2004 IMPREZA SERVICE MANUAL QUICK

2004 IMPREZA SERVICE MANUAL QUICK
2004 IMPREZA SERVICE MANUAL
QUICK REFERENCE INDEX
BODY SECTION
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reassembling, inspection and adjustment of
components and diagnostics for guidance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
HVAC SYSTEM (AUTO A/C)
(DIAGNOSTICS)
AC(diag)
AIRBAG SYSTEM
AB
AIRBAG SYSTEM (DIAGNOSTICS)
AB(diag)
SEAT BELT SYSTEM
SB
LIGHTING SYSTEM
LI
WIPER AND WASHER SYSTEMS
WW
ENTERTAINMENT
ET
COMMUNICATION SYSTEM
COM
GLASS/WINDOWS/MIRRORS
GW
BODY STRUCTURE
BS
INSTRUMENTATION/DRIVER INFO
IDI
SEATS
SE
SECURITY AND LOCKS
SL
SUNROOF/T-TOP/CONVERTIBLE TOP
(SUNROOF)
SR
EXTERIOR/INTERIOR TRIM
EI
EXTERIOR BODY PANELS
EB
G1870GE6
2004 IMPREZA SERVICE MANUAL
QUICK REFERENCE INDEX
BODY SECTION
CRUISE CONTROL SYSTEM
CC
CRUISE CONTROL SYSTEM
(DIAGNOSTICS)
CC(diag)
IMMOBILIZER (DIAGNOSTICS)
IM(diag)
G1870GE6
HVAC SYSTEM
(HEATER, VENTILATOR AND A/C)
AC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Page
General Description ....................................................................................2
Refrigerant Pressure with Manifold Gauge Set.........................................20
Refrigerant Recovery Procedure...............................................................21
Refrigerant Charging Procedure ...............................................................22
Refrigerant Leak Check ............................................................................25
Compressor Oil .........................................................................................26
Blower Motor Unit Assembly .....................................................................27
Power Transistor (Auto A/C Model) ..........................................................28
Blower Resistor (Without A/C Model and Manual A/C Model) ..................29
Heater Core...............................................................................................30
Control Unit ...............................................................................................31
Compressor...............................................................................................32
Condenser.................................................................................................33
Heater and Cooling Unit............................................................................34
Evaporator.................................................................................................35
Hose and Tube..........................................................................................36
Relay and Fuse .........................................................................................37
Pressure Switch (Dual Switch)..................................................................38
Ambient Sensor (Auto A/C Model) ............................................................39
Sunload Sensor (Auto A/C Model) ............................................................40
Air Vent Grille ............................................................................................41
Heater Duct ...............................................................................................42
Heater Vent Duct.......................................................................................43
General Diagnostic Table..........................................................................44
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
1. General Description
A: SPECIFICATIONS
1. HEATER SYSTEM
Item
Specifications
Condition
• Mode selector switch: HEAT
• Temperature control switch: FULL HOT
• Temperature difference between hot water
and inlet air: 65°C (149°F)
• Hot water flow rate: 360 2 (95.1 US gal,
79.2 Imp gal)/h
Heating capacity
5.0 kW (4,300 kcal/h, 17,062
BTU/h) or more
Air flow rate
280 m3 (9,888 cu ft)/h
Heat mode (FRESH), FULL HOT at 12.5 V
Max air flow rate
450 m3 (15,892 cu ft)/h
• Temperature control switch: FULL COLD
• Blower fan speed: 4th position
• Mode selector lever: RECIRC
Heater core size
(height × length × width)
Type
Blower
Fan type and size
motor
(diameter × width)
163.9 × 200 × 25.0 mm
(6.45 × 7.87 × 0.984 in)
Magnet motor 200 W or less
Sirocco fan type
150 × 75 mm (5.91 × 2.95 in)
—
at 12 V
—
2. A/C SYSTEM
• AUTO A/C MODEL
Item
Specifications
Reheat air-mix type
5.1 kW
(4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
[0.5±0.05 kg (0.99±0.11 lb)]
Vane rotary, fix volume (CR-14)
Type of air conditioner
Cooling capacity
Refrigerant
Type
Compressor
Discharge
Magnet clutch
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
Condenser
Core thickness
0.21 m2 (2.26 sq ft)
16 mm (0.63 in)
Radiation area
5.34 m2 (57.48 sq ft)
Core face area
Receiver drier
Effective inner capacity
Expansion valve
Type
Type
Evaporator
Dimensions (W × H × T)
Blower fan
144 cm3 (8.79 cu in)/rev
7,000 rpm
Dry, single-disc type
47 W
V-Ribbed 4 PK
125 mm (4.92 in)
1.064
Corrugated fin (Sub cool type)
Fan type
Outer diameter × width
Power consumption
AC-2
250 cm3 (15.26 cu in)
Internal equalizing
Single tank
255 × 200 × 48 mm
(10 × 7.87 × 1.89 in)
Sirocco fan
150 × 75 mm (5.91 × 2.95 in)
200 W
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Motor type
Power consumption
Fan outer diameter
Motor type
Power consumption
Fan outer diameter
MPFI model
Condenser fan (Sub fan)
Radiator fan (Main fan)
Idling speed (A/C ON)
ON → OFF
Low-pressure switch
operating pressure
Dual switch
(Pressure switch)
High-pressure switch
operating pressure
Magnet
120 W (Turbo model), 70 W (Non-turbo model)
320 mm (12.6 in)
Magnet
120 W (Turbo model), 70 W (Non-turbo model)
320 mm (12.6 in)
850±100 rpm
278±29 kPa
(2.83±0.3 kg/cm2, 40.3±4.2 psi)
287+39/−25 kPa
OFF → ON
(2.9+0.4/−0.25 kg/cm2, 42+5.7/−3.6 psi)
2,800±100 kPa
(29±1 kg/cm2, 406±15 psi)
600±200 kPa
(6.12±2 kg/cm2, 87±29 psi)
ON → OFF
DIFF
(3)
(1)
Thermo control amplifier working temperature
(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 2.5±0.5°C (36.5±0.9°F)
(4) 1.5±0.5°C (35±0.9°F)
• MANUAL A/C MODEL
Item
Specifications
Reheat air-mix type
5.1 kW (4,385 kcal/h, 17,402 BTU/h)
HFC-134a (CH2FCF3)
[0.5±0.05 kg (1.10±0.11 lb)]
Vane rotary, fix volume (CR-14)
Type of air conditioner
Cooling capacity
Refrigerant
Type
Compressor
Discharge
Magnet clutch
Max. permissible speed
Type
Power consumption
Type of belt
Pulley dia. (effective dia.)
Pulley ratio
Type
144 cm3 (8.79 cu in)/rev
7,000 rpm
Dry, single-disc type
47 W
V-Ribbed 4 PK
125 mm (4.92 in)
1.064
Corrugated fin (Sub cool type)
Core thickness
0.21 m2 (2.26 sq ft)
16 mm (0.63 in)
Radiation area
5.34 m2 (57.48 sq ft)
Receiver drier
Effective inner capacity
Expansion valve
Type
250 cm3 (15.26 cu in)
Externally equalizing
Condenser
Core face area
AC-3
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Type
Evaporator
Dimensions (W × H × T)
Blower fan
Condenser fan (Sub fan)
Radiator fan (Main fan)
Idling speed (A/C ON)
Fan type
Outer diameter × width
Power consumption
Motor type
Power consumption
Fan outer diameter
Motor type
Power consumption
Fan outer diameter
MPFI model
ON → OFF
Low-pressure switch
operating pressure
Dual switch
(Pressure switch)
High-pressure switch
operating pressure
Single tank
255 × 200 × 48 mm
(10 × 7.87 × 1.89 in)
Sirocco fan
150 × 75 mm (5.91 × 2.95 in)
200 W
Magnet
120 W (Turbo model), 70 W (Non-turbo model)
320 mm (12.6 in)
Magnet
120 W (Turbo model), 70 W (Non-turbo model)
320 mm (12.6 in)
850±100 rpm
278±29 kPa
(2.83±0.3 kg/cm2, 40.3±4.2 psi)
287+39/−25 kPa
OFF → ON
(2.9+0.4/−0.25 kg/cm2, 42+5.7/−3.6 psi)
2,800±100 kPa
(29±1 kg/cm2, 406±15 psi)
600±200 kPa
(6.12±2 kg/cm2, 87±29 psi)
ON → OFF
DIFF
(3)
(1)
Thermo control amplifier working temperature
(Evaporator outlet air)
(2)
(4)
AC-00601
(1) ON
(2) OFF
(3) 1.5±0.5°C (35±0.9°F)
(4) 3.0±0.5°C (37±0.9°F)
AC-4
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
B: COMPONENT
1. HEATER COOLING UNIT
• AUTO A/C MODEL
(24)
(20)
(21)
(23)
T
(26)
(25)
(18)
(22)
(16)
(8)
(7)
(6)
(4)
(5)
(14)
(15)
(3)
(19)
(2)
(17)
(20)
T
(20)
(1)
(10)
(13)
(11)
(12)
(9)
AC-00603
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Unit cover
Mode actuator
Side link
Mode actuator lever
Foot lever
Spring
Mode actuator link
Defroster lever
Foot nozzle
Unit duct cover
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
Heater core clamp
Heater core
Drain hose
Mix actuator
Mix actuator lever
Unit assembly
Aspirator hose
Aspirator
Foot duct
Packing
AC-5
(21)
(22)
(23)
(24)
(25)
(26)
Cooling unit block
O-ring
Expansion valve
Evaporator
Evaporator cover
Thermistor
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.4)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
• MANUAL A/C MODEL
(20)
(16)
(17)
(19)
(22)
T
(21)
(18)
(13)
(7)
(6)
(5)
(8)
(4)
(15)
(12)
(3)
(2)
(14)
T
(15)
(11)
(1)
(9)
(10)
(8)
AC-00733
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Unit cover
Side link
Mode lever
Foot lever
Spring
Mode link
Defroster lever
Foot nozzle
Unit duct cover
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Heater core
Drain hose
Mix lever
Unit assembly
Foot duct
Clip
Packing
Cooling unit block
AC-6
(18)
(19)
(20)
(21)
(22)
O-ring
Expansion valve
Evaporator
Evaporator cover
Thermistor
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.4)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
2. BLOWER MOTOR UNIT
• AUTO A/C MODEL
(4)
(9)
(3)
(6)
(2)
(5)
(7)
T
(10)
(1)
(11)
(12)
T
(8)
AC-00605
(1)
(2)
(3)
(4)
(5)
Upper case
Servo motor
Blower link
Blower link lever A
Blower link lever B
(6)
(7)
(8)
(9)
(10)
Blower link lever C
Filter cover
Filter
Blower motor assembly
Hose
AC-7
(11)
(12)
Power transistor
Power transistor cover
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.4)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
• WITHOUT A/C MODEL AND MANUAL A/C MODEL
(8)
(2)
(4)
(3)
(5)
(6)
T
(9)
(1)
(10)
T
(7)
AC-00734
(1)
(2)
(3)
(4)
(5)
Upper case
Blower link
Blower link lever A
Blower link lever B
Clip
(6)
(7)
(8)
(9)
(10)
Filter cover
Filter
Blower motor assembly
Hose
Blower resistor
AC-8
Tightening torque: N·m (kgf-m, ft-lb)
T: 7.4 (0.75, 5.4)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
3. CONTROL UNIT
• AUTO A/C MODEL
(9)
(7)
(6)
(10)
(8)
(2)
(4)
(5)
(3)
(1)
(2)
AC-00607
(1)
(2)
(3)
(4)
Switch
Control lever
Control panel
In-vehicle sensor
(5)
(6)
(7)
(8)
Aspirator hose
Switch assembly
Control base
Electronic control unit
AC-9
(9)
(10)
Bulb
Control case
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
• WITHOUT A/C MODEL AND MANUAL A/C MODEL
(14)
(10)
(11)
(13)
(9)
(7)
(15)
(12)
(8)
(4)
(1)
(6)
(1)
(5)
(3)
(1)
(2)
AC-00608
(1)
(2)
(3)
(4)
(5)
Dial
Fan control plate
Temperature control plate
Mode control plate
FRESH/RECIRC switching knob
(6)
(7)
(8)
(9)
(10)
Heater control panel
A/C switch (with A/C model)
Rear window defogger switch
Heater control base
Intake cable
AC-10
(11)
(12)
(13)
(14)
(15)
Mode cable
Temperature cable
Bulb
Fan switch ASSY
Harness
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
4. AIR CONDITIONING UNIT
• LHD MODEL
(5)
(8)
(10)
(7)
T2
(6)
(2)
(6)
(6)
T1
(6)
(6)
(4)
T1
T1
T2
T1
(6)
T1
(1)
(9)
(3)
T2
(7)
(6)
T1
AC-00609
(1)
(2)
(3)
(4)
(5)
Condenser
Hose (High-pressure)
Hose (Low-pressure)
Bracket
Compressor
(6)
(7)
(8)
(9)
(10)
O-ring
Clamp A
Clamp B
Tube (To condenser)
Tube (To evaporator)
AC-11
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.4 (0.75, 5.4)
T2: 15 (1.5, 10.8)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
• RHD MODEL
(5)
T2
(6)
(2)
(6)
(6)
(6)
(6)
(3)
T2
T2
T2
T2
(1)
(4)
(6)
T1
AC-00979
(1)
(2)
(3)
Condenser
Hose (High-pressure)
Hose (Low-pressure)
(4)
(5)
(6)
Tube
Compressor
O-ring
AC-12
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.4 (0.75, 5.4)
T2: 15 (1.5, 10.8)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. COMPRESSOR
T5
(4)
(5)
T5
T3
T5
(9)
(2)
(3)
(1)
T2
T1
(6)
(7)
T1
T4
(8)
AC-00611
(1)
(2)
(3)
(4)
(5)
(6)
Idler pulley bracket
Idler pulley adjuster
Idler pulley
Compressor upper bracket
Compressor
Compressor lower bracket
(7)
(8)
(9)
V-belt
Compressor belt cover
Compressor belt cover bracket
AC-13
Tightening torque: N·m (kgf-m, ft-lb)
T1: 7.4 (0.75, 5.4)
T2: 22.6 (2.3, 16.6)
T3: 23.0 (2.35, 17.0)
T4: 28.9 (2.95, 21.3)
T5: 35 (3.6, 26)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
6. HEATER DUCT
(2)
(1)
(3)
(4)
(5)
(7)
(6)
AC-00612
(1)
(2)
(3)
Front defroster nozzle
Side defroster duct (LH)
Side defroster duct (RH)
(4)
(5)
(6)
Side ventilation duct (LH)
Side ventilation duct (RH)
Rear heater duct (LH)
AC-14
(7)
Rear heater duct (RH)
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
C: CAUTION
1. HFC-134A A/C SYSTEM
• Unlike the old conventional CFC-12 system components, the cooling system components for the
HFC-134a system such as the refrigerant and compressor oil are incompatible.
• 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 in the vehicle.
(A)
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 hot water in 40°C (104°F) max.
• 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. The
high-pressure gas will back-flow resulting in an explosion of the can.
• Provide good ventilation and do not work in a
closed area.
• In order to prevent global warning, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.
AC-00006
2. COMPRESSOR OIL
(A)
• HFC-134a compressor oil has no compatibility
with that for R12 system.
• Use only the manufacturer-authorized compressor oil for the HFC-134a system; only use DH-PR.
• Do not mix multiple compressor oils.
If CFC-12 compressor oil is used in a 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 the atmosphere using a plug or tape. In order to avoid moisture, store
the oil in a container with its cap tightly closed.
(C)
(B)
(D)
(F)
(E)
3. REFRIGERANT
AC-00007
• The CFC-12 refrigerant cannot be used in the
HFC-134a A/C system. The HFC-134a refrigerant,
also, cannot be used in the CFC-12 A/C system.
• If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may
be damaged.
4. HANDLING OF REFRIGERANT
• The refrigerant boils at approx. −30°C (−22°F).
When handling it, be sure to wear safety goggles
and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.
AC-15
(A)
(B)
(C)
(D)
(E)
(F)
Goggles
Gloves
Avoid open flame
No direct heat on container
Do not discharge
Loosen
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
5. O-RING CONNECTIONS
• Use new O-rings.
• In order to keep the O-rings free of lint which will
cause a refrigerant gas leak, perform operations
without gloves and shop cloths.
• Apply the compressor oil to the O-rings to avoid
sticking, then install them.
• Use a torque wrench to tighten the O-ring fittings:
Over-tightening will damage the O-ring and tube
end distortion.
• If the operation is interrupted before completing a
pipe connection, recap the tubes, components, and
fittings with a plug or tape to prevent contamination
from entering.
• Use the oil specified in the service manual to lubricate the O-rings.
Apply the oil to the top and sides of the O-rings before installation.
Apply the oil to the area including the O-rings and
tube beads.
AC-00010
(A)
• After tightening, use a clean shop cloth to remove excess 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 retighten the connections, Disconnect the connections, remove the O-rings, and check the Orings, threads, and connections.
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 at right angle to the tube
beards.
(A)
(B)
(D)
(C)
CAUTION:
When working on vehicles with the HFC-134a
system, only use HFC-134a specified tools and
parts. Do not mix with CFC-12 tools and parts. If
HFC-134a and CFC-12 refrigerant or compressor oil is mixed, poor lubrication will result and
the compressor itself may be destroyed.
In order to help prevent mixing HFC-134a and
CFC-12 parts and liquid, the tool and screw
type and the type of service valves used are different. The gas leak detectors for the HFC-134a
and CFC-12 systems must also not be interchanged.
(C)
Tool & screw type
Valve type
AC-00009
(A)
(B)
(C)
(D)
O-ring
OK
NG
Bead
AC-16
HFC-134a
Millimeter size
Quick joint type
CFC-12
Inch size
Screw-in type
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Description
Tools and Equipment
Wrench
Various WRENCHES will be required to service any A/C system. A 7 to
40 N·m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench with various crowfoot wrenches will be needed. Open end or flare nut wrenches will be
needed for back-up on the tube and hose fittings.
AC-00213
Applicator bottle
A small APPLICATOR BOTTLE is recommended to apply refrigerant
oil to the various parts. They can be obtained at a hardware or drug
store.
AC-00012
Manifold gauge set
A MANIFOLD GAUGE SET (with hoses) can be obtained from either a
commercial refrigeration supply house or from an auto shop equipment
supplier.
AC-00013
Refrigerant recovery system
A REFRIGERANT RECOVERY SYSTEM is used for the recovery and
reuse of A/C system refrigerant after contaminants and moisture have
been removed from the refrigerant.
AC-00014
AC-17
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Description
Tools and Equipment
Syringe
A graduated plastic SYRINGE will be needed to add oil back into the
system. The syringe can be found at a pharmacy or drug store.
AC-00015
Vacuum pump
A VACUUM PUMP (in good working condition) is necessary, and may
be obtained from either a commercial refrigeration supply house or an
automotive equipment supplier.
AC-00016
Can tap
A CAN TAP for the 397 g (14 oz) can is available from an auto supply
store.
AC-00017
Thermometer
Pocket THERMOMETERS are available from either industrial hardware store or commercial refrigeration supply houses.
AC-00018
AC-18
General Description
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
Description
Tools and Equipment
Electronic leak detector
An ELECTRONIC LEAK DETECTOR can be obtained from either a
specialty tool supply 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-19
Refrigerant Pressure with Manifold Gauge Set
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
2. Refrigerant Pressure with Manifold Gauge Set
A: OPERATION
1) Place the vehicle in the shade and windless condition.
2) Connect the manifold gauge set.
3) Open the front windows and close all doors.
4) Open the front hood.
5) Increase the engine to 1,500 rpm.
6) Turn ON the A/C switch.
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
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
• Defective compressor
• Not enough refrigerant
• Clogged expansion valve
• Expansion valve frozen temporarily by
moisture
• Defective compressor
• Defective expansion valve
• Too much refrigerant
• Not enough refrigerant
• Clogged expansion valve
• Expansion valve frozen temporarily by
moisture
• Saturated receiver dryer
AC-20
Repair order
• Replace the fan motor.
• Clean the condenser fin.
• Discharge refrigerant.
• Replace the receiver dryer.
• After revacuating the receiver dryer,
charge appropriate amount of refrigerant.
• Replace the compressor.
• Check for leaks.
• Replace the expansion valve.
• Fully evacuate the expansion valve.
•
•
•
•
•
•
Replace the compressor.
Replace the expansion valve.
Discharge refrigerant.
Check for leaks.
Replace the expansion valve.
Replace the receiver dryer.
Refrigerant Recovery Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
3. Refrigerant Recovery Procedure
4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the
vehicle respectively.
A: OPERATION
CAUTION:
• During operation, be sure to wear safety goggles and protective gloves.
• Connect the refrigerant recovery system with
the manifold gauge set to discharge the refrigerant from the A/C system and reuse it.
• When reusing the discharged refrigerant,
keep service cans on hand. Because the discharge 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 the compressor oil return operation.
<Ref. to AC-26, OPERATION, Compressor Oil.>
2) Stop the engine.
3) Make sure the valves on low-/high-pressure
sides of manifold gauge set are fully closed.
(A)
(C)
(A)
(C)
(D)
(B)
(C)
(E)
AC-00022
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(D) Low-pressure side service port
(E) High-pressure side service port
5) Connect the center hose to the refrigerant recovery system.
6) Follow the operation manual to activate the refrigerant recovery system.
(B)
(C)
AC-00021
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
AC-21
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
4. Refrigerant Charging Procedure
4) Carefully open the valves on the low-/high-pressure sides to activate the vacuum pump.
A: OPERATION
(A)
CAUTION:
• During operation, be sure to wear safety goggles and protective gloves.
• Before charging the refrigerant, evacuate the
system to remove small amounts of moisture
remaining in the system.
The moisture in the system can be completely
evacuated only under the minimum vacuum
level. The minimum vacuum level affects the
temperature in the system.
• The list below shows the vacuum values necessary to boil water in various temperature. In
addition, the vacuum levels indicated on the
gauge are approx. 3.3 kPa (25 mmHg, 0.98 inHg)
lower than those measured at 304.8 m (1,000 ft)
above sea level.
Vacuum level required to boil water (at sea level)
Temperature
Vacuum
1.7°C (35°F)
100.9 kPa (757 mmHg, 29.8 inHg)
7.2°C (45°F)
100.5 kPa (754 mmHg, 29.7 inHg)
12.8°C (55°F)
99.8 kPa (749 mmHg, 29.5 inHg)
18.3°C (65°F)
99.2 kPa (744 mmHg, 29.3 inHg)
23.9°C (75°F)
98.5 kPa (739 mmHg, 29.1 inHg)
29.4°C (85°F)
97.2 kPa (729 mmHg, 28.7 inHg)
35°C (95°F)
95.8 kPa (719 mmHg, 28.3 inHg)
(B)
(C)
(C)
(D)
AC-00024
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Slowly open
(D) Vacuum pump turn on
5) After the low-pressure gauge reaches 100.0 kPa
(750 mmHg, 29.5 inHg) or higher, evacuate the
system for approx. 15 minutes (Continue evacuation).
1) Close the valves on low-/high-pressure sides of
the manifold gauge.
AC-00025
(A)
(C)
6) After 15 minutes of evacuation, if the reading
shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher,
close the valves on the both sides to stop the vacuum pump.
(B)
(C)
(A)
(B)
AC-00023
(C)
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(C)
(D)
AC-00026
2) Install the low-/high-pressure hoses to the corresponding service ports on the vehicle respectively.
3) Connect the center hose of the manifold gauge
set with the vacuum pump.
AC-22
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(D) Vacuum pump turn off
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
7) Note the low-pressure gauge reading.
12) Confirm that all the 3 hoses are tightly connected to the manifold gauge set.
(A)
(B)
(C)
(C)
AC-00027
8) Leave it at least 5 minutes, and then check the
low-pressure gauge reading for any changes.
When a gauge indicator shows near to zero point,
this is a sign of leakage. Check pipe connector
points, repair them, make sure there is no leakage
by air bleeding.
9) Following the can tap operation manual instructions, install it to the refrigerant can.
(A)
(B)
AC-00030
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
13) Open the valve on the HFC-134a source.
14) Loosen the center hose connection on the
manifold gauge set (if applicable, press a purge
valve on the manifold gauge set) only for a couple
of seconds to allow the air in the center hose to escape by the refrigerant.
15) Carefully open the high-pressure valve with the
engine stopping.
CAUTION:
Do not open the low-pressure valve.
AC-00028
(A)
(A) Tap valve
(B) Center manifold hose
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 refrigerant amount in use using
a weighting scale.
(C)
(D)
(E)
AC-00031
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
(D) Ignition switch OFF
(E) Slowly open
(A)
(B)
AC-00029
(A) Refrigerant container (HFC-134a)
(B) Weight scale
(B)
CAUTION:
Never run the engine during charging from the
high-pressure side.
16) Close the high-pressure valve when the lowpressure gauge reaches 98 kPa (1 kg/cm2, 14 psi).
Using a leak tester, check the system for leaks.
If any leakage is found after the refrigerant recovery is completed, repair the applicable area.
AC-23
Refrigerant Charging Procedure
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
17) After confirming that there are no leaks with the
leak test, charge the required amount of refrigerant.
CAUTION:
Never run the engine during charging from the
high-pressure side.
18) Close the high-pressure valve when;
• the readings of low-/high-pressure gauges become almost equal, after the charging speed is reduced.
• the HFC-134a source becomes empty, or the
system is filled with the gas.
23) While reading the low-pressure gauge, carefully open the low-pressure valve with the refrigerant
source connected and the service hose purged.
CAUTION:
Never open the high-pressure valve with the engine running. Doing so may result in a reflow of
high-pressure gas and refrigerant can’s explosion.
AC-00034
AC-00032
19) If the HFC-134a source is empty, close the
high-pressure valve, close the valve on the can tap,
and replace the HFC-134a source with a new one
to restart the operation.
24) Adjust the refrigerant flow to maintain the pressure on the low-pressure side at 276 kPa (2.81 kg/
cm2, 40 psi) max.
25) After the system is fully charged, close the lowpressure valve.
26) Close the valve on the refrigerant source.
Refrigerant
HFC-134a
(A)
(C)
(B)
Refrigerant amount
Minimum
450 g (0.99 lb)
Maximum
550 g (1.21 lb)
27) Disconnect the hose from the service port, and
install the service port cap.
(C)
AC-00033
(A) Low-pressure gauge (Compound pressure
gauge)
(B) High-pressure gauge
(C) Close
20) Confirm that both the low-/high-pressure
valves can be closed. Start the engine with the A/C
switch OFF.
21) Quickly repeat ON-OFF cycles a few times to
prevent initial compressor damage.
22) Set up the vehicle to the following status:
• 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”
• Windows open
AC-24
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 confirm that the high-pressure side shows at
least 690 kPa (7.03 kg/cm2, 100 psi). Then stop the
engine to start the leak test.
2) Starting from the connection between the highpressure 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 the pressure
switch (dual pressure switch) and high-pressure
pipe.
4) Check the connections between the 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 the compressor and
hoses.
6) Check the machined area of compressor and
other joints on the compressor.
7) Check the compressor shaft seal at the area
near the center of compressor clutch pulley.
Some shaft seals 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 the lowpressure 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 two parts
• Connection between the pipe and plate
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 ON position, and run
the blower at high speed for 1 minute. Stop the
blower to 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 point for at least 10 seconds.
AC-00037
12) Check the valve in the service port.
13) Visually check the rubber seal in service port
cap.
AC-00035
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.
AC-00038
AC-25
Compressor Oil
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
6. Compressor Oil
A: OPERATION
NOTE:
Before making repairs, conduct the oil return operation to return the compressor oil in circulation with
the refrigerant to compressor.
1) Increase the engine speed to 1,500 rpm.
2) Turn ON the A/C switch.
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 is replaced, add an appropriate
amount of compressor oil.
• When replacing the compressor, the new compressor will already have the specified amount of
oil in it. Install the new compressor after removing
the same amount of oil that is remaining in the compressor removed.
Replacement parts
Evaporator
Condenser
Hose
Amount of oil replenishment
114 m2 (3.9 US fl oz, 4.0 Imp fl oz)
7 m2 (0.24 US fl oz, 0.25 Imp fl oz)
1 m2 (0.03 US fl oz, 0.04 Imp fl oz)
AC-26
Blower Motor Unit Assembly
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
7. Blower Motor Unit Assembly
A: REMOVAL
6) Loosen the bolt and nut to remove the blower
motor unit assembly.
1) Disconnect the ground cable from battery.
2) Remove the glove box. <Ref. to EI-39, REMOVAL, Glove Box.>
3) Loosen the nut to remove the support beam
stay.
AC-00616
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-5, HEATER COOLING UNIT,
COMPONENT, General Description.> and
<Ref. to AC-7, BLOWER MOTOR UNIT,
COMPONENT, General Description.>
AC-00218
4) Disconnect the blower motor connector.
C: INSPECTION
Connect the motor connector terminal 1 from the
battery to the positive (+) lead and terminal 2 to the
negative (−) lead. Make sure the motor runs
smoothly.
AC-00614
5) Disconnect the power transistor or blower resistor connector.
AC-00617
AC-00615
AC-27
Power Transistor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
8. Power Transistor (Auto A/C
Model)
A: REMOVAL
1) Remove the glove box. <Ref. to EI-39, REMOVAL, Glove Box.>
2) Disconnect the power transistor connector.
3) Loosen the two screws to remove the power
transistor.
AC-00615
B: INSTALLATION
Install in the reverse order of removal.
AC-28
Blower Resistor (Without A/C Model and Manual A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
9. Blower Resistor (Without A/C
Model and Manual A/C Model)
A: REMOVAL
1) Remove the glove box. <Ref. to EI-39, REMOVAL, Glove Box.>
2) Disconnect the blower resistor connector.
3) Loosen the two screws to remove the blower resistor.
AC-00615
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
(1)
(2)
(4)
(3)
AC-00621
Measure the blower resistor resistance.
Terminal No.
3 and 1
3 and 2
3 and 4
Standard
Approx. 0.51 Ω
Approx. 2.70 Ω
Approx. 1.43 Ω
If NG, replace the blower resistor.
AC-29
Heater Core
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
10.Heater Core
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-34, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws to remove the heater core
cover.
AC-00622
3) Remove the heater core.
AC-00623
B: INSTALLATION
Install in the reverse order of removal.
AC-30
Control Unit
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
11.Control Unit
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Remove the center console panel.
3) Disconnect the connector and aspirator hose
(A).
(A)
AC-00624
B: INSTALLATION
Install in the reverse order of removal.
AC-31
Compressor
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
12.Compressor
8) Disconnect the compressor harness from body
harness.
9) Loosen the bolts to remove the compressor
bracket.
A: INSPECTION
1. MAGNETIC CLUTCH CLEARANCE
Check the clearance of the entire circumference
around the drive plate and pulley.
Standard:
0.45±0.15 mm (0.0177±0.0059 in)
2. MAGNETIC CLUTCH OPERATION
1) Disconnect the compressor connector.
2) Connect the battery positive (+) terminal to the
terminal of compressor connector.
AC-00627
10) Remove the bolts, and then separate the compressor and bracket.
AC-00625
3) Make sure the magnet clutch engages.
If NG, replace the compressor.
AC-00628
B: REMOVAL
1) Perform the compressor oil return operation.
<Ref. to AC-26, OPERATION, Compressor Oil.>
2) Turn the A/C switch OFF and stop the engine.
3) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-21, OPERATION,
Refrigerant Recovery Procedure.>
4) Disconnect the ground cable from battery.
5) Remove the V-belt. <Ref. to ME(H4SO)-43, REMOVAL, V-belt.> or <Ref. to ME(H4DOTC)-54,
REMOVAL, V-belt.>
6) Remove the generator. <Ref. to SC(H4SO)-13,
REMOVAL, Generator.>
7) Remove the low-pressure hose and high-pressure hose.
C: INSTALLATION
1) Install in the reverse order of removal.
2) Replace the O-rings on low-/high-pressure hoses with new ones, then apply compressor oil.
3) When replacing compressor, adjust amount of
compressor oil. <Ref. to AC-26, OPERATION,
Compressor Oil.>
4) Charge refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-11, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
and <Ref. to AC-13, COMPRESSOR,
COMPONENT, General Description.>
AC-00626
AC-32
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, discharge refrigerant. <Ref. to AC-21, OPERATION,
Refrigerant Recovery Procedure.>
2) Disconnect the ground cable from battery.
3) Disconnect the pressure hose and pipe from
condenser.
CAUTION:
Replace the O-rings on hoses or pipes with new
ones, and then apply compressor oil. Confirm
that lower guide of condenser (A) has been fitted into holes on radiator panel.
(A)
AC-00631
AC-00980
2) Charge refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
4) Remove the radiator bracket (A).
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-11, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
and <Ref. to CO(H4SO)-4, RADIATOR AND
RADIATOR FAN, COMPONENT, General Description.>
C: INSPECTION
(A)
AC-00053
5) Remove the two bolts. While lifting the condenser, pull it out through the space between radiator
and radiator panel.
1) Confirm that no dust or insects are found on the
condenser fins. Air-blow or flush fins with water as
needed.
2) Confirm that no oil leaks from condenser. If a
failure is found, replace the condenser with a new
one.
AC-00630
CAUTION:
• Be careful not to damage the condenser fins.
If a damaged fin is found, repair it using a thin
screwdriver.
• If the condenser is replaced, add appropriate
amount of compressor oil to the compressor.
<Ref. to AC-26, REPLACEMENT, Compressor
Oil.>
AC-33
Heater and Cooling Unit
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
14.Heater and Cooling Unit
9) Loosen the bolt and nuts to remove the heater
and cooling unit.
A: REMOVAL
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-21, OPERATION,
Refrigerant Recovery Procedure.>
3) Drain LLC from the radiator.
4) Remove the bolt securing expansion valve and
pipe in engine compartment. Release the heater
hose clamps in engine compartment to remove the
hoses.
• LHD MODEL
AC-00055
B: INSTALLATION
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-5, HEATER COOLING UNIT,
COMPONENT, General Description.>
AC-00632
• RHD MODEL
AC-00054
5) Remove the instrument panel. <Ref. to EI-43,
REMOVAL, Instrument Panel Assembly.>
6) Remove the support beam.
7) Remove the blower motor unit assembly. <Ref.
to AC-27, REMOVAL, Blower Motor Unit Assembly.>
8) Disconnect the servo motor connectors.
AC-34
Evaporator
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
15.Evaporator
A: REMOVAL
1) Remove the heater and cooling unit. <Ref. to
AC-34, REMOVAL, Heater and Cooling Unit.>
2) Loosen the screws and clip to remove the evaporator cover.
AC-00633
3) Remove the evaporator.
AC-00634
4) Loosen the two bolts to remove the expansion
valve.
AC-00635
CAUTION:
If the evaporator is replaced, add appropriate
amount of compressor oil to evaporator. <Ref.
to AC-26, REPLACEMENT, Compressor Oil.>
B: INSTALLATION
Install in the reverse order of removal.
AC-35
Hose and Tube
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
16.Hose and Tube
B: INSTALLATION
A: REMOVAL
CAUTION:
• When disconnecting/connecting hoses, do
not apply an excessive force to them. Confirm
that no torsion and excessive tension exists after installing.
• Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering.
1) Install in the reverse order of removal.
2) Charge refrigerant. <Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
CAUTION:
• When disconnecting/connecting hoses, do
not apply excessive force to them. Confirm that
no torsion and excessive tension exists after
installing.
• Seal the disconnected hose with a plug or vinyl tape to prevent contamination from entering.
1) Disconnect the ground cable from battery.
2) Using the refrigerant recovery system, discharge refrigerant. <Ref. to AC-21, OPERATION,
Refrigerant Recovery Procedure.>
3) Remove the evaporator unit mounting bolt (A).
4) Remove the low-pressure hose attaching bolts
(B).
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 bolts
(C).
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
(D).
13) Remove the high-pressure tube from vehicle.
Tightening torque:
Refer to COMPONENT in General Description. <Ref. to AC-11, AIR CONDITIONING
UNIT, COMPONENT, General Description.>
C: INSPECTION
NOTE:
If cracking, damage, or swelling is found on a hose,
replace it with a new one.
(A)
(C)
(B)
(C)
(D)
AC-00639
AC-36
Relay and Fuse
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
17.Relay and Fuse
B: INSPECTION
A: LOCATION
2
5
3
(H)
4
1
(1)
(A)
(B)
4
(C)
3
5
(D)
1
2
(E)
(F)
(G)
AC-00093
(2)
AC-00640
(1) — (2): Continuity exists.
(3) — (4): Continuity exists.
(3) — (5): No continuity
(1) Joint box
(2) Main fuse box
Main Fan Relay 1
Main Fan Relay 2
Sub Fan Relay 1
Sub Fan Relay 2
A/C Relay
Main Fan Fuse
Sub Fan Fuse
A/C Fuse
A
B
C
E
D
F
G
H
While applying battery voltage to the terminal between (1) and (2), check continuity between (3) and
(5).
If no continuity exists, replace the relay with a new
one.
AC-37
Pressure Switch (Dual Switch)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
18.Pressure Switch (Dual Switch)
A: INSPECTION
1) Connect the manifold gauge to the service valve on high-pressure side.
2) Remove the pressure switch harness connector. Using a circuit tester, inspect the ON-OFF operation of
pressure switch.
2
1
AC-00981
Terminal
No.
High and low pressure switch
1 and 2
Standard
kPa (kg/cm2, psi)
Operation
Increasing to
2,800±100 (29±1, 406±15)
Turns OFF.
Decreasing to
278±29 (2.83±0.3, 40.3±4.2)
Increasing to
287+39/−25 (2.9+0.4/−0.25, 42+5.7/−3.6)
Turns ON.
Decreasing to
2,200±200 (22.4±2, 319±29)
AC-38
Ambient Sensor (Auto A/C Model)
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
19.Ambient Sensor (Auto A/C
Model)
A: REMOVAL
1) Open the front hood.
2) Disconnect the ground cable from battery.
3) Disconnect the ambient sensor connector.
4) Remove the ambient sensor from radiator lower
panel.
AC-00125
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC(diag)-29, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>
AC-39
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 battery.
2) Remove the front defroster grille.
3) Disconnect the sunload sensor connector (A).
(A)
AC-00643
CAUTION:
Be careful not to damage the sensors and interior trims when removing them.
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
<Ref. to AC(diag)-33, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>
AC-40
Air Vent Grille
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
21.Air Vent Grille
A: REMOVAL
1. CENTER GRILLE
1) Disconnect the ground cable from battery.
2) Remove the center console panel (A).
3) Loosen the two screws to remove the center air
vent grille (B).
(B)
(A)
AC-00644
2. SIDE GRILLE
1) Disconnect the ground cable from battery.
2) Remove the heater vent duct. <Ref. to AC-43,
REMOVAL, Heater Vent Duct.>
3) Loosen the screws to remove the side air vent
grille.
AC-00645
B: INSTALLATION
Install in the reverse order of removal.
C: INSPECTION
The direction and amount of air should be adjusted
smoothly.
The adjustment should be kept in each position.
AC-41
Heater Duct
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
22.Heater Duct
A: REMOVAL
1) Remove the front seat. <Ref. to SE-6, REMOVAL, Front Seat.>
2) Remove the front side sill cover.
3) Pull off the floor mat to remove the heater duct.
AC-00646
B: INSTALLATION
Install in the reverse order of removal.
AC-42
Heater Vent Duct
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
23.Heater Vent Duct
A: REMOVAL
1) Remove the instrument panel. <Ref. to EI-43,
REMOVAL, Instrument Panel Assembly.>
2) Remove the screws.
3) Remove the heater vent duct.
AC-00647
B: INSTALLATION
Install in the reverse order of removal.
AC-43
General Diagnostic Table
HVAC SYSTEM (HEATER, VENTILATOR AND A/C)
24.General Diagnostic Table
A: INSPECTION
Symptom
Blower motor
Doesn’t move.
Strange noise
Doesn’t move.
Compressor
Strange noise
Cold air not emitted.
Warm air not emitted.
Temperature of air from vents does not change.
Unable to switch blow vents.
Unable to switch suction vents.
Repair order
Fuse
Blower motor relay
Blower motor
Blower motor resistor
Blower switch
Wire harness
Blower motor
Refrigerant
Fuse
Air conditioning relay
Magnet clutch
Compressor
Pressure switch
A/C switch
Blower switch
Wire harness
V-Belt
Magnet clutch
Compressor
Refrigerant
V-Belt
Magnet clutch
Compressor
Pressure switch
A/C switch
Blower switch
Wire harness
Heater duct
Heater vent duct
Engine coolant
Blower switch
Heater core
Engine coolant
Mode actuator
Wire harness
Mode actuator
Air flow switch
Wire harness
Air inlet select switch
FRESH/RECIRC actuator
Wire harness
AC-44
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