2003 forester service manual quick reference index body section

2003 forester service manual quick reference index body section

2003 FORESTER SERVICE MANUAL

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.

QUICK REFERENCE INDEX

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)

AIRBAG SYSTEM

AC

AC

AB

AB AIRBAG SYSTEM (DIAGNOSTICS)

SEAT BELT SYSTEM SB

LI LIGHTING SYSTEM

WIPER AND WASHER SYSTEMS WW

ET ENTERTAINMENT

COMMUNICATION SYSTEM COM

GW GLASS/WINDOWS/MIRRORS

BODY STRUCTURE BS

IDI INSTRUMENTATION/DRIVER INFO

SEATS SE

SL SECURITY AND LOCKS

IMMOBILIZER (DIAGNOSTICS) IM

SUNROOF/T-TOP/CONVERTIBLE TOP

(SUNROOF)

SR

EXTERIOR/INTERIOR TRIM EI

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.

G8070GE6

2003 FORESTER SERVICE MANUAL

BODY SECTION

QUICK REFERENCE INDEX

EXTERIOR BODY PANELS

CRUISE CONTROL SYSTEM

CRUISE CONTROL SYSTEM

(DIAGNOSTICS)

EB

CC

CC

G8070GE6

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

AC

Page

1.

General Description ....................................................................................2

2.

Refrigerant Pressure with Manifold Gauge Set.........................................25

3.

Refrigerant Recovery Procedure...............................................................26

4.

Refrigerant Charging Procedure ...............................................................27

5.

Refrigerant Leak Check ............................................................................30

6.

Compressor Oil .........................................................................................32

7.

Blower Motor Unit Assembly .....................................................................33

8.

Blower Resistor (Manual A/C Model) ........................................................34

9.

Heater Core...............................................................................................35

10.

Control Unit ...............................................................................................36

11.

Compressor...............................................................................................37

12.

Condenser.................................................................................................39

13.

Condenser Fan (Sub Fan) ........................................................................40

14.

Heater Cooling Unit...................................................................................41

15.

Evaporator.................................................................................................42

16.

Hose and Tube..........................................................................................43

17.

Relay and Fuse .........................................................................................44

18.

Pressure Switch (Triple Pressure Switch) .................................................45

19.

Ambient Sensor (Auto A/C Model) ............................................................46

20.

Sun-load Sensor (Auto A/C Model)...........................................................47

21.

Air Vent Grille ............................................................................................48

22.

Heater Duct ...............................................................................................49

23.

Heater Vent Duct.......................................................................................50

24.

General Diagnostics ..................................................................................51

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

1. General Description

A: SPECIFICATIONS

1. HEATER SYSTEM

Heating capacity

Air flow rate

Max air flow rate

Item

Heater core size

(height

× length × width)

Blower motor

Type

Fan type and size

(diameter

× width)

Specifications

5.0 kW (4,300 kcal/h, 17,062

BTU/h) or more

280 m

3

(9,888 cu ft)/h

480 m

3

(16,951 cu ft)/h

134.1

× 224.3 × 32 mm

(5.28

× 8.83 × 1.26 in)

Auto A/C (Brushless motor)

230 W or less

Manual A/C (Cylinder motor)

260 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)

• Hot 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: 4th position

• Mode selector switch: RECIRC

12.5 V

12.5 V

AC-2

2. A/C SYSTEM

• AUTO A/C MODEL

Type of air conditioner

Cooling capacity

Refrigerant

Compressor

Item

Magnet clutch

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Idling speed (A/C ON)

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Type

Discharge

Max. permissible speed

Type

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

Type

Core face area

Core thickness

Radiation area

Effective inner capacity

Type

Type

Dimensions (W

× H × T)

Fan type

Outer diameter

× width

Power consumption

Motor type

Power consumption

Fan outer diameter

Motor type

Power consumption

Fan outer diameter

Specifications

Reheat air-mix type

5.1 kW

(4,386 kcal/h, 17,403 BTU/h)

HFC-134a (CH

2

FCF

3

)

[0.6

±0.05 kg (1.32±0.11 lb)]

Vane rotary, fix volume (DKV-14G)

140 cm

3

(8.54 cu in)/rev

7,000 rpm

Dry, single-disc type

38 W (DC 12 V, 25

°C)

V-Ribbed 4 PK

125 mm (4.92 in)

1.064

Corrugated fin (Sub cool type)

0.234 m

2

(2.52 sq ft)

16 mm (0.63 in)

5.6 m

2

(62.28 sq ft)

220 cm

3

(13.42 cu in)

External equalizing

Single tank

176.5

× 266 × 60 mm

(6.95

× 10.47 × 2.36 in)

Sirocco fan

150

× 75 mm (5.91 × 2.95 in)

230 W at 12.5 V

Magnet

70 W at 12 V

320 mm (12.6 in)

Magnet

70 W at 12 V

320 mm (12.6 in)

800

±100 rpm

AC-3

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Item

Triple switch

(Pressure switch)

Low-pressure switch operating pressure

High-pressure switch operating pressure

ON

→ OFF

OFF

→ ON

ON

→ OFF

DIFF

Middle pressure switch operating pressure

ON

→ OFF

OFF

→ ON

Specifications

177

±25 kPa

(1.80

±0.25 kg/cm

2

, 25.60

±3.56 psi)

206

±30 kPa

(2.10

±0.31 kg/cm 2

, 29.86

±4.41 psi)

2,940

±200 kPa

(29.98

±2.03 kg/cm 2

, 426.32

±28.87 psi)

590

±200 kPa

(6.02

±2.03 kg/cm

2

, 85.6

±28.87 psi)

1370

±120 kPa

(13.97

±1.22 kg/cm

2

, 198.65

±17.35 psi)

1,770

±100 kPa

(18.05

±1.02 kg/cm

2

, 256.81

±14.50 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

3.0

0.3

ON

OFF

AC-00082

AC-4

• MANUAL A/C MODEL

Type of air conditioner

Cooling capacity

Refrigerant

Compressor

Item

Magnet clutch

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Idling speed (A/C ON)

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Type

Discharge

Max. permissible speed

Type

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

Type

Core face area

Core thickness

Radiation area

Effective inner capacity

Type

Type

Dimensions (W

× H × T)

Fan type

Outer diameter

× width

Power consumption

Motor type

Power consumption

Fan outer diameter

Motor type

Power consumption

Fan outer diameter

MPFI model

Specifications

Reheat air-mix type

5.1 kW (4,386 kcal/h, 17,403 BTU/h)

HFC-134a (CH

2

FCF

3

)

[600

±50 g (1.32±0.11 lb)]

Vane rotary, fix volume (DKV-14G)

140 cm

3

(8.54 cu in)/rev

7,000 rpm

Dry, single-disc type

38 W (DC12 V, 25

°C)

V-Ribbed 4 PK

125 mm (4.92 in)

1.064

Corrugated fin (Sub cool type)

0.234 m

2

(2.52 sq ft)

16 mm (0.63 in)

5.6 m

2

(6.26 sq ft)

220 cm

3

(13.42 cu in)

External equalizing

Single tank

176.5

× 266 × 60 mm

(6.95

× 10.47 × 2.36 in)

Sirocco fan

150

× 75 mm (5.91 × 2.95 in)

260 W or less at 12.5 V

Magnet

70 W at 12 V

320 mm (12.6 in)

Magnet

70 W at 12 V

320 mm (12.6 in)

800

±100 rpm

AC-5

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Item

Triple switch

(Pressure switch)

Low-pressure switch operating pressure

High-pressure switch operating pressure

ON

→ OFF

OFF

→ ON

ON

→ OFF

DIFF

Middle pressure switch operating pressure

ON

→ OFF

OFF

→ ON

Specifications

177

±25 kPa

(1.80

±0.25 kg/cm

2

, 25.60

±3.56 psi)

206

±31 kPa

(2.10

±0.31 kg/cm 2

, 29.86

±4.41 psi)

2,940

±200 kPa

(29.98

±2.03 kg/cm 2

, 426.32

±28.87 psi)

590

±200 kPa

(6.02

±2.03 kg/cm

2

, 85.6

±28.87 psi)

1,370

±120 kPa

(13.97

±1.22 kg/cm

2

, 198.65

±17.35 psi)

1,770

±100 kPa

(18.05

±1.02 kg/cm

2

, 256.81

±14.50 psi)

Thermo control amplifier working temperature

(Evaporator outlet air)

3.0

0.3

ON

OFF

AC-00082

AC-6

B: COMPONENT

1. HEATER COOLING UNIT

• LHD MODEL WITH AUTO A/C

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

T

(17)

(6)

(7)

(21)

(19)

(19)

(18)

(22)

(20)

(23)

(15)

(13)

T

(4)

(3)

(5)

(16)

(1) Evaporator cover

(2) Mode actuator

(3) Mode main lever

(4) Vent door lever

(5) Foot door lever

(6) Mode actuator link

(7) Defroster lever

(8) Foot duct

(9) Lower case

(2)

(14)

(10)

(10) Heater core

(11) Drain hose

(12) Mix actuator

(13) Mix door lever

(14) Foot door lever (B)

(15) Upper case

(16) Aspirator

(17) Packing

(18) Cooling unit pipe

(9)

(12)

(1)

(8)

T

(11)

AC-00358

(19) O-ring

(20) Expansion valve

(21) Evaporator

(22) Evaporator lining

(23) Evaporator sensor

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-7

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• RHD MODEL WITH AUTO A/C

T

(22)

(18)

(21)

(20)

(20)

(24)

(23)

(19)

(15)

(6)

(7)

(4)

(3)

(5)

(2)

(14)

(13)

T

(17)

(9)

(12)

(16)

(1)

(8)

T

(10)

(11)

(1) Evaporator cover

(2) Mode actuator

(3) Mode main lever

(4) Vent door lever

(5) Foot door lever (A)

(6) Mode actuator link

(7) Defroster lever

(8) Foot duct

(9) Lower case

(10) Heater core

(11) Drain hose

(12) Mix actuator

(13) Mix door lever

(14) Foot door lever (B)

(15) Upper case

(16) Aspirator hose

(17) Aspirator

(18) Packing

AC-00001

(19) Cooling unit pipe

(20) O-ring

(21) Expansion valve

(22) Evaporator

(23) Evaporator lining

(24) Evaporator sensor

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-8

• LHD MODEL WITH MANUAL A/C

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(16)

(16)

(15)

T

(14)

(18)

(19)

(17)

(20)

(13)

(5)

(6)

(11)

T

(3)

(2)

(4)

(12)

(1) Evaporator cover

(2) Mode main lever

(3) Vent door lever

(4) Foot door lever

(5) Mode actuator link

(6) Defroster lever

(7) Foot duct

(8) Lower case

(9)

(9) Heater core

(10) Drain hose

(11) Mix actuator lever

(12) Foot door lever

(13) Upper case

(14) Packing

(15) Cooling unit pipe

(16) O-ring

(8)

(1)

(7)

T

(10)

AC-00359

(17) Expansion valve

(18) Evaporator

(19) Evaporator lining

(20) Evaporator sensor

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-9

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• RHD MODEL WITH MANUAL A/C

T

(20)

(16)

(19)

(18)

(18)

(22)

(21)

(17)

(15)

(6)

(7)

(4)

(3)

(5)

(2)

(14)

(9)

(13)

(12)

T

(1) Evaporator cover

(2) Side rod

(3) Mode actuator lever

(4) Vent door lever

(5) Foot door lever

(6) Mode actuator link

(7) Defroster lever

(8) Foot duct

(9) Lower case

(1)

(8)

T

(10)

(11)

(10) Heater core

(11) Drain hose

(12) Mix actuator rod

(13) Mix actuator lever

(14) Foot door lever

(15) Upper case

(16) Packing

(17) Cooling unit pipe

(18) O-ring

AC-00084

(19) Expansion valve

(20) Evaporator

(21) Evaporator lining

(22) Evaporator sensor

Tightening torque: N·m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-10

2. BLOWER MOTOR UNIT

• LHD MODEL WITH AUTO A/C

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(4)

(6)

(7)

(2)

(3)

(1)

(5)

(8)

(1) Upper case

(2) Air inlet select actuator

(3) Air inlet select link

(4) Link lever

(5) Filter cover

(6) Cover

(7) Lower case

(8) Blower motor ASSY

AC-00334

AC-11

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• RHD MODEL WITH AUTO A/C

(4)

(3)

(2)

(1)

(5)

(6)

(7)

(8)

(1) Upper case

(2) Air inlet select actuator

(3) Air inlet select link

(4) Link lever

(5) Filter cover

(6) Cover

(7) Lower case

(8) Blower motor assembly

AC-00332

AC-12

• LHD MODEL WITH MANUAL A/C

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(4)

(7)

(8)

(2)

(3)

(1)

(6)

(5)

(9)

(1) Upper case

(2) Air inlet select actuator

(3) Air inlet select link

(4) Link rod

(5) Filter cover

(6) Blower resistor

(7) Cover

(8) Lower case

(9) Blower motor ASSY

AC-00209

AC-13

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• RHD MODEL WITH MANUAL A/C

(4)

(7)

(3)

(2)

(8)

(1)

(6)

(5)

(9)

(1) Upper case

(2) Air inlet select actuator

(3) Air inlet select lever

(4) Air inlet select link

(5) Filter cover

(6) Blower resister

(7) Cover

(8) Lower case

(9) Blower motor assembly

AC-00085

AC-14

3. CONTROL UNIT

• AUTO A/C MODEL

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(1) Panel

(2) Control dial

(3) Switch

(7)

(6)

(5)

(4)

(1)

(4) Control case (front)

(5) Bulb

(6) Control unit circuit

(2)

(7) Control case (rear)

(3)

AC-00210

AC-15

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• LHD MODEL WITH MANUAL A/C

(11)

(9)

(10)

(2)

(8)

(1)

(1) Panel

(2) Mode control dial

(3) Fan dial

(4) Temperature control dial

(5) A/C button

(6) Rear defogger button

(7) Air inlet select button

(8) Switch circuit board

(4)

(3)

(7)

(5)

(6)

AC-00211

(9) Temperature control cable

(10) Mode control cable

(11) Bulb

AC-16

• RHD MODEL WITH MANUAL A/C

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(9)

(11)

(10)

(2)

(8)

(1)

(6)

(5)

(7)

(3)

(4)

(1) Panel

(2) Mode control dial

(3) Fan dial

(4) Temperature control dial

(5) A/C switch

(6) Rear defogger switch

(7) Air inlet select switch

(8) Switch circuit board

(9) Mode control cable

(10) Temperature control cable

(11) Bulb

AC-00333

AC-17

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

4. AIR CONDITIONING UNIT

T1

(1)

(6)

(6)

(5)

T2

(6)

(3)

T2

(2)

T1

(7)

(4)

(6)

(6)

(1) Condenser

(2) Hose (High-pressure)

(3) Hose (Low-pressure)

(4) Pipe

(5) Compressor

(6) O-ring

(7) Triple pressure switch

AC-00243

Tightening torque: N·m (kgf-m, ft-lb)

T1: 7.4 (0.75, 5.4)

T2: 15 (1.5, 10.8)

AC-18

5. COMPRESSOR

T3

T2

(1)

T1

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

T5

(4)

T5

T5

(5)

(8)

(2)

(7)

(3)

(6)

T4

T4

(1) Idler pulley bracket

(2) Idler pulley adjuster

(3) Idler pulley

(4) Compressor bracket

(5) Compressor

(6) V-belt

AC-00335

(7) Compressor belt cover (Non-turbo model)

(8) Compressor stay

Tightening torque: N·m (kgf-m, ft-lb)

T1: 4.0 (0.40, 2.95)

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)

AC-19

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

6. HEATER DUCT

(5)

(3)

(4)

(1)

(2)

(6)

(1) Front defroster nozzle

(2) Side defroster duct (RH)

(3) Side defroster duct (LH)

(4) Side ventilation duct (RH)

(5) Side ventilation duct (LH)

(6) Rear heater duct

AC-00212

AC-20

C: CAUTION

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

1. HFC-134A A/C SYSTEM

• Unlike the old conventional HFC-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.

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.

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

• 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

ZXL200PG.

• Do not mix multiple compressor oils.

If HFC-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 HFC-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.

3. REFRIGERANT

• The HFC-12 refrigerant cannot be used in the

HFC-134a A/C system. The HFC-134a refrigerant, also, cannot be used in the HFC-12 A/C system.

• If an incorrect or no refrigerant is used, poor lubrication will result and the compressor itself may be damaged.

AC-00007

(A) Goggles

(B) Gloves

(C) Avoid open flame

(D) No direct heat on container

(E) Do not discharge

(F) Loosen

AC-21

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 towels.

• 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-00008

(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)

(C)

AC-00009

AC-00010

• After tightening, use a clean shop towel 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.

D: PREPARATION TOOL

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.

Tool & screw type

Valve type

HFC-134a

Millimeter size

Quick joint type

CFC-12

Inch size

Screw-in type

(A) O-ring

(B) OK

(C) NG

(D) Bead

AC-22

Description

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

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

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

AC-23

GENERAL DESCRIPTION

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Description Tools and Equipment

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

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-24

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 draftless condition.

2) Connect the manifold gauge set.

3) Open the front windows and close all doors.

4) Open the 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/cm

Ambient temperature: 30 — 35

°°°°C (86 — 95 °°°°F)

2

, 18 — 28 psi)

High pressure: 1,471 — 1,667 kPa (15 — 17 kg/cm

2

, 213 — 242 psi)

B: INSPECTION

Symptom

High-pressure side is unusually high.

High-pressure side is unusually low.

Probable cause

• Defective condenser fan motor

• Clogged condenser fin

• Too much refrigerant

• Air inside the system

• Defective receiver dryer

Repair order

• Replace the fan motor.

• Clean the condenser fin.

• Discharge refrigerant.

• Replace the receiver dryer.

• After reevacuating the receiver dryer, charge appropriate amount of refrigerant.

• Replace the compressor.

• Check for leaks.

• Replace the expansion valve.

• Fully evacuate the expansion valve.

Low-pressure side is unusually high.

Low-pressure side is unusually low.

• 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

• Replace the compressor.

• Replace the expansion valve.

• Discharge refigerant.

• Check for leaks.

• Replace the expansion valve.

• Replace the receiver dryer.

AC-25

REFRIGERANT RECOVERY PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

3. Refrigerant Recovery Procedure

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-32, OPERATION, Compressor Oil.>

2) Stop the engine.

3) Make sure the valves on low-/high-pressure sides of manifold gauge set are fully closed.

4) Install the low-/high-pressure hoses to the service ports on the low-/high-pressure sides of the vehicle respectively.

(1) (2)

(3)

AC-00147

(1)

L H

(3)

(1) Low service port

(2) High service port

(3) Close

5) Connect the center hose to the refrigerant recovery system.

6) Follow the operation manual to activate the refrigerant recovery system.

(4)

(2)

(6)

(5)

(1)

L: Low-pressure gauge

H: High-pressure gauge

(1) Low-pressure valve

(2) Vacuum pump valve

(3) High-pressure valve

(4) For low-pressure

(5) For vacuum pump

(6) For high-pressure

(2)

(3)

AC-00146

AC-26

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

4. Refrigerant Charging Procedure

A: OPERATION

CAUTION:

• During operation, be sure to wear safety goggles and protective gloves.

• If air is mixed in refrigeration cycle, poor cooling may result, and also if moisture is mixed in refrigeration cycle, clogging (freezing) or rust may result.

Before charging the refrigerant, evacuate the system using vacuum pump to remove air and moisture in the system. Moisture can be evaporated and removed easily even at normal temperature, if the system is evacuated using vacuum pump.

1) Close all valves of manifold gauge.

2) Install the low-/high-pressure hoses to corresponding service ports on vehicle.

(1) (2)

(3)

L H

(1)

(4)

(2)

(5)

(6)

(3)

AC-00147

(1) Low service port

(2) High service port

(3) Close

CAUTION:

Be sure that the hoses are securely connected.

3) Connect the center hose of manifold gauge with vacuum pump.

4) Activate the vacuum pump and then open the valves on low-/high-pressure sides.

(1)

L: Low-pressure gauge

H: High-pressure gauge

(1) Low-pressure valve

(2) Vacuum pump valve

(3) High-pressure valve

(4) For low-pressure

(5) For vacuum pump

(6) For high-pressure

(2)

(3)

AC-00146

(2)

(1)

AC-00148

(1) Vacuum pump

(2) Open

CAUTION:

Be sure to evacuate the system using vacuum pump.

AC-27

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5) After at least 5 minutes of evacuation, if the lowpressure gauge reading shows 100.0 kPa (750 mmHg, 29.5 inHg) or higher, close the valves on center hose to stop the vacuum pump.

6) Leave it at least 5 to 10 minutes after closing the valves on low-/high-pressure sides, and then check the low-pressure gauge reading for any changes.

When the gauge reading changes, this is a sign of leakage. Check the pipe or hose connector points, and repair if necessary. Repeat the procedure from

1) after repairing the faulty part.

7) If there are no leaks, further evacuate the system 20 to 30 minutes.

8) Close all valves and stop the vacuum pump.

9) Following the can tap operation manual instructions, install it to refrigerant can.

12) Open the valve on HFC-134a source.

13) Loosen the center hose connection on manifold gauge (if applicable, press a purge valve on manifold gauge) only for a couple of seconds to allow the air in the center hose to escape by the refrigerant.

AC-00216

14) Make sure that the high-pressure valve of manifold gauge is closed, and then open the low-pressure side valve only to charge the refrigerant.

(1)

(2)

AC-00214

(1) Tap valve

(2) Connect to center hose

10) Disconnect the vacuum pump from center hose, and connect the hose to tap valve.

11) When a refrigerant recovery container is used, measure the refrigerant amount in use using a weighting scale before connecting to center hose.

(1) Refrigerant recovery container

(2) Weighting scale

AC-00215

AC-00217

(1) Open

(2) Close

CAUTION:

Do not open the high-pressure valve. Be sure to open the low-pressure valve.

15) Close the low-pressure valve when the lowpressure gauge reading reaches 200 kPa (1,500 mmHg, 59.1 inHg).

16) Using a leak tester, check the system for refrigerant leaks.

17) After confirming that there are no leaks with the leak test, charge the required amount of refrigerant.

18) If the HFC-134a source is empty, close the lowpressure valve and then close the valve on can tap before replacing the empty source. Restart charging operation after replacing the HFC-134a source with a new one and purging.

19) Close the low-pressure valve if the charge rate of refrigerant becomes worse.

20) Confirm that both the low-/high-pressure valves are closed. Start the engine with A/C switch

OFF.

AC-28

REFRIGERANT CHARGING PROCEDURE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

21) Quickly repeat A/C switch 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”

• Window open

23) Open the low-pressure valve and charge the specified amount of refrigerant.

24) Close all valves and disconnect the hoses from service port after charging the refrigerant.

25) Install the cap to service port.

AC-29

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/cm

2

, 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 (triple 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 28 g (1.0 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

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.

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-00035

12) Check the valve in the service port.

AC-00037

AC-30

REFRIGERANT LEAK CHECK

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

13) Visually check the rubber seal in the service port cap.

AC-00038

AC-31

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 the compressor.

1) Increase engine 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

Receiver dryer

Amount of oil replenishment

Approx. 50 cm

3

(1.7 US fl oz, 1.8 Imp fl oz)

Approx. 30 cm

3

(1.0 US fl oz, 1.1 Imp fl oz)

Approx. 10 cm

3

(0.4 US fl oz, 0.4 Imp fl oz)

Approx. 10 cm

3

(0.4 US fl oz, 0.4 Imp fl oz)

AC-32

BLOWER MOTOR UNIT ASSEMBLY

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

7. Blower Motor Unit Assembly

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the glove box. <Ref. to EI-37, REMOV-

AL, Glove Box.>

3) Loosen the nut to remove the support beam stay.

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-7, HEATER COOLING UNIT,

COMPONENT, General Description.> and

<Ref. to AC-11, BLOWER MOTOR UNIT,

COMPONENT, General Description.>

C: INSPECTION

Inspection of Auto A/C Brush-less Motor

Operation

Connect the motor connector terminal 5 from the battery to the positive (+) lead and terminal 2 and 1 at the same type to the negative (

−) lead. Make sure the motor runs smoothly.

AC-00218

4) Disconnect the connectors of blower motor and intake actuator resistor.

1

2

5

5 2 1

AC-00244

AC-00219

5) Loosen the bolt and nut to remove blower motor unit assembly.

AC-00220

AC-33

BLOWER RESISTOR (MANUAL A/C MODEL)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

8. Blower Resistor (Manual A/C

Model)

A: REMOVAL

1) Remove the glove box. <Ref. to EI-37, REMOV-

AL, Glove Box.>

2) Disconnect the blower resistor connector.

3) Loosen the two screws to remove blower resistor.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

AC-00221

0.4

0.7

1.5

1

4

2 3

6

MO H MH ML L

2 1 4

6

3

AC-00245

Measure the blower resistor resistance.

Terminal No.

3 and 6

3 and 4

2 and 1

Standard

Approx. 0.4

Approx. 1.1

Approx. 2.6

If NG, replace the blower resistor.

AC-34

HEATER CORE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

9. Heater Core

A: REMOVAL

1) Remove the heater cooling unit. <Ref. to AC-41,

REMOVAL, Heater Cooling Unit.>

2) Open the heater core pipe cover. (RHD model)

6) Loosen the screws to remove lower case.

AC-00046

7) Remove the heater core.

AC-00042

3) Loosen the screws to remove mode actuator.

B: INSTALLATION

Install in the reverse order of removal.

AC-00047

AC-00043

4) Loosen the screws to remove foot duct.

AC-00044

5) Loosen the screws to remove evaporator cover.

AC-00045

AC-35

CONTROL UNIT

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

10.Control Unit

A: REMOVAL

1) Disconnect the ground cable from battery.

2) In case of manual A/C, remove the mode cable and air-mix cable from links of heater unit.

3) Remove the front cover.

(A)

(A)

(A)

(A)

(A)

(A) Hook

4) Remove the center console panel.

(A)

(A)

(A)

(A)

(A)

EI-00059

EI-00102

(A) Clip

5) Loosen the screws on rear side of center console panel, and then remove the control unit.

B: INSTALLATION

Install in the reverse order of removal.

AC-36

COMPRESSOR

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

11.Compressor

A: INSPECTION

1. MAGNETIC CLUTCH CLEARANCE

1) 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

No.3 terminal of the compressor connector.

9) Loosen the bolts to remove compressor bracket.

AC-00048

3) Make sure the magnet clutch engages.

If NG, replace the compressor.

B: REMOVAL

1) Perform the compressor oil return operation.

<Ref. to AC-32, OPERATION, Compressor Oil.>

2) Turn the A/C switch OFF and stop the engine.

3) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-26, OPERATION,

Refrigerant Recovery Procedure.>

4) Disconnect the ground cable from battery.

5) Remove the V-belt. <Ref. to ME(SOHC)-41, RE-

MOVAL, V-belt.>

6) Remove the generator. <Ref. to SC(SOHC)-15,

REMOVAL, Generator.>

7) Remove the low-pressure hose and high-pressure hose.

AC-00336

10) Remove the bolts and then separate compressor and bracket.

AC-00051

AC-00049

8) Disconnect the compressor harness from body harness.

AC-37

COMPRESSOR

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

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-32, OPERATION,

Compressor Oil.>

4) Charge refrigerant. <Ref. to AC-27, OPERA-

TION, Refrigerant Charging Procedure.>

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-18, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

and <Ref. to AC-19, COMPRESSOR,

COMPONENT, General Description.>

AC-38

12.Condenser

A: REMOVAL

1) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-26, OPERATION,

Refrigerant Recovery Procedure.>

2) Disconnect the ground cable from battery.

3) Disconnect the pressure hose and pipe from condenser.

CONDENSER

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

B: INSTALLATION

1) Install in the reverse order of removal.

CAUTION:

Replace the O-rings on hoses or pipes with new ones, and then apply compressor oil. Confirm that lower guide of condenser has been fitted into holes on radiator panel.

4) Remove the radiator bracket (A).

AC-00246

AC-00053

5) Remove the two bolts. While lifting the condenser, pull it out through the space between radiator and radiator panel.

AC-00092

2) Charge refrigerant. <Ref. to AC-27, OPERA-

TION, Refrigerant Charging Procedure.>

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-18, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

and <Ref. to CO(SOHC)-5, RADIATOR AND

RADIATOR FAN, COMPONENT, General Description.>

C: INSPECTION

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-00091

CAUTION:

Be careful not to damage the radiator fins and condensor 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-32, REPLACEMENT, Compressor

Oil.>

AC-39

CONDENSER FAN (SUB FAN)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

13.Condenser Fan (Sub Fan)

A: REMOVAL

<Ref. to CO(SOHC)-34, REMOVAL, Radiator Main

Fan and Fan Motor.>

B: INSTALLATION

<Ref. to CO(SOHC)-36, INSTALLATION, Radiator

Main Fan and Fan Motor.>

AC-40

HEATER COOLING UNIT

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

14.Heater Cooling Unit

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-26, OPERATION,

Refrigerant Recovery Procedure.>

3) Drain LLC from the radiator.

4) Remove the A/C pipe of toe board. Release the heater hose clamps in engine compartment to remove the hoses.

AC-00054

5) Remove the instrument panel. <Ref. to EI-40,

REMOVAL, Instrument Panel Assembly.>

6) Remove the support beam.

7) Remove the blower motor unit assembly. <Ref.

to AC-33, REMOVAL, Blower Motor Unit Assembly.>

8) Disconnect the servo motor connectors.

9) Loosen the bolt and nuts to remove the heater and cooling unit.

AC-00055

B: INSTALLATION

1) Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-27, OPERA-

TION, Refrigerant Charging Procedure.>

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-7, HEATER COOLING UNIT,

COMPONENT, General Description.>

AC-41

EVAPORATOR

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

15.Evaporator

A: REMOVAL

1) Disconnect the refrigerant recovery & toe board

area A/C pipe.<Ref. to AC-26, OPERATION, Refrigerant Recovery Procedure.>

2) Remove the glove box.

3) Remove lower motor unit assembly.<Ref. to AC-

33, REMOVAL, Blower Motor Unit Assembly.>

4) Loosen the screws and remove evaporator cover.

AC-00045

5) Remove the A/C pipes in unit.

6) Rotate the upper evaporator core and lower evaporator core tilt toward the front vehicle and toward the interior, respectively. Then pull out the heater case to left side.

7) Loosen the two bolts to remove expansion valve.

AC-00057

CAUTION:

If the evaporator is replaced, add appropriate

amount of compressor oil to evaporator. <Ref. to AC-32, REPLACEMENT, Compressor Oil.>

B: INSTALLATION

Install in the reverse order of removal.

NOTE:

Replace the o-ring for refrigerant recovery & toe board area air conditioner pipe with a new one, and then apply compressor oil.

AC-42

16.Hose and Tube

A: REMOVAL

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, dis-

charge refrigerant. <Ref. to AC-26, 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 tube attaching bolt

(D).

12) Remove the high-pressure tube from vehicle.

HOSE AND TUBE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

B: INSTALLATION

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.

• Replace the o-rings for hoses and pipes with new ones, and then apply compressor oil.

1) Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-27, OPERA-

TION, Refrigerant Charging Procedure.>

Tightening torque:

Refer to COMPONENT in General Descrip-

tion. <Ref. to AC-18, 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.

AC-00247

AC-43

RELAY AND FUSE

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

17.Relay and Fuse

A: LOCATION

B: INSPECTION

4

1

2

5

3

AC-00255

3

1

4

5

2

AC-00093

(1) — (2): Continuity exists.

(3) — (4): Continuity exists.

(3) — (5): No continuity.

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-44

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) Remove the pressure switch harness connector.

Using a circuit tester, inspect the ON-OFF operation of the pressure switch.

High and low pressure switch

Middle pressure switch

Terminal

No.

1 and 2

3 and 4

Operation

Standard kPa (kg/cm

2

, psi)

Turns off.

Pressure increases up to 2,940

±200 (30.0±2, 427±28).

Pressure decreases down to 177

±25 (1.8±0.3, 26±4).

Pressure increases up to 206

±30 (2.1±0.3, 30±4).

Turns on.

Pressure decreases down to 2,350

±200 (24±2, 341±28).

Turns off.

Pressure decreases down to 1,370

±120 (14±1, 199±14).

Turns on.

Pressure increases up to 1,770

±100 (18±1, 256±14).

3

1

2

4

AC-00248

AC-45

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-33, AMBIENT SENSOR, Diagnostic

Procedure for Sensors.>

AC-46

SUN-LOAD SENSOR (AUTO A/C MODEL)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

20.Sun-load Sensor (Auto A/C

Model)

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Disconnect the sunload sensor connector (A).

AC-00126

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-41, SUNLOAD SENSOR, Diagnostic

Procedure for Sensors.>

AC-47

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. <Ref. to EI-

40, REMOVAL, Instrument Panel Assembly.>

3) Loosen the two screws to remove the center air vent grille.

AC-00060

2. SIDE GRILLE

1) Remove the side vent grille by prying four points.

AC-00249

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-48

HEATER DUCT

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

22.Heater Duct

A: REMOVAL

1) Remove the front seat. <Ref. to SE-5, REMOV-

AL, Front Seat.>

2) Remove the front side sill cover.

3) Pull off the floor mat, which is connected to remove the cover heater unit and heater duct, and then remove the heater duct.

B: INSTALLATION

Install in the reverse order of removal.

AC-49

HEATER VENT DUCT

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

23.Heater Vent Duct

A: REMOVAL

1) Remove the instrument panel. <Ref. to EI-40, REMOVAL, Instrument Panel Assembly.>

2) Remove the screws.

3) Remove the heater vent duct.

B: INSTALLATION

Install in the reverse order of removal.

AC-00224

AC-50

24.General Diagnostics

A: INSPECTION

Symptom

GENERAL DIAGNOSTICS

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Blower motor

Compressor

Condensor fan

Cold air not emitted.

Warm air not emitted.

Does not run.

Abnormal noise

Does not run.

Abnormal noise

Does not run.

Abnormal noise

Temperature of air from vents does not change.

Repair order

Fuse

Blower motor relay

Wire harness

Blower motor

Blower motor resistor (Manual A/C model)

Blower switch

Blower motor

Refrigerant

Fuse

Air conditioning relay

Wire harness

Magnet clutch

Compressor

Pressure switch

A/C switch

Blower switch

V-Belt

Magnet clutch

Compressor

Fuse

Sub fan relay

Wire harness

Condenser fan motor

Refrigerant

V-Belt

Magnet clutch

Compressor

Pressure switch

Blower fan relay, Blower motor

A/C switch

Blower switch

Wire harness

Heater duct

Heater vent duct

Control unit

Expansion valve

Evaporator

Air mix actuator (Auto A/C), Temerature control cable (Manual

A/C)

Engine coolant

Aspirator hose

Blower switch

Air mix actuator (Auto A/C), Temerature control cable (Manual

A/C)

Heater core

Wire harness

Air mix actuator (Auto A/C), Temerature control cable (Manual

A/C)

Temperature adjustment switch

AC-51

GENERAL DIAGNOSTICS

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Symptom

Unable to switch blow vents.

Unable to switch suction vents.

Repair order

Wire harness

Mode actuator (Auto A/C), Mode control cable (Manual A/C)

Mode switch

Wire harness

FRESH/RECIRC actuator

Air inlet select switch

AC-52

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