2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

2004 LEGACY SERVICE MANUAL QUICK REFERENCE INDEX

2004 LEGACY SERVICE MANUAL

BODY SECTION

QUICK REFERENCE INDEX

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)

HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)

AIRBAG SYSTEM

AC

AC(diag)

AB

AB(diag) 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

SECURITY AND LOCKS SL

SUNROOF/T-TOP/CONVERTIBLE TOP

(SUNROOF)

SR

EXTERIOR/INTERIOR TRIM EI

EXTERIOR BODY PANELS EB

G2320GE7

2003 LEGACY SERVICE MANUAL

BODY SECTION

QUICK REFERENCE INDEX

CRUISE CONTROL SYSTEM

CRUISE CONTROL SYSTEM

(DIAGNOSTICS)

IMMOBILIZER (DIAGNOSTICS)

LAN SYSTEM (DIAGNOSTICS)

CC

CC(diag)

IM(diag)

LAN(diag)

G2320GE7

HVAC SYSTEM

(HEATER, VENTILATOR AND A/C)

AC

Page

1.

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

2.

Refrigerant Pressure with Manifold Gauge Set.........................................19

3.

Refrigerant Recovery Procedure...............................................................20

4.

Refrigerant Charging Procedure ...............................................................21

5.

Refrigerant Leak Check ............................................................................24

6.

Compressor Oil .........................................................................................25

7.

Blower Motor Unit Assembly .....................................................................26

8.

Blower Motor .............................................................................................27

9.

Power Transistor (Auto A/C Model) ..........................................................28

10.

Blower Resistor (Manual A/C Model) ........................................................29

11.

Heater Core...............................................................................................30

12.

Control Unit (Manual A/C Model) ..............................................................31

13.

Control Unit (Auto A/C Model)...................................................................32

14.

Compressor...............................................................................................33

15.

Condenser.................................................................................................35

16.

Heater and Cooling Unit............................................................................36

17.

Evaporator.................................................................................................37

18.

Hose and Tube..........................................................................................38

19.

Relay and Fuse .........................................................................................39

20.

Pressure Switch (Triple Pressure Switch) .................................................40

21.

Ambient Sensor (Auto A/C Model) ............................................................41

22.

Sunload Sensor (Auto A/C Model) ............................................................42

23.

In-Vehicle Sensor (Auto A/C Model) .........................................................43

24.

Air Vent Grille ............................................................................................44

25.

Heater Duct ...............................................................................................45

26.

Heater Vent Duct.......................................................................................46

27.

Heater Cock Solenoid Valve .....................................................................47

28.

General Diagnostic Table..........................................................................48

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

1. General Description

A: SPECIFICATION

1. HEATER SYSTEM

Item Specification

Heating capacity

Air flow rate

Max air flow rate

Heater core size

(height

×

length

×

width)

Type

Blower motor

Fan type and size

(diameter

×

width)

2. A/C SYSTEM

• Auto A/C model

Item

Type of air conditioner

Cooling capacity

5.2 kW (4,471 kcal/h,

17,743 BTU/h) or more

370 m

3

(13,066 cu ft)/h

460 m

3

(16,245 cu ft)/h

264

×

110

×

27 mm

(10.4

×

4.33

×

1.06 in)

Magnet motor 220 W or less

Sirocco fan type

150

×

75 mm (5.91

×

2.95 in)

On 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:

Auto A/C: 6th position

Manual A/C: 4th position

• Mode selector lever: RECIRC

12 V

Refrigerant

Compressor

Magnet clutch

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

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

Specification

Reheat air-mix type

5.3 kW

(4,557 kcal/h, 18,084 BTU/h)

HFC-134a (CH

2

FCF

3

)

[0.4

±

0.03 kg (0.88

±

0.07 lb)]

Scroll, constant volume (SCSA 08C)

74.5 cc (4.55 cu in)/rev

9,000 rpm

Dry, single-disc type

35 W

H4 model: V-belt 4 PK

H6 model: V-belt 6 PK

93 mm (3.7 in)

1.43

Corrugated fin (Sub cool type)

0.186 m

2

(2.002 sq ft)

16 mm (0.63 in)

5.49 m

2

(59.09 sq ft)

190 cm

3

(11.6 cu in)

Internal equalizing

Single tank

298.6

×

151

×

38 mm

(11.76

×

5.94

×

1.50 in)

Sirocco fan

150

×

75 mm (5.91

×

2.95 in)

220 W

AC-2

Condenser fan (Sub fan)

Radiator fan (Main fan)

Idling speed (A/C ON)

Low-pressure switch operating pressure

Triple switch

(Pressure switch)

High-pressure switch operating pressure

Middle-pressure switch operating pressure

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

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

Magnet

H4 model: 90 W

H6 model: 160 W

H4 model: 300 mm (11.8 in)

H6 model: 320 mm (12.6 in)

Magnet

H4 model: 90 W

H6 model: 160 W

H4 model: 300 mm (11.8 in)

H6 model: 320 mm (12.6 in)

800

±

100 rpm

196

±

20 kPa

(2.00

±

0.20 kg/cm

2

, 28.4

±

2.9 psi)

225

+25

29

kPa

(2.29

+0.25

0.30

kg/cm

2

, 32.6

+3.6

4.2

psi)

3,140

+50

200

kPa

(32.02

+0.51

2.04

kg/cm

2

, 455.4

+7.25

29.0

psi)

2,550

±

200 kPa

(26.00

±

2.04 kg/cm

2

, 369.8

±

29.0 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)

(3)

(1)

Thermo-control amplifier working temperature

(Evaporator outlet air)

(2)

(1) ON

(2) OFF

(3) 1

±

0.5

°

C (33.8

±

0.9

°

F)

(4) 4

+1.5

0

°

C (39.2

+2.7

0

°

F)

• Manual A/C model

Type of air conditioner

Cooling capacity

Refrigerant

Compressor

Item

Magnet clutch

Type

Discharge

Max. permissible speed

Type

Power consumption

Type of belt

Pulley dia. (effective dia.)

Pulley ratio

AC-3

(4)

AC-00601

Specification

Reheat air-mix type

5.3 kW (4,557 kcal/h, 18,084 BTU/h)

HFC-134a (CH

2

FCF

3

)

[0.4

±

0.03 kg (0.88

±

0.07 lb)]

Scroll, constant volume (SCSA 08C)

74.5 cc (4.55 cu in)/rev

9,000 rpm

Dry, single-disc type

35 W

V-belt 4 PK

93 mm (3.7 in)

1.43

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Condenser

Receiver drier

Expansion valve

Evaporator

Blower fan

Condenser fan (Sub fan)

Radiator fan (Main fan)

Idling speed (A/C ON)

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

ON

OFF

Low-pressure switch operating pressure

OFF

ON

Triple switch

(Pressure switch)

High-pressure switch operating pressure

Middle-pressure switch operating pressure

ON

OFF

OFF

ON

ON

OFF

OFF

ON

Corrugated fin (Sub cool type)

0.186 m

2

(2.002 sq ft)

16 mm (0.63 in)

5.49 m

2

(59.09 sq ft)

250 cm

3

(15.26 cu in)

Externally equalizing

Single tank

298.6

×

151

×

38 mm

(11.7

×

5.94

×

1.50 in)

Sirocco fan

150

×

75 mm (5.91

×

2.95 in)

220 W

Magnet

90 W

300 mm (11.8 in)

Magnet

90 W

300 mm (11.8 in)

800

±

100 rpm

196

±

20 kPa

(2.00

±

0.20 kg/cm

2

, 28.4

±

2.9 psi)

225

+25

29

kPa

(2.29

+0.25

0.30

kg/cm

2

, 32.6

+3.6

4.2

psi)

3,140

+50

200

kPa

(32.02

+0.51

2.04

kg/cm

2

, 455.4

+7.25

29.0

psi)

2,550

±

200 kPa

(26.00

±

2.04 kg/cm

2

, 369.8

±

29.0 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)

(3)

(1)

Thermo control amplifier working temperature

(Evaporator outlet air)

(2)

(1) ON

(2) OFF

(3) 1

±

0.5

°

C (33.8

±

0.9

°

F)

(4) 4

+1.5

0

°

C (39.2

+2.7

0

°

F)

(4)

AC-00601

AC-4

B: COMPONENT

1. HEATER COOLING UNIT

• Auto A/C model

(10)

(12)

(11)

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(9)

(8)

(14)

(13)

T

(7)

T

(4)

(5)

(6)

(15)

(16)

(3)

(1)

(17)

(1) Foot duct (RH)

(2) Evaporator center

(3) Pipe cover

(4) Evaporator cover

(5) Expansion valve

(6) Packing

(7) Evaporator

(8) Mix actuator

(9) Mode actuator

(10) Heater pipe clamp

(11) Heater core

(12) Heater core cover

(13) Aspirator

(14) Aspirator hose

(2)

AC-00906

(15) Foot duct (LH)

(16) Unit ASSY

(17) Drain hose

Tightening torque: N

m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-5

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• Manual A/C model

(11)

(13)

(12)

(10)

(9)

T

(8)

(7)

T

(4)

(5)

(6)

(14)

(15)

(3)

(1) (16)

(2)

(1) Foot duct (RH)

(2) Thermo amplifier

(3) Pipe cover

(4) Evaporator cover

(5) Expansion valve

(6) Packing

(7) Evaporator

(8) Clip

(9) Air mix door linkage

(10) Mode actuator

(11) Heater pipe clamp

(12) Heater core

(13) Heater core cover

(14) Foot duct (LH)

AC-00907

(15) Unit ASSY

(16) Drain hose

Tightening torque: N

m (kgf-m, ft-lb)

T: 7.5 (0.76, 5.5)

AC-6

2. BLOWER MOTOR UNIT

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(2)

(3)

(1)

T

(4)

(5)

(6)

(7)

T

(1) Upper case

(2) Intake door actuator

(3) Filter (Auto A/C model)

(4) Filter cover

(5) Blower motor ASSY

AC-00908

(6) Control unit (Auto A/C model)

(7) Power transistor (Auto A/C model)

Blower resistor (Manual A/C model)

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)

3. CONTROL PANEL

• Auto A/C model

(A) (B)

(4)

(3)

(2)

(2)

(1)

(A) For integrated audio

(1) Temperature control dial

(2) Control panel assembly

(B) For Mclntosh audio

(3) Board

(1)

AC-00909

(4) Heater control base

AC-8

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• Manual A/C model

(8)

(6)

(4)

(3)

(1)

(1)

(2)

(1)

(10)

(7)

(9)

(5)

(1) Dial

(2) A/C switch

(3) FRESH/RECIRC switch

(4) Rear window defogger switch

(5) Heater control panel

(6) Heater control base

(7) Temperature control cable

(8) Valve

(9) Fan switch ASSY

(10) Switch base

AC-00910

AC-9

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

4. AIR CONDITIONING UNIT

(5)

(6)

T2

(2)

(6)

T1

(4)

T2

(6)

T3

(1)

(6)

(6)

(3)

T1

(8)

(1) Condenser

(2) Hose (High-pressure)

(3) Hose (Low-pressure)

(4) Bracket

T1

T3

(5) Compressor

(6) O-ring

(7) Clamp

(8) Tube

(6)

(7)

AC-00911

Tightening torque: N

m (kgf-m, ft-lb)

T1: 7.5 (0.76, 5.5)

T2: 10 (1.0, 7.4)

T3: 5 (0.5, 3.7)

AC-10

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5. COMPRESSOR

• H4 model

T3

(4)

(5)

T3

T3

T1

(2)

(3)

T1

(1)

(1) Idler pulley bracket

(2) Idler pulley adjuster

(3) Idler pulley

(4) Compressor upper bracket

(7)

(6)

T2

(5) Compressor

(6) Compressor lower bracket

(7) V-Belt

AC-00760

Tightening torque: N

m (kgf-m, ft-lb)

T1: 23.0 (2.35, 17.0)

T2: 28.9 (2.95, 21.3)

T3: 36 (3.7, 26.6)

AC-11

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• H6 model

T2

(1)

(2)

T2

T2

(3)

(1) Compressor upper bracket

(2) Compressor

(3) Compressor lower bracket

T1

AC-00912

Tightening torque: N

m (kgf-m, ft-lb)

T1: 28.9 (2.95, 21.3)

T2: 36 (3.7, 26.6)

AC-12

6. HEATER DUCT

(1)

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(3)

(4)

(2)

(1) Front defroster nozzle

(2) Side ventilation duct (LH)

(3) Side ventilation duct (RH)

(4) Center ventilation duct

(5)

(6)

(5) Rear heater duct (LH)

(6) Rear heater duct (RH)

AC-00913

AC-13

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

C: CAUTION

1. HFC-134a A/C SYSTEM

• The cooling system components for the HFC-

134a system such as the refrigerant and compressor oil are different from the conventional CFC-12 system components and they are incompatible with each other.

• Vehicles with the HFC-134a system can be identified by the label (A) attached to the vehicle.

Before maintenance, check which A/C system is installed to the vehicle.

(A)

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 manifold gauge. The highpressure 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 warming, avoid releasing HFC-134a into the atmosphere. Using a refrigerant recovery system, discharge and reuse it.

AC-00762

2. COMPRESSOR OIL

• HFC-134a compressor oil has no compatibility with that of CFC-12 system.

• Use only Denso Oil 8 which is a manufacturerauthorized compressor oil for HFC-134a system.

• Do not mix multiple compressor oils.

If CFC-12 compressor oil is used in the HFC-134a

A/C system, the compressor may become stuck due to poor lubrication, or the refrigerant may leak due to swelling of rubber parts.

On the other hand, if HFC-134a compressor oil is used in a CFC-12 A/C system, the durability of the

A/C system will be lowered.

• HFC-134a compressor oil is very hygroscopic.

When replacing or installing/removing A/C parts, immediately isolate the oil from atmosphere using a plug or tape. In order to avoid moisture, store the oil in a container with its cap tightly closed.

3. REFRIGERANT

• 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, it will result in poor lubrication 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 protective goggles and protective gloves. Direct contact of the refrigerant with skin may cause frostbite.

(A)

(C) (D)

(B)

(F)

(E)

AC-00007

(A) Goggles

(B) Gloves

(C) Avoid open flame

(D) No direct heat on container

(E) Do not discharge

(F) Loosen

5. O-RING CONNECTIONS

• Always use a new O-ring.

• In order to keep the O-rings free of lint which will cause a refrigerant gas leak, perform operations without gloves and cloth.

AC-14

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

• Apply compressor oil to O-rings to avoid sticking, before installation.

• Use a torque wrench to tighten the O-ring fittings.

Over-tightening will result in damage of 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 foreign matter from entering.

Apply compressor oil to the bead of tube.

(A)

AC-00010

• After tightening, use a clean cloth to remove excess compressor oil from the connections and any oil which may have run on the vehicle body or other parts.

• If any leakage is suspected after tightening, do not further tighten the connections, but disconnect the connections, remove the O-rings, and check the O-rings, threads, and connections.

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 tube beads.

(A)

(B)

(D)

(C)

(C)

AC-00009

(A) O-ring

(B) OK

(C) NG

(D) Bead

• Use compressor oil specified in the service manual to lubricate the O-rings.

Apply oil to the top and sides of O-rings before installation.

AC-15

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

D: PREPARATION TOOL

CAUTION:

When working on vehicles with HFC-134a system, only use HFC-134a specified tools and parts. Do not mix with those of CFC-12. If HFC-134a and CFC-12 refrigerant or compressor oil is mixed, it will result in poor lubrication and the compressor itself may be destroyed.

In order to prevent the mixture of 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

ILLUSTRATION Tools and Equipment

Wrench

Various WRENCHES will be required to service any A/C system. 7 to

40 N

⋅ m (0.7 to 4.1 kgf-m, 5 to 30 ft-lb) torque wrench and various crowfoot wrenches will be needed. Open end or flare nut wrenches will be needed to hold the tube and hose fittings.

AC-00213

Applicator bottle

A small APPLICATOR BOTTLE is recommended to apply compressor oil to the various parts. It can be available at a hardware or drug store.

AC-00012

Manifold gauge set

A MANIFOLD GAUGE SET (with hoses) can be available at either a refrigerant supplier or an automotive equipment supplier.

AC-00013

AC-16

ILLUSTRATION

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

Tools and Equipment

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. A syringe can be available at a pharmacy or drug store.

AC-00015

Vacuum pump

A VACUUM PUMP is necessary (for a good working condition), and may be available at either a refrigerant supplier or an automotive equipment supplier.

AC-00016

Can tap

A CAN TAP for the 397 g (14 oz.) can is available at an automotive equipment supplier.

AC-00017

AC-17

General Description

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

ILLUSTRATION Tools and Equipment

Temperature gauge

A Pocket THERMOMETER is available at either a industrial hardware store or a refrigerant suppliers.

AC-00018

Electronic leak detector

An ELECTRONIC LEAK DETECTOR can be available at either a specialty tool supplier or an A/C equipment supplier.

AC-00019

Weight scale

A WEIGHT SCALE such as an electronic charging scale or a bathroom scale with digital display will be needed, if a 13.6 kg (30 lb) refrigerant container is used.

AC-00020

AC-18

Refrigerant Pressure with Manifold Gauge Set

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

2. Refrigerant Pressure with Manifold Gauge Set

A: PROCEDURE

1) Place the vehicle in the shade and windless condition.

2) 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/cm

2

, 18 — 28 psi)

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

2

, 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.

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 evacuating again, charge an 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 refrigerant.

• Check for leaks.

• Replace the expansion valve.

• Replace the receiver dryer.

AC-19

Refrigerant Recovery Procedure

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

3. Refrigerant Recovery Procedure

A: PROCEDURE

CAUTION:

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

• Connect the refrigerant recovery system with the manifold gauge set to 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-25, PROCEDURE, 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.

(D)

(C)

(A) (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.

(A) (B)

(C)

(C)

AC-00021

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge

(C) Close

AC-20

4. Refrigerant Charging Procedure

A: PROCEDURE

CAUTION:

• During operation, be sure to wear protective 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

1.7

°

C (35

°

F)

7.2

°

C (45

°

F)

12.8

°

C (55

°

F)

18.3

°

C (65

°

F)

23.9

°

C (75

°

F)

29.4

°

C (85

°

F)

35

°

C (95

°

F)

Vacuum

100.9 kPa (757 mmHg, 29.8 inHg)

100.5 kPa (754 mmHg, 29.7 inHg)

99.8 kPa (749 mmHg, 29.5 inHg)

99.2 kPa (744 mmHg, 29.3 inHg)

98.5 kPa (739 mmHg, 29.1 inHg)

97.2 kPa (729 mmHg, 28.7 inHg)

95.8 kPa (719 mmHg, 28.3 inHg)

1) Close the valves on low-/high-pressure sides of the manifold gauge.

(A)

Refrigerant Charging Procedure

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

(B)

4) Carefully open the valves on the low-/high-pressure sides to activate the vacuum pump.

(C)

(A)

(D)

(B)

(C)

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).

AC-00025

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.

(C)

(C)

(A) (B)

AC-00023

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge

(C) Close

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.

(C) (C)

(D)

AC-00026

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge

(C) Close

(D) Vacuum pump turn off

AC-21

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, it 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) 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 weight scale.

(A)

(B)

(A) Refrigerant container (HFC-134a)

(B) Weight scale

AC-00029

(C)

(A) (B)

(D)

(E)

AC-00031

(A) Low-pressure gauge (Compound pressure gauge)

(B) High-pressure gauge

(C) Close

(D) Ignition switch OFF

(E) Slowly open

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/cm

2

, 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-22

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. The high-pressure gas will backflow resulting in an explosion of the can.

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.

(A) (B)

AC-00034

24) Adjust the refrigerant flow to maintain the pressure on the low-pressure side at 276 kPa (2.81 kg/ cm

2

, 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

Refrigerant amount

Minimum Maximum

370 g (0.82 lb) 430 g (0.95 lb)

27) Disconnect the hose from the service port, and install the service port cap.

(C)

(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”

• Window open

AC-23

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-side pressure 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 high-pressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly.

3) Check the joint and seam between pressure switch (dual switch) and high-pressure pipe.

4) Check the connections between condenser and pipes, and welded joints on the condenser.

The leak tester may detect the oil on the condenser fins as a leak.

5) Check the joint between compressor and hoses.

6) Check the machined area of 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 low-pressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly.

• Connection between 2 parts

• Connection between pipe and plate

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 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 approx. 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

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-00037

12) Check the valve in the service port.

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

AC-00038

AC-24

Compressor Oil

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

6. Compressor Oil

A: PROCEDURE

NOTE:

Before making repairs, perform the oil return operation to return the compressor oil in circulation with the refrigerant to the compressor.

1) Increase the engine to 1,500 rpm.

2) Turn 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 has been replaced, add an appropriate amount of compressor oil (same as the amount of remaining oil in removed component).

• When replacing the compressor, the new compressor will already have the specified amount of oil in it. Install the new compressor after removing the same amount of oil that is remaining in the compressor removed.

AC-25

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-51, REMOV-

AL, Glove Box.>

3) Disconnect the connectors of A/C control module, intake door actuator, blower motor, power transistor and blower resistor.

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

AC-00914

B: INSTALLATION

Install in the reverse order of removal.

Tightening torque:

Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to AC-5, HEATER COOLING

UNIT, COMPONENT, General Description.>

<Ref. to AC-7, BLOWER MOTOR UNIT, COM-

PONENT, General Description.>

AC-26

Blower Motor

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

8. Blower Motor

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the glove box lower cover. <Ref. to EI-

51, REMOVAL, Glove Box.>

3) Disconnect the connector of blower motor.

4) Loosen the screw to remove blower motor.

AC-00957

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

Connect the battery positive (+) terminal to terminal

No. 2 of blower motor, and negative (

) terminal to terminal No. 1. Check the blower motor for smooth rotation.

2 1

AC-00915

AC-27

Power Transistor (Auto A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

9. Power Transistor (Auto A/C

Model)

A: REMOVAL

1) Remove the glove box lower cover on passenger side. <Ref. to EI-51, REMOVAL, Glove Box.>

2) Disconnect the power transistor connector.

3) Remove two screws, and then remove the power transistor.

B: INSTALLATION

Install in the reverse order of removal.

AC-00916

AC-28

Blower Resistor (Manual A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

10.Blower Resistor (Manual A/C

Model)

A: REMOVAL

1) Remove the glove box lower cover on passenger side. <Ref. to EI-51, REMOVAL, Glove Box.>

2) Disconnect the blower resistor connector.

3) Remove two screws, and then remove the blower resistor.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

(2)

(1)

AC-00916

(4) (3)

Measure the blower resistor resistance.

AC-00766

Terminal No.

4 and 2

4 and 3

4 and 1

Standard

Approx. 0.44

Approx. 1.12

Approx. 2.92

If NG, replace the blower resistor.

AC-29

Heater Core

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

11.Heater Core

A: REMOVAL

1) Remove the heater and cooling unit. <Ref. to

AC-36, REMOVAL, Heater and Cooling Unit.>

2) Remove the screws and remove the heater core cover and pipe clamp.

3) Remove the heater core.

B: INSTALLATION

Install in the reverse order of removal.

AC-00917

AC-30

Control Unit (Manual A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

12.Control Unit (Manual A/C

Model)

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the glove box. <Ref. to EI-51, REMOV-

AL, Glove Box.>

3) Remove the control wires.

AC-00918

4) Remove the integrated panel. <Ref. to ET-5,

REMOVAL, Audio.>

5) Loosen the screw to remove the control unit from bracket.

B: INSTALLATION

Install in the reverse order of removal.

AC-31

Control Unit (Auto A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

13.Control Unit (Auto A/C Model)

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the glove box. <Ref. to EI-51, REMOV-

AL, Glove Box.>

3) Remove the screw, disconnect the connector and remove the control unit.

B: INSTALLATION

Install in the reverse order of removal.

AC-00919

AC-32

Compressor

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

14.Compressor

A: INSPECTION

1. MAGNETIC CLUTCH CLEARANCE

Check the clearance of 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 terminal No. 1 of compressor connector, and negative

(

) terminal to terminal No. 2.

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

AC-00772

8) Disconnect the compressor harness from body harness.

9) Remove the bolts and remove compressor bracket.

• H4 model

AC-00771

3) Check the magnet clutch engagement.

If NG, replace the compressor.

B: REMOVAL

1) Perform the compressor oil return operation.

<Ref. to AC-25, PROCEDURE, Compressor Oil.>

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

3) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-20, PROCEDURE,

Refrigerant Recovery Procedure.>

4) Disconnect the ground cable from battery.

5) Remove the V-belts. <Ref. to ME(H4SO 2.0)-38,

REMOVAL, V-belt.> <Ref. to ME(H4DOTC)-39,

REMOVAL, V-belt.> <Ref. to ME(H6DO)-33, RE-

MOVAL, V-belt.>

6) Remove the generator. <Ref. to SC(H4SO 2.0)-

14, REMOVAL, Generator.> <Ref. to SC(H6DO)-

14, REMOVAL, Generator.>

• H6 model

AC-00773

AC-00920

10) Remove the bolts, and then remove the bracket from compressor.

AC-00774

AC-33

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 the compressor, adjust amount

of compressor oil. <Ref. to AC-25, PROCEDURE,

Compressor Oil.>

4) Charge refrigerant. <Ref. to AC-21, PROCE-

DURE, Refrigerant Charging Procedure.>

Tightening torque:

Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to AC-10, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

<Ref. to AC-11, COMPRESSOR, COMPO-

NENT, General Description.>

AC-34

15.Condenser

A: REMOVAL

1) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-20, PROCEDURE,

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)

• If the condenser is replaced, add an appropriate amount of compressor oil to the compres-

sor. <Ref. to AC-25, REPLACEMENT,

Compressor Oil.>

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 (A) has been fitted into holes on radiator panel.

AC-00775

4) Remove the radiator bracket (A) and hood stay

(B).

(B)

(A)

(A)

AC-00776

5) Remove the front grille. <Ref. to EI-24, REMOV-

AL, Front Grille.>

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

(A)

AC-00631

2) Charge refrigerant. <Ref. to AC-21, PROCE-

DURE, Refrigerant Charging Procedure.>

Tightening torque:

Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to AC-10, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

<Ref. to CO(H4SO 2.0)-5, RADIATOR AND

RADIATOR FAN, COMPONENT, General Description.>

C: INSPECTION

1) Check no dust or insects are found on the condenser fins. Air-blow or flush fins with water as needed.

2) Inspect for oil leakage from condenser. If a failure is found, replace the condenser with a new one.

AC-00777

CAUTION:

• Be careful not to damage the condenser fins.

If a damaged fin is found, repair it using a thin screwdriver.

AC-35

Heater and Cooling Unit

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

16.Heater and Cooling Unit

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-20, PROCEDURE,

Refrigerant Recovery Procedure.>

3) Drain coolant from the radiator.

4) Remove the bolts securing expansion valve and pipe in engine compartment. Release the heater hose clamps in engine compartment to remove the hoses.

AC-00921

5) Remove the instrument panel. <Ref. to EI-56,

REMOVAL, Instrument Panel Assembly.>

6) Remove the support beam.

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

to AC-26, REMOVAL, Blower Motor Unit Assembly.>

8) Disconnect the actuator connector.

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

AC-00922

B: INSTALLATION

1) Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-21, PROCE-

DURE, Refrigerant Charging Procedure.>

Tightening torque:

Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to AC-5, HEATER COOLING

UNIT, COMPONENT, General Description.>

AC-36

17.Evaporator

Evaporator

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

5) Remove the bolt which holds the pipe to evaporator.

A: REMOVAL

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

to AC-26, REMOVAL, Blower Motor Unit Assembly.>

2) Disconnect the connector, remove the screw and then remove the air-mix door actuator and mode door actuator.

AC-00926

6) Remove the screws and clip to remove the evaporator cover.

AC-00923

3) Disconnect the connector, remove the screw and remove the pipe cover and evaporator sensor.

AC-00927

7) Pull out the evaporator (A) in the direction of arrow.

(A)

AC-00924

4) Remove the bolts securing expansion valve and pipe in engine compartment.

AC-00925

AC-00928

CAUTION:

If the evaporator is replaced, add an appropriate amount of compressor oil to evaporator.

<Ref. to AC-25, REPLACEMENT, Compressor

Oil.>

B: INSTALLATION

Install in the reverse order of removal.

AC-37

Hose and Tube

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

18.Hose and Tube

A: REMOVAL

CAUTION:

• When disconnecting/connecting hoses, do not apply an excessive force to them. Confirm that no torsion and excessive tension is charged after installing.

• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.

1) Disconnect the ground cable from battery.

2) Using the refrigerant recovery system, dis-

charge refrigerant. <Ref. to AC-20, PROCEDURE,

Refrigerant Recovery Procedure.>

3) Remove the evaporator unit mounting bolt (A) and low-pressure hose bracket bolt (B).

4) Remove the low-pressure hose attaching bolts

(C).

5) Disconnect the low-pressure hose from evaporator unit.

6) Disconnect the low-pressure hose from compressor.

7) Remove the low-pressure hose from vehicle.

8) Remove the high-pressure hose attaching bolt

(D).

9) Disconnect the high-pressure hose from compressor.

10) Disconnect the high-pressure hose from condenser.

11) Remove the high-pressure hose from vehicle.

12) Remove the high-pressure attaching bolt (E).

13) Remove the high-pressure tube from vehicle.

B: INSTALLATION

CAUTION:

• When disconnecting or connecting the hoses, do not apply excessive force to them. Confirm that no torsion and excessive tension is charged after installing.

• Seal the disconnected hose with a plug or vinyl tape to prevent foreign matter from entering.

1) Install in the reverse order of removal.

2) Charge refrigerant. <Ref. to AC-21, PROCE-

DURE, Refrigerant Charging Procedure.>

Tightening torque:

Refer to “COMPONENT” of “General Descrip-

tion”. <Ref. to AC-10, AIR CONDITIONING

UNIT, COMPONENT, General Description.>

C: INSPECTION

Check the hoses for cracks, damage and expansion. If any fault is found, replace them with new ones.

(A)

(B)

(C)

(D)

(E)

(D)

AC-00929

AC-38

19.Relay and Fuse

A: LOCATION

Relay and Fuse

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

B: INSPECTION

1

2

4

3

(A)

(E)

(1)

(B)

(D)

(C)

(1) Joint box

(2) Main fuse box

Main Fan Relay 1

Main Fan Relay 2

Sub Fan Relay

A/C Relay

A/C Fuse

(2)

(A)

(B)

(C)

(D)

(E)

AC-00787

2

3

1

4

AC-00641

(3) — (4): Continuity exists

(1) — (2): Continuity does not exist

While applying battery voltage to the terminal between (3) and (4), check continuity between (1) and

(2).

If no continuity exists, replace the relay with a new one.

AC-39

Pressure Switch (Triple Pressure Switch)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

20.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 pressure switch.

4

1

2

3

High and low pressure switch

Middle pressure switch

Terminal

No.

AC-00788

Operation

Turns OFF.

1 and 2

3 and 4

Turns ON.

Turns OFF.

Turns ON.

Standard kPa (kg/cm

2

, psi)

Increasing to 3,140

+50

200

(32.02

+0.51

2.04

, 455.4

+7.25

29.0

)

Decreasing to 196

±

20 (2.00

±

0.20, 28.4

±

2.9)

Increasing to 225

+25

29

(2.29

+0.25

0.30

, 32.6

+3.6

4.2

)

Decreasing to 2,550

±

200 (26.00

±

2.04, 369.8

±

29.0)

Decreasing to 1,370

±

120 (14

±

1, 199

±

14)

Increasing to 1,770

±

100 (18

±

1, 256

±

14)

AC-40

Ambient Sensor (Auto A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

21.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 the radiator lower panel.

AC-00125

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

<Ref. to AC(diag)-30, AMBIENT SENSOR, Diagnostic Procedure for Sensors.>

AC-41

Sunload Sensor (Auto A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

22.Sunload Sensor (Auto A/C

Model)

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Disconnect the connector and remove the sunload sensor.

AC-00930

CAUTION:

Be careful not to damage the interior trims when removing the sensor.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

<Ref. to AC(diag)-36, SUNLOAD SENSOR, Diagnostic Procedure for Sensors.>

AC-42

In-Vehicle Sensor (Auto A/C Model)

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

23.In-Vehicle Sensor (Auto A/C

Model)

A: REMOVAL

1) Disconnect the ground cable from battery.

2) Remove the instrument panel lower cover. <Ref.

to EI-50, REMOVAL, Instrument Panel Lower Cover.>

3) Disconnect the connector and aspirator hose, remove the pawl and remove the in-vehicle sensor

(A) from instrument lower cover.

(A)

AC-00790

CAUTION:

Be careful not to damage the sensors and interior trims when removing.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

<Ref. to AC(diag)-32, IN-VEHICLE SENSOR, Diagnostic Procedure for Sensors.>

AC-43

Air Vent Grille

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

24.Air Vent Grille

A: REMOVAL

1. CENTER GRILLE

1) Disconnect the ground cable from battery.

2) Remove the three pawls and connector to remove center air vent grill.

AC-00931

2. SIDE GRILLE

Remove the two pawls to remove side air vent grill.

AC-00932

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1) Check the direction and amount of air can be adjusted smoothly.

2) Check the adjustment can be kept in each position.

AC-44

Heater Duct

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

25.Heater Duct

A: REMOVAL

1. FRONT HEATER DUCT

1) Remove the instrument panel lower cover. <Ref.

to EI-50, REMOVAL, Instrument Panel Lower Cover.>

2) Remove the screws and detach the front heater duct (A).

(A)

AC-00933

2. REAR HEATER DUCT

1) Remove the heater cooling unit. <Ref. to AC-36,

REMOVAL, Heater and Cooling Unit.>

2) Remove the front seats. <Ref. to SE-7, REMOV-

AL, Front Seat.>

3) Remove the front side sill cover.

4) Pull off the floor mat to remove the rear center heater duct (A) and rear heater duct LH, RH (B).

(A)

(B)

B: INSTALLATION

Install in the reverse order of removal.

AC-00934

AC-45

Heater Vent Duct

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

26.Heater Vent Duct

A: REMOVAL

1) Remove the instrument panel. <Ref. to EI-50,

REMOVAL, Instrument Panel Lower Cover.>

2) Remove the screws and detach the center vent duct (A).

3) Remove the screws and detach the center vent duct (B).

4) Remove the insulator, remove the screws and detach the defroster duct.

(B)

(A) (B)

B: INSTALLATION

Install in the reverse order of removal.

AC-00935

AC-46

27.Heater Cock Solenoid Valve

A: REMOVAL

1) Drain the engine coolant. <Ref. to CO(H4SO

2.0)-13, DRAINING OF ENGINE COOLANT, RE-

PLACEMENT, Engine Coolant.>

2) Disconnect the harness connector (A) of the heater cock solenoid valve.

3) Remove the two bolts to remove the heater cock solenoid from the bracket.

(A)

Heater Cock Solenoid Valve

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

AC-00936

4) Pull out the heater cock solenoid. Loosen the hose clamp and disconnect the two heater hoses.

B: INSTALLATION

Install in the reverse order of removal.

C: INSPECTION

1) Remove the heater cock solenoid valve. <Ref. to

AC-47, REMOVAL, Heater Cock Solenoid Valve.>

2) Connect the positive terminal of battery to No. 1 terminal of heater cock solenoid valve, and the ground terminal to No. 2 terminal. Check that the heater cock solenoid valve opens and closes normally.

2 1

AC-00888

If any failure is found, replace the heater cock solenoid valve.

AC-47

General Diagnostic Table

HVAC SYSTEM (HEATER, VENTILATOR AND A/C)

28.General Diagnostic Table

A: INSPECTION

Symptom

Blower motor

Compressor

Cold air not emitted.

Warm air not emitted.

Unable to switch blow vents.

Unable to switch suction vents.

Doesn’t operate.

Noise

Doesn’t operate.

Noise

Temperature of air from vents does not change.

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

Heater cock solenoid valve

Engine coolant

Air mix actuator (Auto A/C)

Wire harness (Auto A/C)

Temperature control cable (Manual A/C)

Mode actuator (Auto A/C)

Air flow switch (Auto A/C)

Wire harness (Auto A/C)

Mode cable (Manual A/C)

Air inlet select switch (Auto A/C)

FRESH/RECIRC actuator (Auto A/C)

Wire harness (Auto A/C)

Intake cable (Manual A/C)

AC-48

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