITIONING SYSTEM - Water Temperature Switch, Cooling Unit
AC-33
INSPECTION OF WATER TEMPERATURE SWITCH
N0.2, N0.3
(7M-GTE EIG MODEL ONLY)
7M-GTE E/G Onl
INSPECT SWITCH CONTINUITY
Inspect the switch continuity between each terminal at
each water temperature.
7M-GTE E/G Only
Water Temp.
SW No. 3
Water Temp.
SW No. 2
t
OFF
1 12°C (234°F)
If defective, replace the switch.
COOLING UNlT
(See page AC-8)
ON-VEHICLE INSPECTION OF EXPANSION VALVE
1.
CHECK QUANTITY OF REFRIGERANT GAS DURING
REFRIGERATION CYCLE
2.
INSTALL MANIFOLD GAUGE SET
(See page AC-2 1)
3.
RUN ENGINE
Run the engine at 2,000 rpm for at least 5 minutes.
4.
CHECK EXPANSION VALVE
If the expansion valve is clogged, the l o w pressure reading will drop t o 0 kgicm2 (0 psi, 0 kPa), otherwise i t is
OK.
REMOVAL OF COOLING UNlT
1.
DISCONNECT NEGATIVE CABLE FROM BATTERY
2.
DISCHARGE REFRIGERATION SYSTEM
3.
REMOVE CHARCOAL CANISTER WITH BRACKET
4.
DISCONNECT SUCTION TUBE FROM COOLING UNlT
OUTLET FITTING
5.
DISCONNECT LIQUID TUBE FROM COOLING UNlT INLET
FITTING
HINT: Cap the open fittings immediately t o keep moisture
out of the system.
AIR CONDITIONING SYSTEM - Cooling U n i t
AC-34
1
I
6.
REMOVE GROMMETS FROM INLET AND OUTLET
FITTINGS
7.
REMOVE GLOVE BOX AND UNDER COVER
8.
REMOVE GLOVE BOX COVER AND REINFORCEMENT
9.
REMOVE EFI AND A.B.S. COMPUTER
Cooling Unit
10. DISCONNECT CONNECTOR
ncoe.90
11. REMOVE COOLING UNlT
Remove four screws and three nuts
DISASSEMBLY OF COOLING UNlT
I
Upper Unit Case
3r
Drain
7
/
Case
Wire Harness
1.
REMOVE LOWER AND UPPER CASE
(a)
Remove connector of thermistor f r o m unit case.
(b) Remove three clips.
(c)
Remove four screws.
(d)
Remove upper unit case.
(e)
Remove thermistor w i t h thermistor holder.
(f)
Remove lower unit case.
AIR CONDITIONING SYSTEM - Cooling Unit
Hexagonal
2.
AC-35
REMOVE EXPANSION VALVE
(a)
Remove the packing and heat sensing tube from suction and liquid tubes.
(b)
Remove the expansion valve f r o m the evaporator.
Evaporator
INSPECTION OF EVAPORATOR
1.
CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them w i t h compressed air.
NOTICE:
2.
Never use water t o clean the evaporator.
CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
ASSEMBLY OF COOLING UNlT
INSTALL COMPONENTS ON EVAPORATOR
(a)
Connect the expansion valve, suction and liquid tubes
t o the evaporator. Torque the bolt.
Torque:
5 5 kg-cm (47.7 in.-lb, 5 . 4 Nmm)
HINT: Be sure that the O-rings are positioned o n the tube
fitting.
Expansion Valve
(b)
lnstall the holder t o the suction and liquid tubes w i t h
heat sensing tube.
(c)
lnstall the lower unit case t o the evaporator.
(d)
lnstall the thermistor t o the evaporator.
(e)
lnstall the upper unit case.
(f)
lnstall the four screws.
(g)
lnstall three clips.
(h)
lnstall the connector of thermistor.
A C 1859
INSTALLATION OF COOLING UNlT
1.
INSTALL COOLING UNlT
lnstall the cooling unit w i t h four screws and three nuts.
Cooling Unit
2.
CONNECT CONNECTOR OF THERMISTOR
3.
INSTALL EFI AND A.B.S. COMPUTER
4.
INSTALL GLOVE BOX COVER AND REINFORCEMENT
5.
INSTALL GLOVE BOX AND UNDER COVER
6.
INSTALL GROMMETS ON INLET AND OUTLET FITTINGS
AC-36
AIR CONDITIONING SYSTEM - Coolling Unit, Refrigerant Lines
7.
CONNECT LIQUID TUBE TO COOLING UNlT INLET FITTING
Torque the nut.
Torque:
8.
1 3 5 kg-cm ( 1 0 ft-lb, 1 3 N - m )
CONNECT SUCTION TUBE TO COOLING UNlT OUTLET
FITTING
Torque t h e n u t .
Torque:
9.
325 kg-cm ( 2 4 ft-lb, 32 N - m )
IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
Add 4 0 - 5 0 cc (1.4 - 1.7 f l . ~ ~ . )
Compressor oil:
DENSOOIL 6,
SUNlSO No.5GS or equivalent
10. INSTALL CHARCOAL CANISTER WlTH BRACKET
11. CONNECT NEGATIVE CABLE TO BATTERY
12. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
13. CHARGE AIR CONDITIONING SYSTEM WlTH REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount:
6 5 0 - 7 5 0 g (1.4 - I.7 Ib)
REFRIGERANT LINES
(See page AC-8)
ON-VEHICLE INSPECTION
1.
INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT LOOSE
Tighten or replace as necessary.
REPLACEMENT OF REFRIGERANT LINES
1.
DISCHARGE REFRIGERATION SYSTEM
2.
REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fitting immediately t o keep moisture
o u t o f t h e system.
AIR CONDITIONING SYSTEM - Refrigerant Lines, Thermistor
AC-37
3.
TIGHTENING TORQUE FOR O-RING AND BOLTED TYPE
FITTINGS
(See page AC-8)
4.
EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5.
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount:
THERMI
6 5 0 - 7 5 0 g (1.4 - 1.7 Ib)
'OR
REMOVAL AND INSPECTION OF THERMISTOR
1.
DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE GLOVE BOX AND UNDER COVER
3.
CHECK THERMISTOR INSTALLED OPERATION
Using an ohmmeter, measure the resistance at the connector.
Resistance:
1.500 fl at 25OC (77OF)
If resistance value is n o t as specified, replace t h e thermistor.
4.
REMOVE THERMISTOR
(a)
( b ) Remove the screw and thermistor f r o m t h e cooling
unit.
1
Thermometer
n /
Ice
Disconnect the connector.
5.
CHECK THERMISTOR OPERATION
(a)
Place t h e thermistor i n cold water. While varying the
temperature of the water, measure the resistance at
the connector and, at the same time, measure the temperature of t h e water w i t h a thermometer.
( b ) Compare the t w o readings o n the chart.
10 cm
(3.94 in.)
30
32 34 36
Temperature
AC0175
38 4 0 " ~
~ ~ 0 5 4 8
If the intersection is not between the t w o lines, replace the
thermistor.
AC-38
AIR CONDITIONING SYSTEM - A/C Control Panel Assembly
A/C CONTROL PANEL ASSEMBLY
INSPECTION OF A/C CONTROL PANEL
ASSEMBLY
1.
REMOVE A/C CONTROL PANEL ASSEMBLY
2.
MEASURE OUTPUT VOLTAGE
(a)
I
( b ) Connect the negative ( - ) lead from the voltage meter
t o terminal 1 0 and the positive ( + ) lead t o each terminal @ w i t h the resistance.
Blower Speed
REC
FR\S
/
Connect the positive ( + ) lead from the battery t o terminals 1, 2 and the negative ( - 1 lead t o terminal 1 0 .
Mode
LO
HI
Control O F F
M I
( c ) Check that the output voltage is as shown in the chart
below.
l
HINT: Confirm t h a t each indicator lights are lit w i t h butt o n pushed in.
Button
Mode
Control
AlC
Blower
Speed
OFF
AUTO
d
f
2
Resistance @
AUTO
12 or more
1 ;; 1
14
620
12 or more
1 or less
1.5 or less
12 or more
OFF
13
6
DEF
1 2 o r more
1 or less
12 or more
FOOT
620
12 or more
1 or less
BI-LEVE
12 or more
1 or less
FACE
AUTO
AUTO
AC-39
AIR CONDITIONING SYSTEM - A/C Control Panel Assembly
t
Control Button
Mode
Control
Resistance
8
t"
AUTO
Speed
AUTO
I
I
8
1 or less
7
12 or more
620
19
lorless
I
8
1 2 or more
If the voltage is n o t as specified, replace the AIC control
panel assembly.
AIR CONDITIONING SYSTEM - Amplifiers
AC-40
1
Wire Harness Side
AMPLIFIERS
INSPECTION OF AMPLIFIER
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect t h e connector o n the
wire harness side as s h o w n in the chart below.
Test conditions:
( 1 ) Ignition switch: ON
(2) Temperature control lever:
(3) Blower s w i t c h : HI
10 - Ground
Continuity
Voltage
2-10
Resistance
6-9
Specified value
Condition
Tester connection
Check for
M A X COOL
Constant
Continuity
Turn A/C switch on.
Battery voltage
Turn A/C switch off.
Constant
No voltage
Approx. 1.5 k f l a t 2 5 O ~(77°F)
INSPECTION OF SYSTEM AMPLIFIER
(In AIC Control Panel Assembly)
1.
False Signal Input t o System Amplifier
A
False Signal
-
Interior room temperature is very low.
Condition
SYSTEM
AMPL.IFIER
SYSTEM
AMPL.I FI ER
I N-CA R
SENSOR
Your Work
lnterior room temperature is very high.
Remove in-car sensor connector
I-\?
SENSOR
Remove in-car sensor and ground the numl
1 pin of in-car sensor female connector
AIR CONDITIONING SYSTEM - A m p l i f i e r s
2.
System Main Parts
False Signal
A
Air Mix Control
Servo Motor
~
1
AC-41
S y s t e m Operation W h e n I n p u t False Signal
Condition:
S e t t i n g Temperature is a t 25OC (77OF)
Motion
Air mix control servo motor shaft mover towards max. hot side.
Air mix control servo motor shaft moves towards max. cool side.
B
Air Vent Mode Damper
Air Vent Mode
Control Servo
Motor
VENT
BI-LEVEL
HEAT
DEF
A
Close
Close
Open
Close
B
Open
Close
Close
Close
A
Blower motor rotates at high speed.
Blower Motor
B
A
I
OPEN
B
1
CLOSE
Water Valve
I1
FREiREC
Control Servo Motor
I
1
FRE Switch ON
REC Switch ON
1
I
Fresh air is ventilated.
Recirculation air is ventilated.
If necessary, replace t h e s y s t e m amplifier.
AIR CONDITIONING SYSTEM - Sensors
AC-42
SENSORS
1.
IN-CAR SENSOR
Check t h e sensor resistance.
HINT: If there is an open circuit in t h e sensor, t h e syst e m will operate at m a x i m u m heating.
Conversely, if there is a short in the system, i t will operate
at m a x i m u m cooling.
If resistance is n o t as specified, replace the sensor
Thermistor
lknl
I
2.
AMBIENT SENSOR
Check the sensor resistance.
If resistance is n o t as specified, replace t h e sensor.
Thermistor
[kRl
0.62
3.
SOLAR SENSOR
Using an ohmmeter, check the continuity.
HINT: There is t h e solar sensor o n the safety pad of t h e
assistant side.
If there is n o continuity, replace t h e sensor.
AIR CONDITIONING SYSTEM - Functional Test and Adjustment
AC-43
FUNCTIONAL TEST AND
ADJUSTMENT
Automatic Temperature Control
System
ON-VEHICLE INSPECTION
DISCONNECT SHORT CIRCUIT CONNECTOR
MAKE SHORT TERMINALS 1 AND 3 FOR TEST
SET TEMPERATURE CONTROL AT 25OC (77OF)
RUN ENGINE AT IDLING
TURN ON BLOWER SWITCH TO AUTO POSITION
Servo Motor
CHECK AUTOMATIC TEMPERATURE CONTROL SYSTEM
(a)
Verify that the guide plate o n the servo motor is positioned at the mark "0" (between the "R" and "W").
(b)
If t h e guide plate position is n o t at t h e mark " O H , adjust as follows.
(c)
If the guide plate position is over t h e "W" area, conn e c t t h e wire harness RG and BrY.
(dl
If t h e guide plate position is over the "R"
n e c t the wire harness RG and W B .
CONNECT SHORT CIRCUIT CONNECTOR
area, con-
AC-44
AIR CONDITIONING SYSTEM - Functional Test and Adjustment
RECIRCIFRESH Control Servo Motor
INSPECTION OF RECIRCIFRESH CONTROL
SERVO MOTOR
(Operation)
(a)
+
Connect the positive ( ) lead from the battery t o terminal 1 and the negative ( - ) lead t o terminal 2.
(b) Check t h a t the arm rotates smoothly.
(c)
A t this time, check for continuity between terminals
3 and 4 as s h o w n in the illustration.
( d ) Connect the positive ( + ) lead f r o m the battery t o terminal 2 and the negative ( - ) lead t o terminal 1 .
(e)
Check that t h e arm rotates smoothly.
(f)
A t this time, check for continuity between terminals
5 and 6 as s h o w n in the illustration.
If operation is n o t as specified, replace t h e servo motor.
Air Vent Mode Control Servo Motor
INSPECTION OF AIR VENT MODE CONTROL SERVO MOTOR
(Operation)
(a)
Connect the positive ( + ) lead f r o m the battery t o terminal 1 and t h e negative ( - ) lead t o terminal 4.
( b ) Check that the arm rotates smoothly.
(c)
Connect the positive ( + ) lead from the battery t o terminal 4 and t h e negative ( - ) lead t o terminal 1 .
(dl
Check that the arm rotates smoothly.
(Continuity)
Check for continuity between terminal as s h o w n below.
Terminals
\
Arm position
FACE
BI-LEVEL
'K 11
1 1 2
5
6
I
7
I
9
1 1 0 ~ 1 1
Pi-PFW-1
I
FOOT
FOOT-DEF
DEF
I MTWT
1
If operation or continuity is n o t as specified, replace the
servo motor.
AIR CONDITIONING SYSTEM - Functional Test and Adjustment
AC-45
Air Mix Control Servo Motor
INSPECTION OF AIR MIX CONTROL SERVO
MOTOR
(Operation)
(a)
Connect the positive ( + lead from the battery t o terminal 10 and the negative ( - ) lead t o terminal 1 1 .
( b ) Check that the lever moves smoothly from W A R M t o
COOL.
(c)
Connect the positive ( + ) lead from the battery t o terminal 1 1 and the negative ( - ) lead t o terminal 10.
(d)
Check that the lever moves smoothly f r o m COOL t o
WARM.
(Resistance)
While operating the servo motor f r o m either points (a) or
( b ) , measure the resistance values of terminals 5 and 6.
I
I
I
COOL
WARM
BE1168
Position
COOL
WARM
I
I
I
Resistance
(n)
+ 100
200 + 50
1,900
I
I
I
The resistance values f r o m COOL t o W A R M will successively decrease.
If operation or resistance is n o t as specified, replace the
servo motor.
- MEMO -
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