SECTION 1A - HEATING, VENTILATION AND

AIR CONDITIONING (HVAC)

Service Precaution

Heating and Ventilation System

General Description

Heater and Ventilation Associated Parts

Ventilation

Circuit Diagram

Diagnosis

Individual Inspection

Heater Unit

Heater Unit and Associated Parts

Removal

Installation

Heater Core and / or Mode Door

Disassembled View

Removal

Inspection

Installation

Heater Mode Control Link Unit

Disassembled View

Removal

Installation

Heater Temperature Control Link Unit

Disassembled View

Removal

Installation

Blower Assembly

Blower Assembly and Associated Parts

Removal

Installation

Blower Link Unit and / or Mode door

Disassembled View

Removal

Installation

Blower Motor

Blower Motor and Associated Parts

Removal

Installation

Rear Heater Duct, Defroster Nozzle and

Ventilation Duct

Rear Heater Duct, Defroster Nozzle,

Ventilation Duct and Associated Parts

Removal

Installation

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable

and Associated Parts

Removal

Installation

Control Panel Illumination Bulb

Control Panel Illumination Bulb and

Associated Parts

Removal

Installation

Resistor

Resistor and Associated Parts

Removal

Installation

Air Conditioning System

General Description

Circuit Diagram

Diagnosis

Individual Inspection

General Repair Procedure

Leak Check

Compressor Assembly

Compressor Assembly and Associated

Parts (6VD1)

Removal

Installation

Compressor Assembly and Associated

Parts (X22SE)

Removal

Installation

New Compressor Installation

Condenser Assembly

Condenser Assembly and Associated Parts

Removal

Installation

Condenser Fan Motor

Condenser Fan Motor and Associated Parts

Removal

Installation

Receiver / Drier

Receiver / Drier and Associated Parts

Removal

Installation

Pressure Switch

Pressure Switch and Associated Parts

Removal

Installation

Evaporator Assembly

Evaporator Assembly and Associated Parts

Removal

Installation

Techline

Electronic Thermostat, Evaporator Core

and/or Expansion Valve

Disassembled View

Removal

Installation

Refrigerant Line

Refrigerant Line and Associated Parts

Removal

Installation

Main Data And Specifications

Compressor

Service Precaution

General Description

Diagnosis

Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View

Removal

Inspection and Repair

Installation

Compressor Oil

Oil Specification

Handling of Oil

Compressor Oil Check

Checking and Adjusting Oil Quantity for

Used Compressor

Checking and Adjusting for Compressor

Replacement

Contamination of Compressor Oil

Oil Return Operation

Replacement of Component Parts

Main Data and Specifications

Special Tools

Automatic Air Conditioning System

General Description

Automatic Air Conditioner Parts Configuration

Refrigerant Line and Associated Parts

Circuit Diagram

Functions and Features

Automatic Air Conditioner Block Diagram

Control Panel Layout

Air Control Functions

Operation and Functions of Control Panel

Switches

Overview of Construction, Movement and

Control of Major Parts of Automatic Air

Conditioner System

Overview of Automatic Control of

Automatic Air Conditioner

Troubleshooting

Troubleshooting, Its Overview and

Procedures

Auto Air Conditioner Control Unit Power

Supply Diagnosis

Performance and Movement checklist

for Automatic Air Conditioner Related

Parts

Troubleshooting With Self-Diagnosis

Function

Inspection By Failed Location

Inspection of the Sensors

Inspection of the Intake Actuator System

Inspection of the Mix Actuator System

Inspection of the Mode Actuator System

Inspection of the Fan Motor System

Inspection of the Magnetic Clutch System

Condenser Fan Diagnosis

Individual Inspection

On-Vehicle Service

Power Transistor

Removal

Installation

Automatic Heater/Air Conditioner

Control Unit

Removal

Installation

In Car Sensor

Removal

Installation

Ambient Sensor

Removal

Installation

Sun Sensor

Removal

Installation

Electronic Thermostat

Removal

Installation

Mode Actuator

Removal

Installation

Mix Actuator

Removal

Installation

Intake Actuator

Removal

Installation

Service Precaution

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL

RESTRAINT SYSTEM (SRS). REFER TO THE SRS

COMPONENT AND WIRING LOCATION VIEW IN

ORDER TO DETERMINE WHETHER YOU ARE

PERFORMING SERVICE ON OR NEAR THE SRS

COMPONENTS OR THE SRS WIRING. WHEN YOU

ARE PERFORMING SERVICE ON OR NEAR THE

SRS COMPONENTS OR THE SRS WIRING, REFER

TO THE SRS SERVICE INFORMATION. FAILURE TO

FOLLOW WARNINGS COULD RESULT IN

POSSIBLE AIR BAG DEPLOYMENT, PERSONAL

INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM

REPAIRS.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU will also call out

the fasteners that require thread lockers or thread

sealant. UNLESS OTHERWISE SPECIFIED, do not

use supplemental coatings (Paints, greases, or

other corrosion inhibitors) on threaded fasteners or

fastener joint interfaces. Generally, such coatings

adversely affect the fastener torque and the joint

clamping f or ce, and may dama ge the fastener . Wh en

you install fasteners, use the correct tightening

sequence and specifications. Following these

instructions can help you avoid damage to parts

and systems.

Heating and Ventilation System

General Description

Heater

When the engine is warming up, the warmed engine

coolant is sent out into the heater core. The heater

system supplies warm air into the passenger

compartment to warm it up.

Outside air is circulated through the heater core of the

heater unit and then back into the passenger

compartment. By controlling the mixture of outside air

and heater core air, the most comfortable passenger

compartment temperature can be selected and

maintained.

The temperature of warm air sent to the passenger

compartment is controlled by the temperature control

knob . This knob acts to open and close the air mix door ,

thus controlling the amount of air passed through the

heater core.

The air selector knob, with its different modes, also

allows you to select and maintain the most comfor table

temperature.

The air source select lever is used to select either

“FRESH" for the introduction of the outside air, or

“CIRC" for the circulation of the inside air. When the

lever is s et to “FRES H", the outside air is always taken

into the passenger compartment. When setting the

lever to “CIRC" position, the circulation of air is

restricted only to the inside air with no introduction of

the outside air and the air in the passenger

compar tment gets war m quickly. However, the lever is

nor m ally s et to “FRESH" to prevent th e win dshield from

clouding.

Heater and Ventilation Associated Parts

840RY00049

EndOFCallout

Legend

(1) Defroster Nozzle

(2) Heater Hose

(3) Rear Heater Duct

(4) Ventiration Lower Duct

(5) Heater Unit

(6) Evaporator Assembly

(7) Blower Assembly

(8) Ventilation Duct

Ventilation

Setting the air source select lever to “FRESH" position

allows the heating system to work with sending the

fresh air from outside.

The blower fan also serves to deliver fresh outside air to

the passenger compartment to assure adequate

ventilation.

810RW319

Control Lever Assembly

The control lever assembly has some cables to control

the mode and temperature of the heater unit and the

mode door for the air source of the blower assembly.

The fan control is u sed to c ontrol t he a mount of air sen t

out by the resistor at four levels from “LOW" to “HIGH".

865RW006

EndOFCallout

Air Source Select Lever

The intake of outsid e air and the circu lation of insi de air

are controlled by sliding this lever left or right.

Fan Control Lever

This lever controls the blower motor speed to regulate

the amount of air delivered to the defrost, foot, and

ventilation ducts:

1. Low

2. Medium Low

3. Medium High

4. High

Temperature Control Knob

When the temperature control knob is in the “COLD"

position, the air mix door closes to block the flow air to

the heater core.

When the temperature control knob is in the “HOT"

position, the air mix door opens to allow air to pass

through the heater core and heat the passenger

compartment.

Placi ng the knob in a interm ediate positi on will cause a

lesser or greater a mou nt a ir to r each the hea ter c ore. In

this mode the passenger compartment temperature can

be regulated.

Legend

(1) Air Source Select Lever

(2) Air Select Knob

(3) Fan Control Le ver (Fa n Switch)

(4) Air Conditioning (A/C) Switch (W/ A/C)

(5) Temperature Control Knob

(6) Middle Position

Flow of Each Position of the All Select Dials

C01RX001

Air Select Knob

The air select knob allows you to direct heated air into

the passenger compartment through different outlets.

1. Vent – In this position, air is discharged from the

upper air outl et. Ai r quantity is control led by the fan

con tr ol lever.

2. Bi-Level – In this position, air flow is divided

between the upper air outlets and the floor air

outlets, with warmer air delivered to the floor outlets

than the air delivered to the upper air outlets when

the temp lever is in middle position.

3. Foot – In this position, air flow is delivered to the

foot, while sending a small amount of air to the

windshield.

4. Def/Foot – In this position, air flow is delivered to

the foot, while send ing approx. 40% of to tal amount

of air to the windshield.

5. Defrost – In this position, most of the air is delivered

to the windshie ld and a s mal l a mou nt i s del ivered to

the side windows.

Moving the air source select lever to the “CIRC" position

provides quickest heat delivery by closing the blower

assem bly mode doo r. In this po sition, outside ai r is not

delivered to the passenger compartment.

Circuit Diagram

D08RX149

Diagnosis

Heating Cycle diagnosis

Condition Possible cause Correction

No heating or insufficient heating. Blower motor does not run or runs

improperly. Refer to “FAN CONTROL LEVER

(FAN SWITCH) DIAGNOSIS".

Engine coolant temperature is low. Check the engine coolant

temperature after warming up the

engine and ch eck the th er m ostat.

Replace as necessary.

Insufficient engine coolant. Add engine coolant as required.

Circulation volume of engine coolant

is insuf f ic ie nt. Check if the water hose to the

heater core is clogged, collapsed or

twisted. Repair or replace as

necessary.

Heater core cl ogg ed or coll aps ed. Clean or replac e as neces sa ry.

The heater cores is not provided

with air sent from the blower motor. Repair the temperature control link

unit or mode doors.

Duct connections defective or

unsealing. Repair or replace as necessary.

Control lever moves but mode door

does not operate. Cable attaching clip is not correct. Repair

Link unit of heater or blower

assembly defective. Repair

The mode door can not be set to the

mode selected. Link unit of heater unit or blower

assembly defective. Repair.

Control cable is not adjusted. Adjust.

Fan Contro l Lever (Fan Switch) Diagnosi s

Current flows to the blower motor through the heater

relay (X-6) to activate the rotation of the blo w er motor b y

turning “ON" the fan control knob (fan switch). Blower

motor speed is controlled in stages by the resistor, by

operating the switch from “LOW" to “HIGH".

For the inspection of the relays, switches and units in

each table, refer to “INDIVIDUAL INSPECTION" in this

section.

D08RX250

Condition Possible cause Correction

Blower motor does not run. — Refer to Chart A

Blower motor does not run in certain

positi on (s). — Refer to Chart B, C, D and E

Blo w er moto r doe s not stop at “ OFF"

position. — Refer to Chart F

Chart “A" Blower Motor Does Not Run

Chart “B" Blower Motor Does Not Run At Low Position

Chart “C" Blower Motor Does Not Run At Medium Low Position

Chart “D" Blower Motor Does Not Run At Medium High Position

Step Action Yes No

1 Is relay (X-6) OK? Go to Step 2 Replace

2 Is fuse F-4 (20A) OK? Go to Step 3 Replace

3 Is resistor OK? Go to Step 4 Replace

4 Is fan control lever OK? Go to Step 5 Replace control

lever assembly.

5 Is blower motor OK? Go to Step 6 Replace

6 1. Turn the ignition switch “ON".

2. Turn fan control lever “ON".

3. Check to see if battery voltage is present at chassis side

connector terminal No. B5-2

Is there a battery voltage?

Poor ground or

open circuit either

between chassis

side connector

terminal No. B5-1

and No . B3-2 or

No . I23-1 and body

ground (No. B-8).

Open circui t

between No. F-4

(20A) fuse and No .

B5-2.

Step Action Yes No

1 Is resistor OK? Go to Step 2 Replace

2 Is fan control lever (Fan Switch) OK? Open circuit

between chassis

side connector

terminal No. B3-1

and No .I23-2. Replace control

lever assembly.

Step Action Yes No

1 Is resistor OK? Go to Step 2 Replace

2 Is fan control lever (Fan Switch) OK? Open circuit

between the

chassis side

connector terminal

No. B3-4 and No.

I23-3. Replace control

lever assembly.

Step Action Yes No

1 Is resistor OK? Go to Step 2 Replace

2 Is fan control lever (Fan Switch) OK? Open circuit

between chassis

side connector

terminal No. B3-6

and No. I23-4. Replace control

lever assembly.

Chart “E" Blower Motor Does Not Run At High Position

Chart “F" Blower Motor Does Not Stop In The “OFF" Position

Step Action Yes No

1 Is resistor OK? Go to Step 2 Replace

2 Is fan control lever (Fan Switch) OK? Open circuit

between Chassis

side connector

terminal No. B3-3

and No. I23-5. Replace control

lever assembly.

Step Action Yes No

1 Is the fan control lever (Fan Switch) OK? Short circuit

between chassis

side connector

terminal No.B5-1

and

No.B3-2,No.B3-3

and No.I23-5,

No.B3-6 and

No .I23-4, No.B3-4

and No .I23-3 or

No.B3-1 and

No.I23-2 Replace control

lever assembly.

Individual Inspection

Blower Motor

1. Disconnect the blower motor (B-5) connector from

the blower motor.

2. Connect the battery positive terminal to the No. 2

ter mi nal of th e blower moto r and the negative to the

No. 1.

3. Be sure to check to see if the blower motor operates

correctly.

873RW008

Resistor

1. Disconnect the resistor (B-3) connector.

2. Check for continuity and resistance between the

terminals of the resistor.

840RX013

EndOFCallout

Legend

(1) Resi st e r As sembly

(2) Connector Terminal (Resister Side)

(3) Positi on Switc h

Fan Control Lever (Fan Switch)

1. Check for continuity between the terminals of the

fan switch.

D08RX157

EndOFCallout

Heater R elay

1. Disconnect the heater relay (X-6).

• When removing the connector for relay, unfasten

the tank lock of the connector by using a

screwdriver, then pull the relay (1) out.

825RX046

2. Check for continuity between the heater relay (X-6)

terminals.

901RX071

Legend

(1) Control Lever Connector Terminal (Control

Lever Side)

(2) Position Switch

Heater Unit

Heater Unit and Associated Parts

840RY00046

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Drain the engine coolant.

3.Discharge and recover refrigerant (with air

conditioning).

•Refer to Refrigerant Recovery in this section.

4. Remove the Instrument panel assembly.

•Refer to Instrument Panel Assembly in Body and

Accessories sectio n.

5. Remove instrument panel stay.

6. Remove center ventilation duct and side defroster.

7. Dis co nne ct resisto r connector.

8. Remove evaporator assembly.

•Refer to Evaporator Assembly in this section.

9. Remove ventilation lower duct.

10. Remove rear heater duct.

• Remove foot rest, carpet and 3 clips.

11. Remove heater unit assembly.

• Disconnect heater hoses at heater unit.

Legend

(1) Instrument Panel Assembly

(2) Resistor Connector

(3) Heater Hose

(4) Heater Unit Assembly

(5) Evaporator Assembly

(6) Rear Heater Duct

(7) Ventilation Lower Duct

(8) Instrument Panel Stay

(9) Center Ventilation Duct and Side Defroster

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1.When handling the PCM and the control unit, be

careful not to make any improper connection of the

connectors.

2.Adjust the control cables.

•Refer to Control Lever Assembly in this section.

3. When installing the heater unit, defroster nozzle and

center vent duct, be sure that the proper seal is

made, without any gap between them.

4. After putting engine coolant in remove the air well

and confirm the quantity of coolant.

Heater Core and / or Mode Door

Disassembled View

860RX002

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Drain the engine coolant.

Legend

(1) Heater Unit

(2) Case (Temperature Control)

(3) Heater Core

(4) Case (Mode Control)

(5) Duct

(6) Mode Door

3.Discharge and recover refrigerant (with air

conditioning).

•Refer to Refrigerant Recovery in this section.

4.Remove heater unit.•Refer to Heater Unit in this section.

5. Remove duct.

6. Remove case (Mode control) and do not remov e link

unit at this step.

7. Remove case (Temperature control) and separate

two halves of core case.

860RW021

EndOFCallout

8. Remove heater core.

860RW020-1

EndOFCallout

9. Pull out the mode door whil e raising up the cat ch of

the door lever.

860RX004

EndOFCallout

Inspection

Check for foreign m atter in the he ater core, stain or the

core fin defacement.

Installation

To install, follow the removal steps in the reverse order,

noting the following point:

1. Check that each mode door operates properly.

Legend

(1) Heater Core

(2) Core Case

Legend

(1) Heater Core

Legend

(1) Mode Door

(2) Door Lever

Heater Mode Control Link Unit

Disassembled View

860RY00012

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

3.Discharge and recover refrigerant (with air

conditioning)

•Refer to Refrigerant Recovery in this section.

4. Remove heater unit.

•Refer to Heater Unit in this section.

5.Remove the case (Mode control) from heater unit.6.Remove washer and the mode main lever.

7. Remove rod.

8. Press the tab of the sub-lever inward, and take out

the sub-lever.

860RW018

Legend

(1) Heater Unit

(2) Case (Mode Control)

(3) Mode Sub Lever

(4) Door Lever

(5) Clip

(6) Washer and Mode Main Lever

(7) Rod

9.Pull out the door lever while raising up the catch of

the door lever.

10.Remove clip.

Installation

To install, follow the remove steps in the reverse order,

noting the following points:

1.Apply grease to the mode sub-lever and to the

abrasive surface of the heater unit.

2.After installing the link unit, check to see if the link

unit operates correctly.

Heater Temperature Control Link Unit

Disassembled View

860RX001

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Drain engine coolant.

3.Discharge and recover refrigerant (with air

conditioning).

•Refer to Refrigerant Recovery in this section.

4. Remove heater unit.

•Refer to Heater Unit in this section.

5. Remove the case (Temperature control) from the

heater unit.

6. Remove rod.

7. Remove sub-lever.

8. Pull out the door lever while raising up the catch of

the door lever.

9. Remove clip.

Legend

(1) Heater Unit

(2) Case (Temperature control)

(3) Door Lever

(4) Sub Lever

(5) Clip

(6) Rod

(7) Clip

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1. Apply grease to the sub-lever and to the abrasive

surface of the heater unit.

2. After installing the link unit, check to see if the link

unit operates correctly.

Blower Assembly

Blower Assembly and Associated Parts

840RY00045

EndOFCallout

Legend

(1) Instrument Panel Assembly

(2) Blower Assembly

(3) B lower Motor Harness Conne cto r

(4) Resistor Harness Connector

(5) Heater Hose

(6) Heater Unit Assembly

(7) Evaporator Assembly

(8) Rear Heater Duct

(9) Ventilation Lower Duct

(10) Instrument Panel Stay

(11) Cross Beam Assembly

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant (with air

conditioning).

•Refer to Refrigerant Recovery in this section.

3.Remove instrument panel assembly.

•Refer to Instrument Panel Assembly in Body

structure section.

4.Disconnect resistor harness connector.

5.Remove evaporator assembly.

•Refer to Evaporator Assembly in this section.

6.Disconnect blower motor harness connector.

7.Remove blower assembly.

Installation

To install, follow the removal steps in the reverse order,

noting the following point:

1.Adjust the control cables.

•Refer to Control Lever Assembly in this section.

Blower Link Unit and / or Mode door

Disassembled View

873RX002

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant (with air

conditioning).

•Refer to Refrigerant Recovery in this section.

3. Remove blower assembl y.

•Refer to Blower Assembly in this section.

4. Remove lower case.

Legend

(1) Blower Assembly

(2) Door Lever

(3) S ub Lever

(4) Lower C as e

(5) Mode Door

(6) Upper Case

5. Separate the upper case and slit the lining parting

face with a knife.

873RW006

6. Pull ou t the mode door whil e raising up the ca tch of

door lever.

7. Remove sub-lever.

8. Remove door lever.

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1. Apply grease to the door lever and to the abrasive

surface of the upper case.

2. Apply an adhesive to the parting face of the lining

when assembling the upper case.

Blower Motor

Blower Motor and Associated Parts

873RX001

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Remove blower motor connector.

3. Remove attaching screw.

4. Remove blower motor assembly.

5. Remove clip.

6. Remove fan.

7. Remove blower motor.

Installation

To install, follow the re moval steps in the reverse order.

Legend

(1) B lower Motor Connec tor

(2) Attaching Screw

(3) Blowe r Moto r As se mbly

(4) Clip

(5) Fan

(6) Blower Motor

Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts

840RY00047

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove instrument panel assembly.

•Refer to Instrument Panel Assembly in Body

Structure section.

3. Remove center ventilation duct and side defroster

duct.

• Remove 5 screws.

4. Remove instrument panel Stay.

5. Remove cross beam assembly.

6. Remove ventilation lower duct.

7. Remove rear heater duct.

Legend

(1) Cross Beam Assembly

(2) Defroster Nozzle

(3) Ventilation Lower Duct

(4) Rear Heater Duct

(5) Instrument Panel Assembly

(6) Instrument Panel Stay

(7) Center Ventilation Duct and Side Defroster

• Remove foot rest carpet and 3 clips.

8. Remove defroster nozzle.

Installation

To install, follow the removal steps in the reverse order,

noting the following point:

1. Connect each duct and nozzle securely leaving no

clearance between them and making no improper

matching.

Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts

865RX009

EndOFCallout

Legend

(1) Control Cable

(2) Control Lever Assembly

(3) Meter Cluster Assembly

(4) Instrument Panel Driver Lower Cover Assembly

(5) Glove Box

Removal

1.Disconnect the battery ground cable.

2.Remove instrument panel driver lower cover

assembly.

3.Remove meter cluster assembly.

•Refer to Instrument Panel Assembly in Body

Structure section.

4. Remove glove box.

5. Remove the control lever attaching screws.

6. Pull the control lever assembly out and disconnect

the fan switch and air conditioning switch

connectors.

865RX012

7. Remove control lev el assembly.

8. Disconnect control cables at each unit side.

865RX010

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1. Adjust the control cable.

865RX013

• Air source control cable.

1 Slide the control lever to the left (“CIRC"

position).

2 Connect the control cable at the “CIRC"

position of the link unit of the blower assembly

and secure it with the clip.

• Temperature control cable.

1 Turn the control knob to the left (“MAX COLD"

position).

2 Connect the control cable at the “COLD"

position of the temperature control link of the

heater unit and secure it with the clip .

• Air se le ct con t ro l ca ble

1 Turn the control knob to the right

(“DEFROST" position).

2 Connect the control cable at the “DEFROST"

position of the mo de con trol lin k of the heater

unit and secure it with the clip.

2. Check the control cable operation.

Control Panel Illumination Bulb

Control Panel Illumination Bulb and

Associated Parts

865RX011

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove control lever assembly.

•Refer to Control Lever Assembly in this section.

3. Pull out the bulb socket from the panel by tur ning it

counterclockwise.

4. Pull the illumination bulb from the socket.

Installation

To install, follow the re moval steps in the reverse order.

Resistor

Resistor and Associated Parts

840RX021

EndOFCallout

Removal

1. Disconnect the battery ground cable.

2. Remove glove box.

• Remove the 2 inside clips.

3. Remove passenger knee bolster reinforcement.

4. Remove re si st or harnes s co nne cto r.

5. Remove re si st or.

Installation

To install, follow the re moval steps in the reverse order.

Legend

(1) Control Lever Assembly

(2) Bulb Socket

(3) Il lu mi nation Bul b

Legend

(1) Resistor

(2) Passenger Knee Bolster Reinforcement

(3) Resistor Harness Connector

(4) Glove Box

Air Conditioning System

General Description

Air Conditioning Refrigerant Cycle Construction

C01RX004

EndOFCallout

The refrigeration cycle includes the following four

processes as the refrigerant changes repeatedly from

liquid to gas and back to liquid while circulating.

Evaporation

The refr igerant is changed from a liquid to a gas inside

Legend

(1) Electronic Thermostat

(2) Evaporator Core

(3) Evaporator Assembly

(4) Temperature Senso r

(5) Expansion Valve

(6) B lower Motor

(7) Pressure Switch or Pressure Sensor

(8) Receiver/Drier

(9) Condenser

(10) Compressor

(11) Magnetic Clutch

(12) Mode (HEAT) Control Door

(13) Temp. Control Door (Air Mix Door)

(14) Heater Core

(15) Mode (VENT) Control Door

(16) Heater Unit

(17) Mode (DEF) Control Door

the evaporator. The refrigerant mist that enters the

evaporator vaporizes readily. The liquid refrigerant

removes the required quantity of heat (latent heat of

vaporization) from the air around the evaporator core

cooling fins and rapidly vaporizes. Removing the heat

cools the air, which is then radiated from the fins and

lowers the temperature of the air inside the vehicle.

The refrigerant liquid sent from the expansion valve and

the vaporized refrigerant gas are both present inside the

evaporator as the liquid is converted to gas.

With this change from liquid to gas, the pressure inside

the evaporator must be kept low enough for vaporization

to occur at a lower temperature. Because of that, the

vaporized refrigerant is sucked into the compressor.

Compression

The refrigerant is compressed by the compressor until it

is easily liquefied at normal temperature.

The vaporized refrigerant in the evaporator is sucked

into the compressor. This action maintains the

refrigerant inside the evaporator at a low pressure so

that it can easily vaporize, even at low temperatures

close to 0°C (32°Φ).

Also, the refrigerant sucked into the compressor is

compressed inside the cylinder to increase the pressure

and temperature to values such that the refrigerant can

easily liquefy at normal ambient temperatures.

Condensation

The refrigerant inside the condenser is cooled by the

outside air and changes from gas to liquid.

The high temperature, high pressure gas coming from

the compressor is cooled and liquefied by the

condenser with outside air and accumulated in the

receiver/drier. The heat radiated to the outside air by the

high temperature, high pressure gas in the compressor

is called heat of condensation. This is the total quantity

of heat (heat of vaporization) the refrigerant removes

from the vehicle interior via the evaporator and the work

(calculated as the quantity of heat) performed for

compression.

Expansion

The expansion valve lowers the pressure of the

refrigerant liquid so that it can easily vaporize.

The process of lowering the pressure to encourage

vaporization before the liquefied refrigerant is sent to

the evaporator is called expansion. In addition, the

expansion valve controls the flow rate of the refrigerant

liquid while decreasing the pressure.

That is, the quantity of refrigerant liquid vaporized inside

the evaporator is determined by the quantity of heat

which must be removed at a prescribed vaporization

temperature. It is important that the quantity of

refrigerant be controlled to exactly the right value.

Compressor

The compressor performs two main functions:

It compresses low-pressure and low-temperature

refrigerant vapor from the evaporator into high-pressure

and high-temperature refrigerant vapor to the

condenser.

It pumps refrigerant and refrigerant oil through the air

conditioning system.

This vehicle is equipped with a five-vane rotary

compressor.

The specified amount of the compressor oil is 150cc

(5.0fl.oz.).

The oil used in the HFC-134a system compressor

differs from that used in R-12 systems.

Also, compressor oil to be used varies according to the

compressor model. Be sure to avoid mixing two or more

different types of oil.

If the wrong oil is used, lubrication will be poor and the

compressor will seize or malfunction.

The magnetic clutch connector is a waterproof type.

Magnetic Clutch

The compressor is driven by the drive belt from the

crank pulley of the engine. If the compressor is activated

each time the engine is started, this causes too much

load to the engine. The magnetic clutch transmits the

power from the engine to the compressor and activates

it when the air conditioning is ON. Also, it cuts off the

power from the engine to the compressor when the air

conditioning is OFF. Refer to Compressor in this section

for magnetic clutch repair procedure.

871RX026

EndOFCallout

Legend

(1) Magnetic Clutch

(2) Magnetic Clutch Harness Connector

(3) Compressor

Condenser

The condenser assembly is located in front of the

radiator. It provides rapid heat transfer from the

refrigerant to the cooling fins.

Also, it functions to cool and liquefy the high-pressure

and high-temperature vapor sent from the compressor

by the radiator fan or outside air.

A conde nser may malfunction i n two ways: it may leak,

or it may be restricted. A condenser restriction will

result in excessive compressor discharge pressure. If a

partial restriction is present, the refrigerant expands

after passing through the restriction.

Thus, ice or frost may form immediately after the

restriction. If air flow through the condenser or radiator

is blocked, high discharge pressures will result. During

normal condenser operation, the refrigerant outlet line

will be slightly cooler than the inlet line.

The vehicle is equipped with the parallel flow type

condenser. A larger thermal transmission area on the

inner surface of the tube allows the radiant heat to

increase and the ventilation resistance to decrease.

The refrigerant line connection has a bolt at the block

joint, for easy servicing.

875RX003

EndOFCallout

Receiver / Drier

The receiver/drier performs four functions:

• As the quantity of refrigerant circulated varies

depending on the refrigeration cycle conditions,

sufficient refrigerant is stored for the refrigeration

cycle to operate smoothly in accordance with

fluctuations in the quantity circulated.

• The liquefie d refr ige rant from the cond enser i s mixed

with refrigerant gas containing air bubbles. If

refrigerant containing air bubbles. If refrigerant

containi ng air bubbles is se nt to the expansio n valve,

the cooling capacity will decrease considerably.

Therefore, the liquid and air bubbles are separated

and only the liquid is sent to the expansion valve.

• The receiver/drier utilizes a filter and drier to remove

the dirt and water mixed in the cycling refrigerant.

• The sight glass, installed atop the receiver/drier,

show the state of the refrigerant.

A receiver/drier may fail due to a restriction inside the

body of th e unit. A rest ric tion at t he inlet to th e rece iver/

drier will cause high pressure.

Outle t restric tions will be ind icated by low press ure and

little or no cooling. An excessively cold receiver/drier

outlet may indicate a restriction.

The receiver/drier of this vehicle is made of aluminum

with a smaller tank. It has a 300cc refrigerant capacity.

The refrigerant line connection has a bolt at the block

joint , for easy servicing.

Dual Pressure Switch (V6,M/T)

The pressure switch (Dual pressure switch) is installed

on the upper part of the receiver/drier, to detect

excessively high pressure (high pressure switch) and

prevent compressor seizure due to the refrigerant

leaki ng (low pre ssure switch), so that the compr essor is

able to be turned “ON" or “OFF".

Triple Pressure Switch (V6, A/T)

Triple pressure switch is installed on the upper part of

the receiver/drier. This switch is constructed with a

unitized ty pe of two switches. One of th em is a low and

high pressure switch (Dual pressure switch) to switch

“ON" or “OFF" the magnetic clutch as a result of

irregularly high-pressure or low pressure of the

refr igerant. The other one is a medium pressure switch

(Cycli ng switch ) to sw itch “ON" or “O FF" the condens er

fan sensing the condenser high side pressure.

Legend

(1) Pressure Switch

(2) Receiver/Drier

(3) Condenser & Receiver Tank Assembly

(4) Condenser Fan (6VD1 A/T)

Compressor ON

(kPa/psi) OFF

(kPa/psi)

Low-pressure

control 186.3±29.4

(27.0±4.3) 176.5±19.6

(25.6±2.8)

High-pressure

control 2350.4±196.1

(340.7±28.4) 2942.0±196.1

(426.6±28.4)

Compressor ON

(kPa/psi) OFF

(kPa/psi)

Low-pressure

control 186.3±29.4

(27.0±4.3) 176.5±24.5

(25.6±3.6)

High-pressure

control 2353.6±196.1

(341.3±28.4) 2942.0±196.1

(426.6±28.4)

Pressure Sensor

The pressure sensor is installed on the upper part of the

receiver/drier. This sensor converts high pressure

detection of refrigerant to an electrical voltage signal

and su pplies i t to th e PCM. The PCM control s switchin g

compres sor idl e spe ed and c oolin g fa n operatio n by the

electrical voltage signal.

875RY00015

EndOFCallout

Expansion Valve

This ex pansion valve is an ex ternal pressur e type and it

is installed at the evaporator intake port.

The expansion valve converts the high pressure liquid

refrigerant sent from the receiver/drier to a low pressure

liquid refrigerant by forcing it through a tiny port before

sending it to the evaporator.

This type of expansion valve consists of a temperature

sensor, diaphragm, ball valve, ball seat, spring

adjustment screw, etc.

The temperature sensor contacts the evaporator outlet

pipe, and converts changes in temperature to pr essure.

It then transmits these to the top chamber of the

diaphragm.

The refrigerant pressure is transmitted to the

diaphragm's bottom chamber through the external

equalizing pressure tube.

The ball valve is connected to the diaphragm. The

opening angle of the expansion valve is determined by

the force acting on the diaphragm and the spring

pressure.

The expansion valve regulates the flow rate of the

refrigerant. Accordingly, when a malfunction occurs to

this expansion valve, both discharge and suction

pressure get low, resulting in insufficient cooling

capacity of the evaporator.

The calibration has been changed to match the

characteristics of HFC-134a.

874RY00023

EndOFCallout

Evaporator

The evaporator cools and dehumidifies the air before

the air enters the passenger compartment.

High-pressure liquid refrigerant flows through the

expansion valve into the low-pressure area of the

evaporator. The heat in the air passing through the

evap orator core is lost to the cooler surface of the c ore,

thereby cooling the air.

As heat is lost between the air and the evaporator core

surface, moisture in the vehicle condenses on the

outside surface of the evaporator core and is drained off

as water.

When the evaporator mal fun ction s, the trouble will show

up as an inadequate supply of cool air. The cause is

typically a partially plugged core due to dirt, or a

malfunctioning blower motor.

The evaporator core with a laminate louver fin is a

single-sided tank type where only one tank is provided

under the core.

Condenser fan ON

(kPa/psi) OFF

(kPa/psi)

Medium-pressure

control 1471.0±98.1

(213.3±14.2) 1078.7±117.7

(156.4±17.1)

Legend

(1) Pressure Switch

(2) Receiver Drier

Legend

(1) Expansion Valve

(2) Insulator

(3) Evaporator Assembly

874RY00022

EndOFCallout

Electronic Thermostat (With Manual A/C)

The thermostat consists of the thermo sensor and

thermostat unit which functions electrically to reduce the

noises being generated while the system is in operation.

The electronic thermo sensor is mounted at the

evaporator core outlet and senses the surface

temperature of the evaporator core. Temperature

signals are input to the thermostat unit. This information

is compared by the thermo unit and results in the output

to operate the A/C thermostat relay and turn the

magnetic clutch ON or OFF to prevent evaporator

freeze-up.

A characteristic of the sensor is that the resistance

decreases as the temperature increases and the

resistance increases as the temperature decreases.

874RX008

EndOFCallout

Legend

(1) Evaporator Core

(2) Insulator

(3) Expansion Valve

Legend

(1) Duct Sensor

(2) Evaporator Core

(3) Thermostat Unit

Refrigerant Line

Restriction in the refrigerant line will be indicated by:

1. Suction line — A restricted suction line will cause

low suction pressure at the compressor, low

discharge pressure and little or no cooling.

2. Discharge line — A restriction in the discharge line

generally will cause the discharge line to leak.

3. Liquid line — A liquid line restriction will be

evidenced by low discharge and suction pressure

and insufficient cooling.

Refrigerant flexible hoses that have a low permeability

to refrigerant and moisture are used. These low

permeability hoses have a special nylon layer on the

inside.

852RS001

EndOFCallout

Legend

(1) Reinforcement Layer (Polyester)

(2) E xt ernal Rubber Layer

(3) Internal Rubber Layer

(4) Resin Layer (Nylon)

Refriger ant Line As sociat ed Part s

852RY00036

EndOFCallout

Legend

(1) Evaporator Assembly

(2) O-Ring

(3) Liquid Line (High Pressure Pipe)

(4) Pressure Switch

(5) Receiver Drier

(6) Platform Seal

(7) Condenser Asse mbly

(8) Discharge Line (High Pressure Hose)

(9) Compressor

(10) Suction Line (Low – Pressure Hose)

(11) Drain Hose

Circuit Diagram

D08RX151

D08RX150

Diagnosis

Air Conditioning Cycle Diagnosis

*For the execution of the charging and discharging

operation in the table above, refer to Recovery,

Recycling, Evacuating and Charging in this section.

ConditionPossible causeCorrection

No cooling or insufficient cooling.Magnetic clutch does not run.Refer to “Magnetic Clutch

Diagnosis" in this section.

Compressor is not rotating properly.

Drive belt is loosened or broken.Adjust the drive belt to the specified

tension or replace the drive belt.

Compressor is not rotating properly.

Magnetic clutch face is not clean

and slips.

Clean the magnetic clutch face or

replace.

Compressor is not rotating properly.

Incorrect clearance between

magnetic drive plate and pulley.

Adjust the clearance. Refer to

Compressor in this section.

Compressor is not rotating properly.

Compressor oil leaks from the shaft

seal or shell.

Replace the compressor

Compressor is not rotating properly.

Compressor is seized.Replace the compressor

Insufficient or excessive charge of

refrigerant. Discharge and recover the

refrigerant. Recharge to the

specified amount.

Leaks in the refrigerant system.Check the refrigerant system for

leaks and repair as necessary.

Discharge and recover the

refrigerant. Recharge to the

specified amount.

Condenser is clogged or insufficient

radiation. Clean the condenser or replace as

necessary.

Temperature control link unit of the

heat unit is defective.Repair the link unit.

Unsteady operation due to a foreign

substance in the expansion valve.Replace the expansion valve.

Poor operation of the electronic

thermostat. Check the electronic thermostat and

replace as necessary.

Insufficient velocity of cooling air.Evaporator clogged or frosted.Check the evaporator core and

replace or clean the core.

Air leaking from the cooling unit or

air duct.Check the evaporator and duct

connection, then repair as

necessary.

Blower motor does not rotate

properly.Refer to Fan Control Lever (Fan

Switch) Diagnosis in this section.

Checking The Refrigerant System With Manifold Gauge

Since Refrig erant-1 34a (HFC-134a) is used in the air

conditioning system in this vehicle, be sure to

use manifold gauges, charging hoses and other air

conditioning service tools for HFC-134a when

checking the refrigerant system.

Conditions:

• Run the engine at Idling

• Air conditioning switch is “ON"

• Run the blo wer motor at “HIGH" position

• Temperature control lever set to “MAX COLD"

• Air source selector lever at “CIRC"

• Open the engine hood

• Close all the doors

• At ambient temperature: approx. 25–30°C (77–86°F).

Normal Pressure:

• At low-pressure side: approx. 147.1–294.2 kPa

(21.3–4 2.7 psi ).

• At high-pressure side: approx. 1372.9–1863.3 kPa

(199.1–270.2 psi).

Refer to the table on the refrigerant

pressu re-t emp erature re lat ion sh ip.

HFC-134a Pressure-Temperature Relationship

Pressure Temperature

(kPa) (psi) (°

°°

°C) (°

°°

°F)

36 5.3 –20 –4.4

67 9.7 –15 5

104 15 –10 14

147 21 –5 23

196 28 0 32

255 37 5 41

314 45 10 50

392 57 15 59

471 68 20 68

569 82 25 77

677 98 30 86

785 114 35 95

912 132 40 104

1059 154 45 113

1216 176 50 122

Connect The Manifold Gauge

Low-pressure hose (LOW) — Suction side

High pressure hose (HI) — Discha rge side

901RX060

EndOFCallout

Legend

(1) H i gh Side

(2) Low Side

Condition Possible cause Correction

Discharge (High Gauge) Pressure

Abnormally High Condenser clogged or dirty. Clean the condenser fins

Cooling fan does not operate

properly. Check the cooling fan operation.

Discharge (High Gauge) Pressure

Abnormally High.

Insu ffici ent cooling.

Excessive refrigerant in system. Discharge and recover refrigerant.

Recharge to specified amount.

Discharge (High Gauge) Pressure

Abnormally High.

High pressure gauge drop. (After

stopping A/C, the pressure drops

approx. 196kPa (28psi) quickly)

Air in system. Ev acuate and charge refrigerant

system.

Discharge (High Gauge) Pressure

Abnormally Low.

Insu ffici ent cooling

Insufficient refrigerant in system. Check for leaks. Discharge and

recover the refrigerant. Recharge to

the specified amount.

Discharge (High Gauge) Pressure

Abnormally Low.

Low pressure gauge indicates

vacuum.

Clogged or defective expansion

valve. Replace the expansion valve.

Discharge (High Gauge) Pressure

Abnormally Low.

Frost or dew on refrigerant line

before and after the receiver/dri er o r

expansion valve, and low pressure

gauge indicates vacuum.

Restriction caused by debris or

moisture in the receiver/drier. Check system for restriction and

replac e the receiver/drie r.

Discharge (High Gauge) Pressure

Abnormally Low.

High and low pressure gauge

bala nced quickly. (Afte r turned off A/

Compressor seal defective Repair or replace the compressor.

Poor compression due to a defective

compressor gasket. Repair or replace the compressor.

Suction (Low Gauge) Pressure

Abnormally High.

Low pressure gauge (Low pressure

gauge is lowered after condenser is

cooled by water.)

Excessive refrigerant in system. Discharge and recover refrigerant

Recharge to specified amount.

Suction (Low Gauge) Pressure

Abnormally High.

Low pressure hose temperature.

(Low pressure hose temperature

around the compressor refrigerant

line connector is lower than around

evaporator.)

Unsatisfactory valve operation due

to defective temperature sensor of

expansion valve.

Replace the expansion valve.

Expansion valve opens too long. Replace the expansion valve.

Suction (Low Gauge) Pressure

Abnormally High.

High and low pressure gauge

bala nced quickly. (Afte r turned off A/

Compressor gasket is defective. Repair or replace the compressor.

Suction (Low Gauge) Pressure

Abnormally Low.

Insu ffici ent cooling.

Insufficient refrigerant in system. Check for leaks. Discharge and

recover the refrigerant. Recharge to

specified amount.

Suction (Low Gauge) Pressure

Abnormally Low.

Frost on the expansion valve inlet

line

Expansion valve clogged. Replace the expansion valv e.

A/C — Air Conditioning

Suction (Low Gauge) Pressure

Abnormally Low

Receiver/drier inlet and outlet

refrigerant line temperature. (A

distinct difference in temperature

develops.)

Receiver/Drier clogged. Replace the receiver/drier.

Suction (Low Gauge) Pressure

Abnormally Low.

Expansion valve outlet refrigerant

line. (Not cold and low pressure

gauge indicates vacuum.)

Expansion valve temperature sensor

is defe ct ive. Replace the expansion valve.

Suction (Low Gauge) Pressure

Abnormally Low.

When the refrigerant line is clogged

or blocked, the low pressure

gauge reading will decrease, or a

vacuum reading may be shown.

Clogged or blocked refrigerant line. Replace refrigerant line.

Suction (Low Gauge) Pressure

Abnormally Low.

Evaporator core is frozen.

Thermo switch defective. Replace thermo s witch.

Suction (Low Gauge) and Discharge

(High Gauge) Pressure Abnormally

High.

Insu ffici ent cooling.

Excessive refrigerant in system. Discharge and recover the

refrigerant, the Recharge to the

specified amount.

Condenser clogged or dirty. Clean the condenser fin.

Suction (Low Gauge) and Discharge

(High Gauge) Pressure Abnormally

High.

Suction (Low) pressure hose (Not

cold).

Air in system. Evacuate and charge refrigerant.

Suction (Low Gauge) and Discharge

(High Gauge) Pressure Abnormally

Low.

Insu ffici ent cooling

Insufficient refrigerant in system. Check for leaks. Discharge and

recover refrigerant. Recharge to

specified amount.

Condition Possible cause Correction

Magnetic Clutc h Dia gnosis

D08RX249

When the air conditioning switch and the fan control

knob (fan switch) are turned on with the engine running, current flows through the thermostat and the

compressor relay to activate the magnetic clutch.

The air conditioning can be stopped by turning of the air

conditioning switch or the fan control knob (fan switch).

However, even when the air conditioning is in operation,

the electronic thermostat, the pressure switch or the

Powertrain Control Module (PCM;V6-3.2L)/ Engine

Control Module (ECM;L4-2.2L) is used to stop the air

conditioning temporarily by turning off the magnetic

clutch in the prearranged conditions to reduce the

engine load which is being caused by the rise in the

engine coolant temperature, and the acceleration of the

vehicle, etc.

For the inspection of the relays, switches and units in

the table, refer to “Individual Inspection" in this section.

Magnetic Clutch Does Not Run

Step Action Value(s) Yes No

1 Is the fuse No. F-5 normal? — Go to Step 2 Replace the

fuse

2 Are the relay No.X-6 (heater relay). No.X-5

(Thermostat relay) and No.X-4 (compressor relay)

normal?

— Go to Step 3 Replace the

relay

3 Is pressure switch normal? — Go to Step 4 Place the

pressure

switch.

4 Are the air conditioner switch and the fan control

switch normal? — Go to Step 5 Replace the A/

C switch and

fan control

switch

5 1. Turn the ignition switch “ON" (the engine is run).

2. Tur n the air conditioner switch and the fan control

s witch on.

Is the battery voltage applied between harness side

connector terminal No.E3-1 and ground?

Approx.12V Go to Step 6 Go to Step 7

6 Repair an open circuit between compressor side

terminal and ground or replace compressor.

Is the action complete?

—Varify repair —

7 Is there continuity between harness side connector

terminal No.X4-1 and No.E3- 1? — Go to Step 9 Go to Step 8

8 Repair an open circuit between ter minal No.X4-1 and

No.E3-1.

Is the action complete?

— Go to Step 7 —

9 Is the battery voltage applied between harness side

connec tor ter minal No.X4-2 an d grou nd, No.X4-5 and

ground?

Approx.12V Go to Step 11 Go to Step 10

10 Repair and open circuit between terminal No .X4-2 and

No.F-5 fuse, No.X4-5 and No .F-5 fuse.

Is the action complete?

— Go to Step 9 —

11 Is there continuity between harness side connector

terminal No.X4-4 and No.C1-B14? — Go to Step 13 Go to Step 12

12 Repair an open circuit between ter minal No.X4-4 and

No.C1-B14.

Is the action complete?

— Go to Step 11 —

13 Is the battery voltage applied between harness side

connector terminal No.I24-2 and ground? Approx.12V Go to Step 15 Go to Step 14

14 Repai r an open cir cuit between te rmi nal No.I24-2 an d

No.F-5 fuse.

Is the action complete?

— Go to Step 13 —

15 Is the battery voltage applied between harness side

connector terminal No.B4-3 and ground? Approx.12V Go to Step 17 Go to Step 16

Magnetic Clutch Does Not Run (Cont’s)

CAUTION: There are condition whitch air

conditioner system dose not operate except trouble

as follows.

1. The throttle is greater than 90%.

2. The ignition voltage is below 10.5 volts.

3. The engine speed is greater than 4500 RPM for 5

seconds or 5400 RPM.

4. The engine coolant temperature (ECT) is greater

than 125°C (257°F).

5. The intake air temperature (IAT) is less than 5°C

(41°F).

6. The power steering pressure switch signals a high

pressure condition.

Step Action Value(s) Yes No

16 Repair an open circuit between ter minal No.B4-3 and

No.I24-1.

Is the action complete?

— Go to Step 15 —

17 Is there continuity between harness side connector

terminal No.I23-6 and No.B-2? — Go to Step 19 Go to Step 18

18 Repai r an open cir cuit between te rmi nal No.I23-6 an d

No.B4-2.

Is the action complete?

— Go to Step 17 —

19 Is there continuity between harness side connector

terminal No.I23-1 and ground (No.B-8)? — Go to Step 21 Go to Step 20

20 Repai r an open cir cuit between te rmi nal No.I23-1 an d

No.B-8.

Is the action complete?

— Go to Step 19 —

21 Is the battery voltage applied between harness side

connector terminal No.C11-1 and ground? — Go to Step 23 Go to Step 22

22 Repair an open circuit between terminal No.C11-1

and No.F-5 fuse .

Is the action complete?

— Go to Step 21 —

23 Is the battery voltage applied between harness side

connector terminal No.X5-2 and ground? — Go to Step 25 Go to Step 24

24 Repair an open circuit between ter minal No.X5-2 and

No.C11-2.

Is the action complete?

— Go to Step 23 —

25 Is the battery voltage applied between harness side

connector terminal No.B4-1 and ground? — Go to Step 27 Go to Step 26

26 Repair an open circuit between ter minal No.B4-1 and

No.X5-4.

Is the action complete?

— Go to Step 25 —

27 Is there continuity between harness side connector

terminal No.X5-1 and No.C3-E15? — Go to Step 29 Go to Step 28

28 Repair an open circuit between ter minal No.X5-1 and

No.C3-E15.

Is the action complete?

— Verify repair —

29 Replace the PCM.

Is the action complete? — Verify repair —

Individual Inspection

Fan Control Knob (Fan Switch) And Air

Conditioning (A/C) Switch

1.Check for continuity between the fan switch and the

A/C switch side connector terminals.

D08RX254

EndOFCallout

Heater (X-6), Thermostat (X-5), Condenser

Fan (X-9) And Compressor (X-4) Relay

1.Disconnect relays and check for continuity and

resistance between relay terminals.

•For handling of these relays, refer to Heater Relay

in th is section.

901RX071

Pressure Switch

1. Disconnect pressure switch connector and check f or

continuity between pressure switch side connector

termi nal s (1) and (2 ).

875RY00024

Legend

(1) A/C Switch Connector (switch side)

(2) Fan Switch Connector (switch side)

General Repair Procedure

Precautions For Replacement or Repair of

Air Conditioning Parts

There are certain procedures, practices and

precautions that should be followed when servicing air

conditioning systems:

•Keep your work area clean.

•Always wear safety goggle and protective gloves

when working on refrigerant systems.

•Beware of the danger of carbon monoxide fumes

caused by running the engine.

•Beware of discharged refrigerant in enclosed or

improperly ventilated garages.

•Always disconnect the negative battery cable and

discharge and recover the refrigerant whenever

repairing the air conditioning system.

•When discharging and recovering the refrigerant, do

not allow refrigerant to discharge too fast; it will draw

compressor oil out of the system.

•Keep moisture and contaminants out of the system.

When disconnecting or removing any lines or parts,

use plugs or caps to close the fittings immediately.

Never remove the caps or plugs until the lines or

parts are reconnected or installed.

•When disconnecting or reconnecting the lines, use

two wrenches to support the line fitting, to prevent

from twisting or other damage.

•Always install new O-rings whenever a connection is

disassembled.

•Before connecting any hoses or lines, apply new

specified compressor oil to the O-rings.

•When removing and replacing any parts which

require discharging the refrigerant circuit, the

operations described in this section must be

performed in the following sequence:

1Use the J-39500 (ACR4: HFC-134a Refrigerant

Recovery / Recycling / Recharging / System) or

equivalent to thoroughly discharge and recover

the refrigerant.

2Remove and replace the defective part.

3After evacuation, charge the air conditioning

system and check for leaks.

Repair Of Refrigerant Leaks

Refrigerant Line Connections

Install new O-rings, if required. When disconnecting or

connecting lines, use two wrenches to prevent the

connecting portion from twisting or becoming damaged.

852RS003

When connecting the refrigerant line at a block joint,

securely insert the projecting portion of the joint portion

into the connecting hole on the unit side and secure with

a bolt. Apply the specified compressor oil to the

O-rings prior to connecting.

CAUTION: Compressor (PAG) oil to be used varies

according to the compressor model. Be sure to

apply oil specified for the model of compressor.

850RW002

O-ri ngs (2) must be fi tted in the groove (1) of refr i gerant

line.

850RW003

Insert the nut into the union.

First, tig hten th e nut by hand as much as possible, then

tighten the nut to the specified torque.

Leak Check

Inspection of refrigerant leak

Refrigerant leak may cause an adverse effect not only

on the performance and durability of each component of

the air-conditioner, but also on the global atmosphere.

Therefore, it is most impor tant to repair refrigerant leak

when there is any leak found.

Inspection flow of refrigerant leak

Insp ec ti on St eps

Check the compon ents of air- conditioner t o see if th ere

occurs any refrigerant leak along the flow of refrigerant.

• To avoid an error in the detection of refrigerant leak,

make sure of there being no refrigerant vapor or

cigarette smok e around the vehicle before conducting

the inspection. Also, select a location where the

refrigerant vapor will not get blown off with wind.

• Inspection should be conducted chiefly on the pipe

connections and sections where a marked oil

contamination is found. When refrigerant is leaking,

oil inside is also leaking at the same time.

• It is possible to visually check the leak from inside the

cooling unit. Follow the method below when

checking. Remove the drain hose or resistor of the

coolin g unit, and insert a le ak detector to see if there

occurs any leak.

High Pressure Side

1. Discharger section of compressor.

2. Inlet/outlet section of condenser.

3. Inlet/outlet section of receiver driver.

4. Inlet section of cooling unit.

Low Pressure Side

1. Outlet section of cooling unit.

2. Intake section of compressor.

Step Action Yes No

1 1. Evacuate the refrigerant system.

2. Charge the refrigerant.

Is there any refrigerant leak? Repair refrigerant

system. Go to Step 2.

2 1. Operate the compres sor for more than 5 mi nutes to raise t he

pressure on the high pressure side.

Is there any refrigerant leak at high pressure components? Repair refrigerant

system.

Compress or

operation to be

confirmed.

Major Checking Points of Refrig erant Leak

Compressor

• Pipe connection

• Sealing section of shaft

• Mating section or cylinder

Condenser

• Pipe connection

• Welds of condenser body

Receiver driver

• Pipe connection

• Attaching section of pressure s witch

• Section around the sight glass

Evaporator unit (cooling unit)

• Pipe connections

• Connections of expansion valve

• Brazed sections of evaporator

• The evaporator and ex pansion valve are c ontained i n

the case. Remov e the drain hose or the resistor of the

coolin g uni t and insert a le ak dete cto r wh en checkin g

for any leak.

Flexible hose

• Pipe connection

• Caulking section of the hose

• Hose (cracks, pinholes, flaws)

Pipe

• Pipe connection

• Pipe (cracks, flaws)

Charge valve

• The charge valve , which is used to connect the gauge

manifold, is normally provided with a resin cap. When

the valve inside gets deteriorated, refrigerant will leak

out.

Leak at Refrigerant Line Connections

1. Check the torque on the refrigerant line fitting and, if

too loose, tighten to the specified torque.

• Use two wrenches to prevent twisting and

damage to the line.

• Do not over tighten.

2. Perform a leak test on the refrigerant line fitting.

3. If the leak i s still presen t, dis charge and rec over th e

refrigerant from the system.

4. Replace the O-rings.

• O-rings cannot be reused. Always replace with

new ones.

• Be sure to apply the specified compressor oil to

the new O-rings.

5. Retighten the refrigerant line fitting to the specified

torque.

• Use two wrenches to prevent twisting and

damage to the line.

6. Evacuate, charge and retest the system.

Leaks In The Hose

If the compressor inlet or outlet hose is leaking, the

entire hose must be replaced. The refrigerant hose must

not be cut or spliced for repair.

1. Locate the leak.

2. Discharge and recover the refrigerant.

3. Remove the hos e assem bly.

• Cap the open connections at once.

4. Connect the new hose assembly.

• Use two wrenches to prevent twisting or damage

to the hose fitting.

• Tighten the hose fitting to the specified torque.

5. Evacuate, charge and test the system.

Compressor Leaks

If leaks are located around the compressor shaft seal or

shell, replace or repair the compressor.

Recovery, Recycling, Evacuation and

Charging of HFC-134a

Air conditioning systems contain HFC-134a. This is a

chemical mixture which requires special handling

procedures to avoid personal injury.

• Alway s wear safety goggles and protecti ve gloves.

• Always work in a well-ventilated area. D o not weld or

steam clean on or near any vehicle-installed air

conditioning lines or components.

• If HFC-134a should come in cont act with any par t of

the body, flush the exposed area with co ld water and

immediately seek medical help.

• If it is necessary to transport or carry any container of

HFC-134a in a vehicle, do not carry it in the

passenger compartment.

• If it is necessary to fill a small HFC-134a container

from a large one, never fill the container completely.

Space should always be allowed above the liquid for

expansion.

• HFC-134a and R-12 should never be mixed as their

compositions are not the same.

• HFC-134a PAG oil tends to absorb moisture more

quickly than R-12 mineral oil and, therefore, should

be handled more carefully.

• Keep HFC-134a containers stored below 40°C

(100°F).

WARNING:

• SHOULD HFC-134A CONTACT YOUR EYE(S),

CONSULT A DOCTOR IMMEDIATELY.

• DO NOT RUB THE AFFECTED EYE(S). INSTEAD,

SPLASH QUANTITIES OF FRESH COLD WATER

OVER THE AFFECTED AREA TO GRADUALLY

RAISE THE TEMPERATURE OF THE

REFRIGERANT ABOVE THE FREEZING POINT.

• OBTAIN PROPER MEDICAL TREATMENT AS

SOON AS POSSIBLE. SHOULD THE HFC-134A

TOUCH THE SKIN, THE INJURY MUST BE

TREATED THE SAME AS SKIN WHICH HAS BEEN

FROSTBITTEN OR FROZEN.

Refrigerant Recovery

The refrigerant must be discharged and recovered by

using the J-39500 (ACR4:HFC-134a Refrigerant

Recovery/Recycling/Recharging/System) or equivalent

before removing or mounting air conditioning parts.

1. Connect the high and low charging hoses of the

ACR4(or equivalent) as shown below.

901RX057

EndOFCallout

2. Recover the refrigerant by following the

Manufacturer's Instructions.

3. When a par t i s removed, put a cap or a plug on the

connecting portion so that dust, dirt or moisture

cannot get into it.

Refrigerant Recycling

Recycle the refrigerant recovered by J-39500

(ACR4:HFC-134a Refrigerant Recovery / Recycling /

Recharging / System) or equivalent.

F or the details of the actual operation, f ollow the steps in

the ACR4(or equivalent) Manufacturer's Instructions.

Evacuation of The Refrigerant System

901RX058

EndOFCallout

Explained below is a method using a vacuum pump.

Refer to the ACR4(or equivalent) manufacturer's

instructions when ev acuating the system with a ACR4(or

equivalent).

Air and moisture in the refrigerant will cause problems in

the air conditioning system. Therefore, before charging

the refrigerant, be sure to evacuate air and moisture

thoroughly from the system.

1. Connect the gauge manifold.

• High-pressure valve (HI) — Discharge-side.

• Low-pressure valve (LOW) — Suction-side.

2. Discharge and recover the refrigerant.

3. Connect the center hose of the gauge manifold set

to the vacuum pump inlet.

4. Operate the vacuum pump, open shutoff valve and

then open both hand valves.

5. When the low-pressure gauge indicates

approximately 750mmHg (30inHg), continue the

evacuation for 5 minutes or more.

6. Close both hand valves and stop the vacuum pump.

Legend

(1) H i gh Side

(2) Low Side

Legend

(1) High Side

(2) Low Side

7. Check to ensure th at the pressu re does no t change

after 10 minutes or more.

• If the pressure changes, check the system for

leaks.

• If leaks occur, retighten the refrigerant line

connections and repeat the evacuation steps.

8. If no leaks are found, again operate the vacuum

pump for 20 minutes or more. After co nfirmi ng that

the gauge manifold pressure is at 750mmHg

(30inHg), close both hand valves.

9. Close p ositive shutoff valve. Stop the vacuum pump

and disconnect the center hose from the vacuum

pump.

Charging The Refrigerant System

There are various methods of charging refrigerant into

the air conditioning system.

These include using J-39500 (ACR4:HFC-134a

Refrigerant Recovery/Recyclin g/Recharging/System) or

equivalent and direct charging with a weight scale

charging station.

Charging Procedure

•ACR4(or equivalent) Method

For th e charging of r efrigerant rec overed by ACR 4(or

equivalent), follow the manufacturer's instruction.

901RX057

EndOFCallout

•Direct charging with a weight scale charging

station method

1. Make sure the evacuation process is correctly

completed.

2. Connect the center hose of the manifold gauge to

the weight scale.

3. Connect the low pressure charging hose of the

manifold gauge to the low pressure side service

valve of the vehicle.

4. Connect the high pressure charging hose of the

manifold gauge to the high pressure side service

valve of the vehicle.

901RX059

EndOFCallout

5. Place the refrigerant container up right on a weight

scale.

Note the total weight before charging the refrigerant.

a Open the refrigerant container valve.

b Open the low side vale on the manifold gauge

set. Refer to the manufacturer's instructions for

a weight scale charging station.

Legend

(1) H i gh Side

(2) Low Side

Legend

(1) Weight Scale

(2) Refrigerant Contain er

(3) High Side

(4) Low Side

6.Perform a system leak test:

•Charge the system with approximately 200g

(0.44lbs) of HFC-134a.

•Make sure the high pressure valve of the manifold

gauge is closed.

•Check to ensure that the degree of pressure does

not change.

•Check for refrigerant leaks by using a HFC-134a

leak detector.

•If a leak occurs, recover the refrigerant. Repair

the leak and start all over again from the first step

of evacuation.

7.If no leaks are found, continue charging refrigerant

to the air conditioning system.

•Charge the refrigerant until the scale reading

decreases by the amount of the charge specified.

Specified amount: 650g (1.43lbs)

•If charging the system becomes difficult:

1Run the engine at idle and close all the

vehicle doors.

2Turn A/C switch “ON".

3Set the fan switch to its highest position.

4Set the air source selector lever to “CIRC".

5Slowly open the low side valve on the

manifold gauge set.

WARNING: Be absolutely sure not to open the high

pressure valve of the manifold gauge. Should the

high pressure valve be opened, the high pressure

refrigerant would flow backward, and this may

cause the refrigerant container to burst.

8.When finished with the refrigerant charging, close

the low pressure valve of the manifold gauge and

container valve.

9.Check for refrigerant leaks.

Checking The A/C System

1.Run the engine and close all the vehicle doors.

2.Turn A/C switch “ON", set the fan switch to its

highest position.

3.Set the air source lever to “CIRC", set the

temperature lever to the full cool position.

4.Check the high and low pressure of the manifold

gauge.

•Immediately after charging refrigerant, both high

and low pressures might be slightly high, but they

settle down to the pressure guidelines shown

below:

•The ambient temperature should be between 25–

30°C (77–86°F).

•The pressure guideline for the high-pressure side

is approximately 1372.9–1863.3kPa (199.1–

270.2 psi).

•The pressure guideline for the low-pressure side

is approximately 147.1–294.2kPa (21.3–42.7

psi).

•If an abnormal pressure is found, refer to

Checking The Refrigerant System With Manifold

Gauge in this section.

5. Put your hand in front o f the air outlet an d move the

temperature control lever of the control panel to

different positions. Check if the outlet temperature

changes as selected by the control knob.

Reading Sight Glass

The sight glass provides accurate diagnosis only under

the following conditions.

If the vehicle can be tested under these conditions,

check the sight glass appearance and compare to the

chart below.

• Engine speed idle

• A/C switch “ON"

• Blower fan operating at highest speed

• Air source selector lever at “RECIRC"

• Temperature control lever at coldest position

• Ambient temperature below 30°C (86°F) and

humidity below 70% (See NOTE 1)

• High side pressure less than 1667.1 kPa (241.7 psi)

(See NOTE 2)

NOTE: 1. If the vehicle cannot be moved to a testing

location that meets these specifications, then the sight

glass cann ot be used for diagnosis. You must discharge

and recover the refrigerant, then recharge the system

with the specified amount of refrigerant.

Then continue checking the system performance.

NOTE: 2. If the high side pressure is greater than

stated, the sight glass cannot be used f or diagnosis. You

must discharge and recover the refrigerant, then

recharge the system with the specified amount of

refrigerant. Then continue checking system

performance.

High and low

pressure pipe

temperature

The high pressure

pipe is hot and the

low pressure pipe is

cold. There is a

distinct difference in

temperature between

them.

The high pressure

pipe is warm and the

low pressure pipe is

cool. There is no

great difference in

temperature between

them.

There is litttle

difference in

temperature between

the high pressure

pipe and the low

pressure pipe.

The high pressure

pipe is hot and the

low pressure pipe is

slightly warm. There

is a defference in

temperature between

them.

Slight glass condition Almost transparent. A

flow of bubbles can

be seen, but they

disappear when the

throttle is opened.

A flow of bubbles

always can be seen.

It appears sometimes

transparent, and

sometimes frothy.

So mething like fog

faintly can be seen. Even at idle with the

fan at “HI” (with the

window fully open),

the bubbles cannnot

be seen.

Air cond iti oni ng c ycle

condition OK NG

(Not enough

refrigerant)

(Almost no

refrigerant)

(Too much

refrigerant)

Compressor Assembly

Compressor Assembly and Associated Parts (6VD1)

852RY00018

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant

•Refer to Refrigerant Recovery in this section.

3. Disconnect magnetic clutch harness connector.

4. Remove serpentine belt.

• Move serpentine belt tensioner to loose side

using wrench then remove serpentine belt.

Legend

(1) Compressor Bracket

(2) Magnetic Clutch Harness Connector

(3) Compressor

(4) O-ring

(5) To Evapor ator

(6) Suction Line (Low-Pressure Hose)

(7) Discharge Line (Hight-Pressure Hose)

(8) To Condenser

(9) Serpentine Belt

850RW009

EndOFCallout

5. Disconnect refrigerant line connector.

• When removing the line connector, the

connecting part should immediately be plugged

or capped to prevent foreign matter from being

mixed into the line.

6. Remove compressor.

Installation

1. Install compressor.

• Tighten the compressor fixing bolts to the

specifi ed tor que.

Torque: 19N•m (1.9kg•m/14lb ft)

2. Connect refrigerant line connector.

• Tighten the refrigerant line connector fixing bolts

to the specified torque.

Torque: 15N•m (1.5kg•m/11lb ft)

• O-rings cannot be reused. Always replace with

new ones.

• Be sure to apply new compressor oil to the

O-rings when connecting refrigerant lines.

3. Install serpentine belt.

• Move serpentine belt tensioner to loose side

using wrench, then install serpentine belt to

normal position.

4. Connect magnetic clutch harness connector.

Legend

(1) Cooling Fan Pulley

(2) Power Steering Oil Pump

(3) Air Conditioner Compressor

(4) Crankshaft Pulley

(5) Generator

(6) Tensioner

(7) Idler Pu lley

Compressor Assembly and Associated Parts (X22SE)

852RY00031

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant

•Refer to Refrigerant Recovery in this section.

3. Disconnect magnetic clutch harness connector.

Legend

(1) Compressor Bracket

(2) Magnetic Harness Connector

(3) Compressor

(4) O-ring

(5) Suction Line (Low-Pressure Hose)

(6) Discharge Line (High-Pressure Hose)

(7) Serpentine Belt

4.Remove serpentine belt.

•Move serpentine belt tensioner to loose side

using wrench then remove serpentine belt.

850RX006

EndOFCallout

5.Disconnect refrigerant line connector.

•When removing the line connector, the

connecting part should immediately be plugged

or capped to prevent foreign matter from being

mixed into the line.

6.Remove compressor.

Installation

1.Install compressor.

•Tighten the compressor fixing bolts to the

specified torque.

Torque: 19N•m (1.9kg•m/14lb ft)

2.Connect refrigerant line connector.

•Tighten the refrigerant line connector fixing bolts

to the specified torque.

Torque: 15N•m (1.5kg•m/11lb ft)

•O-rings cannot be reused. Always replace with

new ones.

•Be sure to apply new compressor oil to the

O-rings when connecting refrigerant lines.

3.Install serpentine belt.

•Move serpentine belt tensioner to loose side

using wrench, then install serpentine belt to

normal position.

4.Connect magnetic clutch harness connector.

New Compressor Installation

The new compressor is filled with 150cc (5.0fl.oz.)of

compressor oil and nitrogen gas. When mounting the

compressor on the vehicle, perform the following steps;

1.Gently release nitrogen gas from the new

compressor.

•Take care not to let the compressor oil flow out.

•Inspect O-rings and replace if necessary.

871RX033

2.Turn the compressor several times by hand and

release the compressor oil in the rotor.

3.When installing on a new system, the compressor

should installed as it is. When installing on a used

system, the compressor should be installed after

adjusting the amount of compressor oil. (Refer to

Compressor in this section)

871RX035

Legend

(1) Power Steering Oil Pump

(2) Air Conditioner Compressor

(3) Tensioner

(4) Crankshaft Pulley

Condenser Assembly

Condenser Assembly and Associated Parts

875RY00008

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove engine hood front end stay.

5. Remove engine hood lock.

• Appl y setting mar k to the e ngine hood lock fixin g

position before removing it.

6. Disconnect pressure switch connector.

7. Disco nne ct re frigerant li ne.

• When removing the line connector, the

connecting part should immediately be plugged

or capped to prevent foreign matter from being

mixed into the line.

8. Remove condenser asse mbly.

• Handle with care to prevent damaging the

condenser or radiator fin.

Installation

1. Install condenser assembly.

• If installing a new condenser, be sure to add 30cc

(1.0fl.oz.) of new compressor oil to a new one.

• Tighten the condenser fixing bolts to the specified

torque.

Torque: 6N•m (0.6kg•m/52lb in)

2. Connect refrigerant line.

• Tighten the inlet line connector fixing bolt to the

specifi ed tor que.

Torque: 15 N•m (1.5kg•m/11 lb ft)

Legend

(1) Engine Hood Lock

(2) P ress ur e Swi tch Connec to r

(3) Refrigerant Line

(4) Radiator Grille

(5) Engine Hood Front End Sta y

(6) Condenser Asse mbly

•Tighten the outlet line connector fixing bolt to the

specified torque.

Torque: 6 N•m (0.6kg•m/52 lb in)

•O-rings cannot be reused. Always replace with

new ones.

•Be sure to apply new compressor oil to the

O-rings when connecting the refrigerant line.

3.Connect pressure switch connector.

4.Install engine hood lock.

5.Install engine hood front end stay.

6.Install radiator grille.

Condenser Fan Motor

Condenser Fan Motor and Associated Parts

875RY00007

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove condenser fan assembly.

• Disconnect the fan motor connector and remove

the 4 fixing bolts.

5. Remove shroud.

• Remove the 3 fixing nuts.

• Loosen the condenser fixing nut and disconnect

the fan motor connector from bracket.

6. Remove fan.

• Remove the fan fixing C-ring and plate.

7. Remove condenser fan motor.

Installation

To install, follow the removal steps in the reverse order,

noting the following point.

1. Route the fan motor harness in its previous position,

and fix it securely with clip and bracket.

Legend

(1) Condenser Fan Assembly

(2) Condenser Fan Motor

(3) Radiator Grille

(4) Shroud

(5) Fan

Receiver / Drier

Receiver / Drier and Associated

Parts

875RY00012

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Disconnect pressure switch connector.

5. Disco nne ct re frigerant li ne.

• When removing the line connected part, the

connecting part should immediately be plugged

or capped to prevent foreign matter from being

mixed into the line.

6. Remove bracket bolt.

7. Remove receiver/drier.

• Loosen the bolt, then, using care not to touch or

bend the refrigerant line, carefully pull out the

receiver/drier.

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1. If installing a new receiver/drier, be sure to add 30cc

(1.0fl.oz.) of new compressor oil to a new one.

2. Put the receiver/drier in the bracket and connect

with the refrigerant line. Check that no excessive

force is imposed on the line. Fasten the bracket bolt

to the receiver/drier.

3. Tighten the refrigerant line to the specified torque.

Torque: 6 N•m (0.6kg•m/52 lb in)

4. O-r ings cannot be re used. Always replac e with new

ones.

5. Be sure to apply new compressor oil to the O-rings

when connecting the refrigerant line.

Legend

(1) P ress ur e Swi tch Connec to r

(2) Refrigerant Line

(3) Radiator Grille

(4) Receiver / Drier

(5) Bracket Bolt

Pressure Switch

Pressure Switch and Associated

Parts

875RY00012

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to “Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Disconnect pressure switch connector.

5. Disco nne ct pr es sure sw itc h.

• When removing the switch connected part, the

connecting part should immediately be plugged

or capped to prevent foreign matter from being

mixed into the line.

Installation

To install, follow the removal steps in the reverse order,

noting the following point:

1. O-ring cannot be reused. Alwa ys replace with a new

one.

2. Be sure to apply new compressor oil to the O-ring

when connecting pressure switch.

3. Tighten the pressure switch to the specified torque.

Torque: 13 N•m (1.3kg•m/113 lb in)

Legend

(1) P ress ur e Swi tch Connec to r

(2) Refrigerant Line

(3) Radiator Grille

(4) Receiver / Drier

(5) Bracket Bolt

Evaporator Assembly

Evaporator Assembly and Associated Parts

874RY00024

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove glove box.

Legend

(1) Refrigerant Line

(2) Drain Hose

(3) Resistor and Electronic Thermostat Connector

(4) Electronic Thermostat

(5) Evaporator Assembly

(6) Glove Box

(7) Sill Plate

(8) Dash Side Trim Pad

(9) Inst Panel Lower Reinforcement

4. Disconnect resistor (2) and electronic thermostat

connector (1).

874RY00025

5. Disco nnect drain hose.

6. Disco nnect refrigerant li ne.

• Use a back-up wrench when disconnecting and

reconnecting the refrigerant lines.

• When removing the refrigerant line connected

part, the connecting part should immediately be

plugged or cap ped to p reven t foreign matt er from

being mixed into the line.

7. Remove evaporator assembly.

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1. To install a new evaporator assembly, add 50cc

(1.7fl.oz.) of new compressor oil to the new core.

2. Tighten the refrigerant outlet line to the specified

torque.

Torque: 25 N•m (2.5kg•m/18 lb ft)

3. Tighten the refrigerant inlet line to the specified

torque.

Torque: 15 N•m (1.5kg•m/11 lb ft)

4. O-r ings cannot be re used. Always replac e with new

ones.

5. Be sure to apply new compressor oil to the O-rings

when connecting lines.

Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View

874RY00026

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove evaporator assembly.

•Refer to Evaporator Assembly in this section.

4. Remove the electronic thermostat sensor fixing clip.

Pull the sensor from the evaporator assembly.

5. Remove attaching screw.

6. Remove upper case.

7. Remove lower case.

• Slit the case parting face with a knife since the

lining is separated when removing the ev aporator.

874RW034

Legend

(1) Lining

(2) Upper Case

(3) Electronic Thermostat

(4) Evaporator Core

(5) Lining: Case

(6) Attaching Screw

(7) Lower C as e

(8) Evaporator Assembly

(9) O-ring

(10) Expansion Valve

•Lift to remove the upper case.

874RY00027

8.Remove evaporator core.

874RY00028

9.Remove expansion valve.

•Tear off the insulator carefully.

•Remove the sensor fixing clip.

•Use a back-up wrench when disconnecting all

refrigerant pipes.

Installation

To install, follow the removal steps in the reverse order,

noting the following points:

1.The sensor is installed on the core with the clip.

2.The sensor must not interfere with the evaporator

core.

3.When installing the new evaporator core, install the

thermo sensor to the evaporator core specified

position with the clip in the illustration.

874RX014

EndOFCallout

4.O-rings cannot be reused. Always replace with new

ones.

5.Be sure to apply new compressor oil to the O-rings

when connecting lines.

6.Be sure to install the sensor and the insulator on the

place where they were before.

7.To install a new evaporator core, add 50cc (1.7 fl.

oz.) of new compressor oil to the new core.

8.Tighten the refrigerant lines to the specified torque.

Refer to Main Data and Specifications for Torque

Specifications in this section.

9. Apply an adhesive to the parting face of the lining

when assembling the evaporator assembly.

Legend

(1) Evaporator Core

(2) Ther mo Sen so r

(3) Lower C as e

(4) Upper Case

Refrigerant Line

Refrigerant Line and Associated Parts

852RY00032

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Discharge and recover refrigerant.

•Refer to Refrigerant Recovery in this section.

3. Remove radiator grille.

4. Remove clip and clamp.

5. Disconnect liquid line (High-pressure pipe).

6. Disconnect suction line (Low-pressure pipe) using a

back-up wrench.

7. Disconnect suction line (Low-pressure hose) using

a back-up wrench.

8. Disconnect discharge line (High-pressure hose)

using a back-up wrench.

• Use a backup wrench when disconnecting and

reconnecting the refrigerant lines.

• When removing the refrigerant line connecting

part, the connecting part should immediately be

Legend

(1) Clip and Clamp

(2) Liquid Line (High-Pressure Pipe)

(3) Radiator Grille

(4) Discharge Line (High-Pressure Hose)

(5) Suction Line (Low-Pressure Pipe)

plugged or capped to prevent foreign matter from

being mixed into the line.

Installation

To install, follow the removal steps in the reverse order,

noting the following point:

1.O-rings cannot be reused. Always replace with new

ones.

2.Be sure to apply new compressor oil to the O-rings

when connecting lines.

3.Tighten the refrigerant line to the specified torque.

Refer to Main Data and Specifications for Torque

Specifications in this section.

Main Data And Specifications

General Specifications

Heater Unit

Temperature control Reheat air mix system

Capacity 3,700 Kcal./hr.

Air flow 280 m3/h

HEATER CORE

Type AUTO A/C Plate and corrugate-fin type

MANU A/C Fin and tube type

Element dimension MANU A/C 161 mm (6.3) × 163 mm (6.4 in.) × 45 mm (1.8 in.)

AUTO A/C 171 mm (6.7) × 161 mm (6.3 in.) × 25 mm (1 in.)

Radiating area MANU A/C Approx. 2.1 m2

AU TO A/C Approx. 1.3 m 2

EVAPORATOR ASSEMBLY

Capacity AUTO A/C 4,100 Kcal./hr.

MANU A/C 4,200 Kcal./hr.

Air flow AUTO A/C 430 m3/hr

MANU A/C 470 m3/hr

EVAPORATOR CORE

Type Al-laminate louver fin type

Element dimension 235 mm (9.3 in.) × 224 mm (8.8 in.) × 60 mm (2.4 in.)

EXPANSION VALVE

Type Internal pressure equalizer type

THERMOSTAT SWITCH

Type Electronic thermostat

OFF: Below 0.5 ± 0.5 °C (32.9 ± 0.9 °F)

ON: Above 4.5 ± 0.5 °C (40.1 ± 0.9 °F)

CONDENSER

Type Parallel flow type

Radiation performance 9,400 Kcal./hr

RECEIVER/DRIER

Type Assembly includes sight glass with dual (triple) pressure

switch (V6) or pressure sensor (L4)

Internal volume 300 cc (10 fl.oz.)

PRESSURE SWITCH

Type Dual pressure switch

Low pressure control

ON: 186.3±29.4 kPa (27.0±4.3 psi)

OFF: 176.5±24.5 kPa (25.6±3.6 psi)

High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

OFF: 2942.0±196.1 kPa (426.6±28.4 psi)

Triple pressure switch (V6, A/T)

Low pressure control

ON: 196.3±29.4 kPa (27.0±4.3 psi)

OFF: 176.5±19.6 kPa (25.6±2.8 psi)

Medium pressure control

ON: 1471.0±98.1 kPa (213.3±14.2 psi)

OFF: 1078.7±117.7 kPa (156.4±17.7 psi)

High pressure control

ON: 2353.6±196.1 kPa (341.3±28.4 psi)

OFF: 2942.0±196.1 kPa (426.6±28.4 psi)

REFRIGERANT

Type HFC-134a

Specified amount 650 g (1.43 lbs.)

Torque Specifications N•m (kg•m/lb ft)

E06RY00007

E06RY00008

Compressor

Service Precaution

WARNING: This vehicle has a Supplemental

Restraint System (SRS). Refer to the SRSComponent Location View in order to determinewhether you are performing service on or near theSRS components or the SRS wiring. When you areperforming service on or near the SRS componentsor the SRS wiring, refer to the SRS On-Vehicle

Service Information. Failure to follow CAUTIONScould result in possible air bag deployment,personal injury, or otherwise unneeded SRS systemrepairs.

CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use

ONLY the exact part number for that application.

ISUZU will call out those fasteners that require a

replacement after removal. ISUZU will also call out

the fasteners that require thread lockers or thread

sealant. UNLESS OTHERWISE SPECIFIED, do not

use supplemental coatings (paints, greases, or

other corrosion inhibitors) on threaded fas teners or

fastener joint interfaces. Generally, such coatings

adversely affect the fastener torque and the joint

c lamping for ce, and may damage the fastener . When

you install fasteners, use the correct tightening

sequence and specifications. Following these

instructions can help you avoid damage to parts

and systems.

General Description

When servicing the compressor, keep dirt or foreign

material from getting on or into the compressor parts

and system. Clean tools and a clean work area are

important for proper service. The compressor

connections and the outside of the compressor should

be cleaned before any "On-Vehicle" repair, or before

removal of the compressor. The parts must be kept

clean at all times and any parts to be reassembled

should be cleaned with Trichloroethane, naphtha,

kerosene, or equivalent solvent, and dried with dry air.

Use only lint free cloths to wipe parts.

The operations described below are based on bench

overhaul with compressor removed from the vehicle,

except as noted. They have been prepared in order of

access ibility of the comp onents. When th e compre ssor

is removed from the vehicle for servicing, the oil

remaining in the compressor should be discarded and

new compressor oil added to the compressor.

Compressor malfunction will appear in one of four ways:

noise, seizure, leakage or low discharge pressure.

Resonant compressor noises are not cause for alarm;

however, irregular noise or rattles may indicate broken

parts or excessive clearances due to wear. To check

seizure, de-energize the magnetic clutch and check to

see if the drive plate can be rotated. If rotation is

impossible, the compressor is seized. Low discharge

pressure may be due to a faulty internal seal of the

compressor, or a restriction in the compressor. Low

discharge pressure may also be due to an insufficient

refrigerant charge or a restriction elsewhere in the

system. These possibilities should be checked prior to

servicing the compressor. If the compressor is

inoperative, but is not seized, check to see if current is

being supplied to the magnetic clutch coil terminals.

The compressor oil used in the HFC-134a system

compressor differs from that used in R-12 systems.

Also, compressor oil to be used varies acco rding to the

compressor model. Be sure to av oid mixing two or more

different types of oil.

If the wrong oil is used, lubrication will be p oor and the

compressor will seize or malfunction.

DKV -1 4G Type Co m pressor

DKV-14G is equipped with five-vane rotary compressor.

These vanes are built into a rotor which is mounted on a

shaft.

When the shaft rotates, the vanes bui lt into the cylinder

block assembly are operated by centrifugal force.

This changes the volume of the spare formed by the

rotor and cylinder, resulting in the intake and

compression of the refrigerant gas. The discharge v alve

and the valve stopper, which protects the discharge

valve, are built into the cylinder block assembly. There

is no suction valve but a shaft seal is insta lled between

the shaft and head; a trigger valve, which applies back

pressure to the vanes, is installed in the cylinder block

and a refrig erant gas temperature sensor is installed in

the front head.

The spec ified quantity of compress or oil is con tained in

the compressor to lubricate the various par ts using the

refrigerant gas discharge pressure.

A01RS003

Diagnosis

Condition Possible cause Correction

Noise from compression Defective rotor/piston Replace compressor/cylinder and

shaft assembly

Defective shaft Replace compressor/cylinder and

shaft assembly

Noise from magnetic clutch Defective bearing Replace magnetic clutch

Defective clutch Replace magnetic clutch

Clearance between drive plate and

pulley not standard Adjust the clearance or replace

magnetic clutch

Insufficient cooling Defective gasket Replace compressor/gasket

Defective rotor/reed valve Replace compressor/valve plate

Defective trigger valve/suction valve Replace compressor/suction valve

Not rotating Defective rotor/piston Replace compressor/cylinder and

shaft assembly

Defective shaft Replace compressor/cylinder and

shaft assembly

Rotating parts seized due to

insufficient oil Replace compressor

Oil and/or gas leakage Defective seal Replace compressor/shaft seal

Defe ctive O-ring Replace

Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View

871RX025

EndOFCallout

Removal

1. Using drive plate holder J-33939 (1) to prevent the

drive plate from rotating, then remove the drive plate

bolt.

871RX029

2. Remove drive plate by using drive plate puller

J-339 44-A (2 ) and forcing screw J-33944-4 (1 ).

871RX023

Legend

(1) Drive Plate bolt

(2) Drive Plate

(3) Snap Ring

(4) Pulley Assembly

(5) Field Coil

(6) Shim (s)

(7) Lead Wire

3. Remove shim (s).

4. Remove snap ring (1) by using snap ring pliers.

871RY00029

5. Remove pulley assembly by using pull ey pu ller pi lot

J-384 24(2), pulley pu ller J -843 3(1) a nd pu lley pull er

leg J-24092-2(3).

871RY00033

6. Loosen screw and disconnect the field coil wire

connector.

871RY00030

7. Loosen three screws and remove the field coil.

871RY00034

Inspection and Repair

Drive Pla te

If the frictional surface shows signs of damage due to

excessive heat, the drive plate and pulley should be

replaced.

Pulley Asse mbly

Check the appearance of the pulley assembly. If the

fric tional surface of the pulley shows signs o f excess ive

grooving due to slippage, both the pulley and drive plate

should be replaced. The frictional surfaces of the pulley

assembly should be cleaned with a suitable solvent

before reinstallation.

Coil

Check coil for loose connector or cracked insulation.

Installation

1. Install field coil.

• Align the located portion (1) of the field coil and

compressor.

871RY00035

• Tighten the mounting screw to the specified

torque.

Torque: 5N·m (0.5kg·m/44 lb in)

2. Connect the lead wire connector with the rubber

hold and tighten the screw.

3. Install pulley assembly by using pulley installer

J-339 40-A (2 ) and dr ive handle J-8092( 1).

871RY00032

4. Install snap ring.

5. Install shim (s).

6. Install the drive plate to the compressor drive shaft

together with the original shim(s)(1). Press the drive

plate by hand.

871RY00031

7. Install drive plate bolt by using drive plate holder

J-33939 (1) to prevent the drive plate from rotating.

871RX029

• Tighten the drive plate bolt to the specified

torque.

Torque: 13 N·m (1.3kg·m/113 lb in)

• After tightening the drive plate bolt, check to be

sure the pulley rotates smoothly.

• Check to be sure that the clutch clearance is

between 0.3-0.6 mm (0.01-0.02 in.)

871RY00028

EndOFCallout

• If necessary, install adjusting shim(s).

• Adjusting shims are available in the following

thickness.

Thickness

•0.1 mm (0.0039 in.)

•0.3 mm (0.0118 in.)

•0.5 mm (0.0197 in.)

Legend

(1) Dial Gauge

(2) Pulley Assembly

(3) Field Coil Wire Connector

Compressor Oil

Oil Specification

•The HFC-134a system requires a synthetic (PAG)

compressor oil whereas the R-12 system requires a

mineral compressor oil. The two oils must never be

mixed.

•Compressor (PAG) oil varies according to

compressor model. Be sure to use oil specified for

the model of compressor.

•Always use HFC-134a Vane Rotary Type

Compressor Oil (AIPDN Part No.2-90188-301-0)

Handling of Oil

•The oil should be free from moisture, dust, metal

powder, etc.

•Do not mix with other oil.

•The water content in the oil increases when exposed

to the air. After use, seal oil from air immediately.

(HFC-134a Vane Rotary Compressor Oil absorbs

moisture very easily.)

•The compressor oil must be stored in steel

containers, not in plastic containers.

Compressor Oil Check

The oil used to lubricate the compressor is circulating

with the refrigerant.

Whenever replacing any component of the system or a

large amount of gas leakage occurs, add oil to maintain

the original amount of oil.

Oil Capacity

Capacity total in system: 150cc (5.0 fl.oz)

Compressor (Service parts) charging amount:

150 cc (5.0 fl.oz)

Checking and Adjusting Oil Quantity

for Used Compressor

1.Perform oil return operation. Refer to Oil Return

Operation in this section.

2.Discharge and recover refrigerant and remove the

compressor.

3.Drain the compressor oil and measure the extracted

oil with a measuring cylinder.

871RX020

4.If the amount of oil drained is much less than 90 cc

(3.0 fl. oz.), some refrigerant may have leaked out.

Conduct a leak tests on the connections of each

system, and if necessary, repair or replace faulty

parts.

5.Check the compressor oil contamination. (Refer to

Contamination of Compressor Oil in this section.)

6. Adjust the oil level following the next procedure

below.

7. Install the compressor, then evacuate, charge and

perform the oil return operation.

8. Check system operation.

When it is impossible to preform oil return

operation, the compressor oil should be checked in

the following order:

1. Discharge and recover refrigerant and remove the

compressor.

2. Drain the compressor oil and measure the extracted

oil with a measuring cylinder.

3. Check the oil for contamination.

4. If more than 90 cc (3.0 fl. oz.) of oil is e xtracted from

the compressor, supply the same amount of oil to

the compressor to be installed.

5. If the amount of oi l extracted is le ss than 90 cc (3.0

fl. oz.), recheck the compressor oil in the following

order.

6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor

and install it onto the vehicle.

(Charging Amount) (Collected Amount)

more than 90cc (3.0 fl.oz) same as collected

amount

less than 90 cc (3.0 fl.oz) 90cc (3.0 fl.oz)

7. Evacuate and recharge with the proper amount of

refrigerant.

8. Perform the oil return operation.

9. Remove the compressor and recheck the amount of

oil.

10. Adjust the compressor oil, if necessary.

Checking and Adjusting for

Compressor Replacement

150 cc (5.0 fl.oz.) of oil is charged in compressor

(service parts). So it is necessary to drain the proper

amount of oil from the new compressor.

1. Perform oil return operation.

2. Discharge and recover the refrigerant and remove

the compressor.

3. Drain the compressor oil and measure the extracted

oil.

4. Check the compressor oil for contamination.

5. Adjust the oil level as required.

6. Evacuate, charge and perform the oil return

operation.

7. Check the system operation .

Contamination of Compressor Oil

Unlike engine oil, no cleaning agent is added to the

compressor oil. Even if the compressor runs for a long

peri od of ti me (ap pr oximately one sea so n) , the oil never

becomes contaminated as long as there is nothing

wrong with the compressor or its method of use.

Inspect the extracted oil for any of the following

conditions:

• The capacity of the oil has increased.

• The oil has changed to red.

• Foreign substances, metal powder, etc., are present

in the oil.

If any of these conditions exists, the compressor oil

is contaminated. Whenever contaminated

compressor oil is discovered, the receiver/drier

must be replaced.

Oil Return Operation

There is close affinity between the oil and the

refrigerant. During normal operation, part of the oil

recirculates with the refrigerant in the system. When

checking the amount of oil in the system, or replacing

any compone nt of the system, th e compressor must be

run in advance for oil return operation. The procedure is

as follows:

1. Open all the doors and the engine hood.

2. Start the eng ine a nd air co nditionin g swi tch to “O N"

and set the fan control knob at its highest position.

3. Run the compressor for more than 20 minutes

between 800 and 1,000 r pm in order to ope ra te the

system.

4. Stop the engine.

Replacement of Component Parts

When replacing the system component parts, supply

the following amoun t of oil to the com pon ent parts to be

installed.

(Collected Amount) (Charging Amount)

more than 90 cc (3.0 fl.oz) same as collected

amount

less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

(Amount of oil drained

from used compressor) (Draining amount of oil

from new compressor)

less than 90 cc (3.0 fl.oz) Same as drained amount

more than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)

(Component parts to be

installed) (Amount of Oil)

Evaporator 50 cc (1.7 fl. oz.)

Condenser 30 cc (1.0 fl. oz.)

Receiver/dryer 30 cc (1.0 fl. oz.)

Refrigerant line (on e

piece) 10 cc (0.3 fl. oz.)

Main Data and Specifications

General Specifications

COMPRESSOR

Model DKV-14G

Type Vane rotary type

Number of vanes 5

Rotor diameter 64 mm (2.52 in.)

Stroke 8.75 mm (0.34 in.)

Displacement 140 cc (47.3 fl.oz.)

Maximum speed 7,000 rpm (up to 8,400 rpm)

Direction of rotation Clockwise (Front-side view)

Lubrication system Pressure differential type

Lubricant HFC-134a Vane Rotary Type Compressor Oil

Be Equivalent to ZXL 200 PG

150 cc (5.0 fl.oz.)

Refrigerant HFC-134a, 650 g (1.43 lbs.)

Shaft seal Lip type

W eight 3.6 kg

MAGNETIC CL UTCH

Type Electromagnetic single-plate dry clutch

Rated voltage 12 Volts D.C.

Current consumption 3.7 A

Starting torque 49 N·m (36 lb·ft)

Direction of rotation Clockwise (Front-side view)

W eight 2.4 kg (5.3 lbs.)

Torque Specifications

N·m (kg·m/lb in)

871RY00038

Special Tools

ILLUSTRATION TOOL NO.

TOOL NAME

J-33939

Dri ve plate holder

J-33944-A

Dri ve plate puller

J-33944-4

Forcing screw

J-38424

Pulley puller pilot

J-8433

Pulley puller

J-24092-2

Pulley puller leg

J-33940-A

Pulley inst aller

J-8092

Drive handle

ILLUSTRATION TOOL NO.

TOOL NAME

Automatic Air Conditioning System

General Description

Using a variety of sensors, this automatic heater and air

conditioner accurately senses outside air temperature,

solar radiation quantity, evaporator's blowing

temperature, and interior temperature, then enters

these data to the automatic heater/air conditioner

control unit (equippe d with the built-in micro-co mputer).

The data provided to the control unit enables to

automatically control blow temperature and blow air

quantity, turn on or off the compressor and switch the

blow port as well as switching between the fresh air

intake and interior air circulation.

Resetti ng the automati c function allows you to switch to

the manual control mode.

The sel f-di agno is is f unc ti on of t he auto mat ic he ate r and

air conditioner control unit (with the built-in micro-

computer) allows the unit to access and diagnose a

failed part easier and quicker.

Automatic Air Conditioner Parts Configuration

865RY00025

EndOFCallout

Legend

(1) Ambient Sensor

(2) Intake Actuator

(3) Evaporator Assembly

(4) Duct Sensor

(5) Sun Sensor

(6) Mix Actuator

(7) Mode Actuator

(8) Heater Unit

(9) In Car Sensor

(10) Automatic Air Conditioner Control Unit

(11) Max – High Relay

(12) Blower Unit

Refrigerant Line and Associated Parts

852RY00035

EndOFCallout

Legend

(1) Evapolator Assembly

(2) O – Ring

(3) Liquid Line (High Pressure Pipe)

(4) Ambient Sensor

(5) Engine Hood Seal

(6) Receiver Dr yer

(7) Pressure Switch

(8) High Pressure Hose

(9) Condenser Asse mbly

(10) Condenser Fan

(11) Compressor

(12) Suction Line (Low Pressure Hose)

(13) Drain Hose

Circuit Diagram

6VD1 Engine

D08RX145

D08RX146

D08RY00885

D08RX148

D08RX144

D08RX143

Functions and Features

Automatic interior temperature control

This function enables to maintain the interior

temperature at the level specified from the

temperature control switch despite of changes in

factors such as vehicle speeds, outside air

temperature and number of passengers.

Maximum cooling and heating function

You can select FC (Full cool, namely maximum cooling

temperature) or FH (Full heat, maximum heating

temperature) from the temperature control lever.

Automatic air flow control

Air flow is automatically and consecutively fine tuned

according to the specified interior temperature and

changes in aperture of the heater unit mix door.

Mode (blow port) control

This function automatically selects either one of the

VENT, BI-LEVEL, FOOT or DEF mode for the blow

port according to changes of temperature on the

blow port. Using the mode switch allows you to

select a desired blow port manually.

Intake (switching between the fresh air intake and

circulation of interior air) control

The intake (switching between fresh air intake and

circulation of interior air) mode automatically selects

either FRESH (fresh air intake), MIX or RECIRC

(interior air circulation) according to changes of the

blow port temperature. Using the intake switch

allows you to select a desired intake port manually

(in the manual operation, FRESH and RECIRC

modes alone are available). Pressing the DEF

(defrost) mode switch selects the FRESH (fresh air

intake).

Cooler start-up timing control

This function is used for maintaining the air flow at

“LOW" level until the evaporator is sufficiently cooled

down. It is intended to prevent a large volume of hot

air being blowing into inside of a vehicle when the

cooler is turned on in hot summer season.

Heater start-up timing control

This function is used for maintained the air flow at

“LOW" level and also for maintaining the defrost

mode until temperature of coolant in the heater core

is sufficiently heated. It is intended to prevent a large

volume of cool air being blown into inside of a vehicle

when the heater is turned on in cold winter season.

Solar radiation quantity offset control

The photodiode on the solar radiation sensor

determines solar radiation quantity accurately to

offset interior temperature quickly.

Switch position storing function

This function is used for storing switch positions being

selected in the immediately preceding operation,

namely the last time the ignition has been turned off.

It simplifies the setup procedures when restarting the

system.

Self-diagnosis function

The self-diagnosis function turned on from the panel

switch makes your troubleshooting easier (for detail

of this function, refer to the section titled

“Self-Diagnosis").

Automatic Air Conditioner Block Diagram

F01RY00006

Control Panel Layout

C01RW007

EndOFCallout

Legend

(1) Auto Switch

(2) Mode Switch

(3) DEF Switch

(4) Intake Switch

(5) Fan Switch

(6) Air Conditioning Switch

(7) Temperature Control Knob

Air Control Functions

C01RX002

EndOFCallout

Legend

(1) Interior Air Intake

(2) Fresh Air Intake

(3) Evaporator Core

(4) Air Mix Door

(5) DEF Door

(6) VENT Door

(7) Foot Door

(8) Sub Air Mix Door

(9) Heater Unit

(10) Heater Core

(11) Evaporator Unit

(12) Blower Unit

Operation and Functions of Control Panel Switches

Auto Switch

1. Pressing this switch turns on the automatic control

mode. It resets all manual switches except that for

the fan control. However, when the Manual REC is

selected for the intake or the Manual Open is

selected, the modes are maintained.

2. It causes the A/C (air conditioner) to the ON mode

(this function, however, available only when the fan

is turned on and also the compressor is turned on

because of the given outside air temperature level).

Indication

• The AUTO LED comes on.

• Curren tly s elected mod e fo r the Mod e and In take are

respecti vely indicate d.

• The A/C LED remains turned on even if the

compressor has been turned off because of the given

outside air temperature level. Pressing the air

conditioning switch in this state turns off the A/C LED .

Mode Switch

1. Pressi ng the VE NT, B/L or FO OT switc h selects the

corresponding mode.

2. When th e Auto is selec ted for the Mode and Intake,

pressing the mode switch fixes the Intake to the

immedi atel y prec edi ng sta tus.

Indication

• Turns off the Auto LED.

• Currently selected blow port is indicated.

DEF Switch

Press this switch to select the DEF mode.

*1: When the manual REC is selected for the Intake, the

manual REC is maintained.

*2: The ON mode is enabled only when the fun is turned

on, and also the compressor is turned on because of

the given outside air temperature level.

Indication

• The Auto LED is turned off.

• DEF is indi cat ed for the b lo w port, A/C LED come s on

(only when the fan is turned on), and status display is

provided for the Intake and Cold Air Bypass.

F01RX006

Blow port Intake port A/C MIX

DEF Auto FRESH *1 ON mode *2 Auto

Intake Swit ch

Pressing this switch sequentially selects a different

intake port in the followi ng ord er.

F01RX005

Indication

• The Auto LED maintains unaffected.

• Currently selected intake port is indicated.

F01RX007

Fa n Switch

1. Sets the fan to the specified mode.

2. Even when the fan switch is turned off, status

display for the Mode, Intake and Cold Air Bypass is

maintained.

Temperature Control Knob

1. This knob is operable only when the fan is turned

on. It may be used for the MAX control of each

block except the fan.

2. When the manual mode is selected for the fan

control, this manual mode is maintained.

MAX Control Mix Fan Mode Intake Cold air

bypass A/C

MAX/COOL Full cool MAX/HI VENT REC*1 OPEN*2 ON mode*3

MAX/HEAT Full hot AUTO/HI FOOT*4 FRESH CLOSE Current status

is maintaine d

*1: In the A/C: OFF mode, FRESH shall be selected.

*2: When the fan is turned ON, CLOSE shall be

selected.

*3: The ON mo de is avail able only when ON is se lecte d

for the fan as well as for the cold outside air ON/OFF

selection.

*4: When the MAX control is selected from the DEF

mode, this DEF mode shall be maintained.

F01RX008

Indication

• As long as the MAX control is selected, the

immedi ately preced ing indica tio n sh all b e mai ntaine d

for the AUTO.

• Status display is provided for others.

Air Conditioning Switch

Pressing this switch turns on or off the A/C (air

conditio ning) control. (The compressor rema ins tur ned

off if the fan is turned off and also the compressor has

been turned off because of the given outside air

temperature level.)

Indication

1. The A/C LED remains turned on even if the

compressor has been turned off because of the

given outside air temperature level. In this case,

however, the AUTO or DEF switch must be turned

on and the A/C ON mode must also be turned on

(by the MAX/C mode).

2. Pressing the A/C switch from the above state (1)

turns off the A/C LED.

Overview of Construction, Movement

and Control of Major Parts of

Automatic Air Conditioner System

Automatic Heater/Air Conditioner Control

Unit

Equipped with the built-in micro-computer, this control

unit operate s on sig nals from s ensors and input si gnals

from switches to offer total control of the blower fan, and

actuators used for the mode door, intake door and air

mix door.

Its self-diagnosis function enables quicker access to a

failed part and its more accurate troubleshooting.

In Car Sensor

It is a sensor used for detecting room temperature of a

v ehicle. This sensor converts a given room temperature

into a resistance value before entering the data to the

automatic heater/air conditioner control unit.

This in car s ensor un ite s t he p ower dri ven aspirator an d

the motor fan so that a small amount of room air ma y be

constantly fed to the sensor.

This sensor is provided on the control panel.

865RX015

EndOFCallout

Ambient Sensor

This sensor is used for detecting temperature outside

the vehicle. It conver ts a given outside air temperature

into a resistance value before entering the data to the

automatic heater/air conditioner control unit.

Ther mal effects from the conden ser and radiator durin g

idling after a run can be measured and offset the

automatic amplifier.

This sensor is provided on the side plate situated at

upper right side of the condenser.

875RY00021

EndOFCallout

Duct Sensor

The duct sensor is the sensor to detect temperature

change of the side of evaporator blower coming by fresh

recirculation of intake door or “on" “off" of compressor.

The temperature is converted to resistant rate.

And it works as thermostat to control to prevent freezing

of evaporator.

This sensor is installed in the upper case of evaporator.

874RX014

EndOFCallout

Legend

(1) In Car Sensor

(2) Automatic Air Conditioner Control Unit

Legend

(1) Ambient Sensor

Legend

(1) Evaporator Core

(2) Duct Sensor

(3) Lower C as e

(4) Upper Case

Sun Sensor

It is a photodiode used for detecting quantity of solar

radiation. This sensor converts the offset signal

generated by changes in the interior temperature (which

results from fluctuations in solar radiation) into

photoelectric current to ente r into the automatic heater/

air conditioner control unit.

This sensor is provided at top of the defroster grill.

865RW009

EndOFCallout

Power Transistor

Receiving base current from the automatic heater/air

conditioner control unit, the power transistor implements

stage-less speed change of the blower fan motor. This

transistor is provided on the evaporator.

874RX015

EndOFCallout

Max Hi Relay

This relay turned on or off by the signal from the

automatic heater/air conditioner control unit. As the

Max Hi relay is tur ned on, supply voltage is directly fed

to the blower fan motor to select the Max Hi mode.

860RW028

EndOFCallout

Actuator

The ac tuators are power driven type cont aining a s mall

motor. Receiving output current from the automatic

heater/air conditioner control unit, actuators drive the

heater and blower unit mode doors.

Actuators consist of the mode actuator used for

switching the mode (blow port selection), the mix

actuato r used for chang ing aperture of t he air mi x door,

the intake actuator used for switching the intake

mode(fresh air/interior air) and the cold air bypassing

actuator.

860RW029

Legend

(1) Sun Sensor

Legend

(1) Evaporator Assembly

(2) Power Transistor

Legend

(1) Blower Unit

(2) Max High Relay

EndOFCallout

The actuator changes the motor speed using the gear

and drives each door rotating the output axis united with

the sliding contact.

860RW026

EndOFCallout

The mode and mix actuators are common actuators

with the built-in potentiometer. For the intake actuator,

the contact switch type is selected.

The potentiometer is a register assembled to the printed

circuit board of the mix and mode actuators. It detects

the air mix door position specified by rotation of the

output axis as a ratio of the variable terminal (VM)

voltage against the reference voltage (VDD: 5V), then

signals the value to the automat ic h eater/ air con ditio ner

control unit.

C01RX016

Movement of Mix Actuator

Position of the air mix door is determined by the

controller on the automatic heater/air conditioner control

unit.

As the heat or cool side of the controller is grounded,

the transistor on the driver is activated and, thus, the

motor rotation is turned on. The sliding contact

connected to the motor sends the position detection

signal from the potentiometer to the automatic heater/air

conditioner control unit. As the set temperature and

inter io r temperature a re bal anced , the co ntroller r eturns

to the neutral and the motor rotation is stopped.

C01RX005

Legend

(1) Mix Actuator

(2) Heater Unit

(3) Intake Actuator

(4) Mode Actuator

(5) Blower Unit

Legend

(1) Output Axis

(2) Motor

(3) Printed Circuit Board

(4) Sliding Contact

C-45 Rotation

direction Remarks

(+) side (-) side

8 6 Clockwise Full heat side

68Counter

clockwise Full cool side

Movement of Mode Actuator

As target position of the mode door is decided on the

controller of the control unit, the control unit reads the

position detection signal from the actu ator to select the

clockwise or counter clockwise motor rotation direction.

Grounding the controller VENT or DEF side after the

direction selection activates the transistor on the driver,

thus turning on the motor rotation. Accompanying the

motor rotation, the sliding contact rotates, too. When

the target position is reached, the controller on the

control unit returns to the neutral and the motor stops.

C01RX017

Movement of Intake Actuator

The controller on the automatic heater/air conditioner

control unit selects an intake mode to be used.

As the Terminal No.5 B-26 is grounded via the sliding

contact on the terminal plate, the transistor on the driver

is activated, thus turning on the motor rotation. Then,

accompanying move of the motor, the sliding contact

rotates until grounding of the Terminal No.5 B-26 is

removed, thus stopping the motor.

C01RX006

Overview of Automatic Control of

Automatic Air Conditioner

The automati c heate r and air con ditio ner on this vehicle

has the following features:

• Interior temperature control.

• Air flow control.

• Mode (blow port) control.

• Intake (switching between fresh air and interior air)

control.

• Heater start timing control.

• Cooler start timing control.

• Compressor ON/OFF function according to outside

air temperature level.

• Evaporator anti-freeze control.

Interior Temperature Control

The automatic heater/air conditioner control unit

operates on the setup temperature signal from the

temperature control switch and other sensor signals to

der ive the total si gnal. Then , the contro l unit c ompares

this signal against the signal from the potentiometer to

determine rotation direction of the mix actuator. The

mix actuator moves the air mix door to the aperture

specif ied by the total signal so that the specifie d inter i or

temperature is achi eved.

If the compressor is turned off in the A/C (air

conditioning) mode, aperture of the air mix door is offset

Conduction pin Rotation

direction Remarks

(+) side (-) side

5 1 Clock wise VENT to DEF

direction

1 5 Counter

clockwise DEF to VENT

direction

Grounding

terminal Rotation

direction Remarks

No.5 B-26 Clockwise RE-CIRCULATI

ON→MIX→FRE

according to the outside air temperature or the specified

interior temperature. This function removes the

difference in the blowing temperature in this state and

that of when the compressor is turned on.

When FH or FC is selected for the setup temperature,

the air mix door is accordingly fixed to the Full Heat or

Full Cool mode.

When the VENT mode is selected, aperture of the air

mix door is controlled so that excessiv ely heated air ma y

not be blown from the VENT blow port.

C01RY00015

Air Flow Control

In the Auto Mode

• The automatic heater/air conditioner control unit

operates on the setup temperature signal and other

sensor signals to derive the total signal. Then, the

control unit adjusts base potential of the power

transistor to match it to the voltage pattern of the

target fan so that stage-less fa n spe ed c ontrol can be

achieved.

When solar radiation quantity is detected in the VENT

or B/L mode, the control unit increases the minimum

fan voltage to offset.

When FH or FC is selected from the temperature

contro l switch, air flow is accordi ngly fixed to MAX HI

or AUTO HI.

In the Manual Mode

• Air flow specified from the fan switch is entered to the

automatic heater/air conditioner control unit as the

manual signa l. The s ignal modifie s the air flow to the

level specified from the fan switch so that the required

fan voltage is attained.

C01RY00008

Mode (Blow Port) Control

The automatic heater/air conditioner control unit

operates on the setup temperature from the control

switch, and temperature and solar radiation quantify

from the sensors to determine the total mode control

signal. According to the pattern specified by this signal,

the control unit selects either one of the VENT,

BI-LEVEL, FOOT or DEF/FOOT mode.

The mode actuator determines the rotation direction

comparing the target position against the current

position being determined by the position detection

signal.

When FH or FC is selected fo r the temperature from the

temp erature c on tro l switch, mode is a cc or di ng ly f ixed to

the VENT or FOOT.

• In the manual operation of th e mode switch, you can

select a desired blow port mode pressing the

corresponding mode switch.

• Operating the DEF mode switch selects the DEF for

the blow port mode.

C01RY00009

Intake (Fresh air/interior air switching)

Control

In the Full Auto mode, the automatic heater/air

conditioner control unit operates on the setup

temperature signal and other sensor input signals to

derive the total signal. According to the pattern

specified by this signal, the control unit provides the

intake control.

When the fan is turned off or the A/C (air conditioning) is

turned off, the intake is fixed to the FRESH mode.

When FC or FH is selected from the contro l switch, th e

intake mode is accordingly fixed to the RECIRC or

FRESH.

In the Manual Operation

• Pressing the FRESH (fresh air intake) or the RECIRC

(room air circulation) accordingly selects the FRESH

or RECIRC mode.

When the DEF Mode Switch is depressed

• The intake mode is fixed to the FRESH. When the

MANU REC is selected, however, the mode is fixed

the RECIRC.

When the Mode Switch is depressed

• If the automatic intake control is selected, the intake

is fixed to the currently selected mode.

C01RY00012

Compressor Control

In the automatic control mode, the automatic heater/air

conditioner control unit turns on or off the compressor

with the evaporator anti-freeze mechanism using the

evaporation sensor. And, when outside air is detected

to be low through the outside air temperature sensor

signal, the control unit turns off the compressor using

the compressor control function.

Ma nu al C o nt ro l

• In the automatic control mode, pressing the A/C (air

conditioning) switch turns off the compressor.

• Pressing the DEF mode switch automatically turns on

the compressor.

C01RY00010

Heating Start Timing Control

When the automatic heater/air conditioner is started,

heating is tur ned on only whe n the coola nt temperature

detected by the coolant temperature sensor is 18°C or

less and total signal derived from the sensor signals has

detected that the heating condition is met.

If the coolant temperature detected by the sensor is

18°C or less, 4.5V is set for the blower fan motor

terminal voltage and the DEF is selected for the blow

port mode.

When the temperature detected by the sensor is above

18°C, the blow port mode is switched to the Auto

Control and the voltage across the blower fan motor

terminal is linearly increased from 4.5V to auto control

voltage (auto airflow).

840RX015

Cooling Star t Timing Control

When the automatic heater/air conditioner is started,

cooling is turned on only when the temperature

detected by the interior temperature sensor is 30°C or

above and the total signal derived from the sensor

signals has detected that the cooling condition is met.

When the cooling condition has been met, the fan

voltage across the blower fan motor terminal is set to

4.5V for 7 seconds maximum, then it is linearly

increased up to the auto airflow level at the rate of 0.6V/

sec.

C06RX003

Troubleshooting

Troubleshooting, Its Overview and Procedures

The automatic heater and air conditioner equips with

the “Self-Diagnosis Function" to check its major

components.

This function makes access to the sensors, actuators

and blower fan motor system easier when checking

them up an d, when a failed part is l ocated, th is fu nctio n

restores its original performance.

When implementing the troubleshooting, this

self-diagnosis function narrows the range to be

searche d a t the fir st s tep, then check relevant p arts one

by one according to the “Checking Procedures by Failed

Location". As for a location this function is

unappreciable, the system accurately determines

characteristics of a given trouble and checks relevant

par ts according to the “Checking Procedures by Failed

Location".

The following illustrates basic troubleshooting flow.

Basic Troubleshooting Flow

F01RX009

Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto

amplifie r (contr ol un it) power sup ply cir cuit or gr oundin g

circuit prevents accurate troubleshooting.

D08RX284

Condition Possible cause Correction

P o wer source does not supply to auto

air conditioner control unit. — Refer to Chart A

Chart “A": Check of Auto Amplifier Power Supply System

Step Action Value(s) Yes No

1 Is the fuse C–5 normal? — Go to Step 2 Replace the

fuse

2 Is the fuse F–5 normal? — Go to Step 3 Replace the

fuse

3 Disconnect the auto A/C control unit connector I–20.

Is the battery voltage applied between the harness

side connector terminal No.I20–8 and the ground? Approx. 12V Go to Step 5 Go to Step 4

4 Repair an open circuit between the fuse C–5 and

terminal No.I20–8.

Is the action complete? — Go to Step 4 —

5 Is there continuity between the harness side

connector terminal No.I20–16 and the ground? — Go to Step 7 Go to Step 6

6 Repair an open circuit between terminal No.I20–16

and the ground No.B–8.

Is the action complete? — Go to Step 5 —

7 Is there continuity between the harness side

connector terminal No.I20–9 and the ground? — Go to Step 9 Go to Step 8

8 Repair an open circuit between terminal No.I20–9 and

the ground No.B–8.

Is the action complete? — Go to Step 7 —

9 Tur n the lig hti ng switch on.

Is the battery voltage applied between the harness

side connector terminal No.I20–10 and the ground? Approx. 12V Go to Step 11 Go to Step 10

10 Repair an open circuit between the lighting switch and

terminal No.I20–10.

Is the action complete? — Go to Step 9 —

11 Turn the starter switch on.

Is the battery voltage applied between the harness

side connector terminal No.I20–7 and the ground? Approx. 12V — Go to Step 12

12 Repair an open circuit between the fuse F–5 and

terminal No.I20–7.

Is the action complete? — Verify repair —

Performance and Movement checklist for Automatic Air Conditioner Related

Parts

Star t the eng ine, a nd when the engine coolant reache d

50°C check performance and movement of the related

parts according the following checklist.

Performance Ch eck Using the Manual Switch

No. Item Checki ng Approach Acceptance criteria

Condition Operation

Blowing

temperature (check

movement of air

mix door)

Auto switch must be

turned on (FAN-AUTO

MODE-AUTO)

1. Select FC for the

setup temperature.

2. Select FH for the

setup temperature.

→ Then, select the

MAX Control.

1. Cold air shall be blown out.

2. Hot air shall be blown out.

Airflow volume

(check movement

of the mode door)

Set temperature to

25.0°C. 1. Turn the fan knob

off.

2. Turn the fan knob

from LOW to HI.

1. The fan shall be stopped, thus

stopping air blow, too.

2. Airflow v olume shall change from

LOW to HI.

Blowing

temperature

(check movement

of the mode door)

Set temperature to

25.0°C. Set the fan

knob to HI.

Press the mode switch

to change the blow port

mode sequentially from

the VENT through

BI-LEVEL, FOOT up to

DEF.

LED corresponding to each mode

shall be tur ned on and th e blow por t

mode shall be switched smoothly.

The in terior /ou tsi de

air switching mode

(check movement

of intake door)

Set temperature to

25.0°C. Turn the LED off using

the interior/outside air

switch (this introduces

the outside air intake

mode). Then, the set

fan knob to HI and

press the interior/

outside switch to turn

on the LED.

The LED indication shall be s witched

from OFF to ON accompanying a

change in air blowing sound.

Compressor Set the temperature to

18.0°C (FC). (Outside

air temperature is 0°C

or above and interior

temperature at ordinary

temperature.)

Press the “OFF" switch.

1. Press the Auto

switch.

2. Press the Air

Conditioner switch.

1. As the fan knob is set to the Auto

position, the A/C switch LED

shall come on and the

compressor shall be t urned on.

2. As the A/C LED comes off, the

compressor shall be t urned off.

Check of Auto Function

No. Item Checking Approach Acceptance criteria

Condition Operation

1 A uto function FAN KNOB “AUTO"

MODE SW “AUTO"

Select FC for the

temperature.

The LED shall come on.

Cold air shall be blown out.

The following LEDs shall come on:

• Blow port mode:

• Intake mode

• Fan speed: MAX

•A/C

Change the

temperature

gradually starting

with 18°C up to

32°C.

The following phenomena shall be

recognized.

• Temperature of blown air: Cold air is

changed to hot air.

• Change in the air flow volume.

• The blow port mode LED indication

changes in the following sequence:

Select FH for the

temperature.

Cold air shall be blown out. The

following LEDs shall come on.

• Blow port mode:

• Fan speed: Max.

Troubleshooting With Self-Diagnosis Function

Overview of Self-Diagnosis Function

The self-diagnosis is implemented in 3 steps for each

target. For detail of check procedure contained in each

step, refer to the relevant section of “Check Procedure

by Failed Location" listed in the Self-Diagnosis

Operation Procedure.

For turning on the self-diagnosis function and switching

of the check step, refer to the flow chart given below.

You can reset the self-diagno sis function by tur ning the

ignition switch off or turning the DEF switch on for 5

seconds.

Self-Diagnosis Operation Pr ocedure

Step Action Value(s) Yes No

1 1. Set the IG to the OFF position.

2. Apply 60W bulb light to the solar radiation sensor.

3. Set the tem perat ure s etti ng l ever on the aut oma tic

heater/air conditioner panel to the center position

(25°C).

4. Set the fan switch on the same panel to the Auto

position.

Is the action complete? — Go to Step 2 —

2 While holding both the Auto switch and the DEF

switch on the automatic heater/air conditioner panel,

turn the IG off and then on.

Is the current trouble diagnosing function turned on

approximately in 10 seconds? — Go to Step 3 —

3 Does the A/C LED flash every 0.5 second interval? — Go to Step 4 Refer to *1.

4 Press the A/C switch once.

Does the A/C LED flash every 0.5 second interval? — Go to Step 5 Refer to *2.

5 Refer to *3 chart “Check of Output Equipment".

Does each output equipment function normally

according to operation of the temperature setting

level?

— Go to Step 6

Repair or

replace the

output

equipment or

repair the

harness

6 Press the DEF switch for 5 seconds consecutively or

turn on and off the IG.

Is the action complete? — Go to Step 1 —

*1Displaying the Current Trouble Diagnosing Table

Start the engine while holding down both the Auto

switch and the DEF switch on the control panel, and the

table will appear in approximately 10 seconds to the

indicator lamp (LED) of the air conditioning switch.

Result of the diagnosis along the following 9 items will

be shown on e by one in 0.5 se con d i nte rval irre sp ec tive

of presence or absence of a trouble for a given item.

When the display 9 items is completed, it is repeated

with 3 seconds of interval in between. A failed item is

indicated by flashing of the LED that is repeated 3 times

within 0.5 seconds. If a trouble is indicated, you can

locate the failed section by knowing when in the total

sequence it has been displayed.

F01RX010

Item for Current Trouble Diagnosis

F01RY00008

As shown above, display of result along nine items is

repeated with 3-seco nd inte rval in between.

Note 1: When checking the solar radiation sensor, apply

sufficient light using a 60W bulb. Otherwise, it can be

diagnosed as failed.

Note 2: If the temperature setting lever is set on both

ends (one set to 18°C, blue scale = Full cool and the

other to 31°C, red scale = Full hot), they can be

diagnosed as failed.

Note 3: Likewise, the fan switch can be diagnosed as

failed if set on both ends.

*2Displaying the Past Trouble Diagnosing Table

The past trouble diagnosis displays only the items on

which trouble has recurred 16 times in the past.

If you press the air conditioning switch once while the

current trouble diagnosis is taking place, display of the

past trouble dia gnosis will appear on the indic ator lamp

(LED) of the air conditioning switch.

Results of the diagnosis along the following five items

are displayed one by one in 0.5 second interval

irres pect iv e of pres ence or abs enc e of a t r oub le . A failed

item i s indi cated by flash ing o f the LED that i s repe ated

3 times within 0.5 seconds. You can locate the failed

section by counting in what sequence it has been

displayed.

F01RX011

F01RY00007

*3Check of Output Equipment

F01RX015

Inspection By Failed Location

Inspection of the Sensors

When the self-diagnosis function has determined that

trouble is present on the sensors, check them according

to the following flow chart.

F01RY00005

Chart 1: In Car Sensor

D08RY00888

Step Action Value(s) Yes No

1 Disconnect the in car sensor connector. (No.I-4)

Is performance of the sensor normal? (Refer to the

later section on “Individual Inspection") — Go to Step 2 Replace the in

ca r sensor

2 Is there continuity between the harness side

connector No.I44–1 and No.I4–3? — Go to Step 4 Go to Step 3

3 Re pair an open cir cuit betwee n ter minal N o.44–1 an d

No.I4–3.

Is the action complete? — Go to Step 2 —

4 Is there continuity between the harness side

connector No.I44–11 and No.I4–4? — Go to Step 6 Go to Step 5

5 Repair an open circuit between terminal No.I44–11

and No.I4–4.

Is the action complete? — Verify repair —

6 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Chart 2: Ambient Sensor

D08RY00886

Step Action Value(s) Yes No

1 Disconnect ambient sensor connector. (No .C–8)

Is performance of the ambient sensor nor mal? (Refer

to the later section on “Individual inspection") — Go to Step 2 Replace the

ambient sensor

2 Connect the ambient sensor connector.

Is resistance between the harness side connector

No.I44–2 and No.I44–11 normal?

Refer to the

later section

on “Individual

inspection" Go to Step 4 Go to Step 3

3 Repair an open circuit between terminal No.I44–2 and

No.C8–1 or No.I44–11 and No.C8–2.

Is the action complete? — Verify repair —

4 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Chart 3: Sun Sensor

D08RY00887

Step Action Value(s) Yes No

1 Disconnect the sun sensor connector. (No.I–50)

Is performance of the sun sensor normal? (Refer to

the later section on individual inspection) — Go to Step 2 Replace the

sun sensor.

2 Is there continuity between the harness side

connector terminal No.I44–3 and No.I50–2? — Go to Step 4 Go to Step 4

3 Repair an open circuit between terminal No.I44–3 and

No.50–2.

Is the action complete? — Go to Step 2 —

4 Is there continuity between the harness side

connector terminal No.I44–11 and No.I50–1? — Go to Step 6 Go to Step 5

5 Repair an open circuit between terminal No.I44–11

and I50–1.

Is the action complete? — Go to Step 4 —

6 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Inspection of the Intake Actuator System

D08RX230

Chart A: Does Not Work At All

Condition Possible cause Correction

Does not work at all — Refer to Chart A

Control failure — Ref er to Chart B

Step Action Value(s) Yes No

1 Is the fuse C–14 normal? — Go to Step 2 Replace the

fuse

2 Is the fuse F–5 normal? — Go to Step 3 Replace the

fuse

3 Is the relay X–6 normal? — Go to Step 4 Replace the

relay

4 Turn on the ignition switch. (the engine is run.)

Is the battery voltage applied between the harness

side connector terminal No.B26–3 and ground? Approx 12V Go to Step 6 Go to Step 5

5 Repair an open circuit between terminal No.B26–3

and No.X6–1.

Is the action complete? — Go to Step 4 —

6 Is the battery voltage applied between the harness

side connector terminal No.B26–4 and ground? Approx 12V Go to Step 8 Go to Step 7

7 Replace the intake actuator motor.

Is the action complete? — Go to Step 6 —

8 Is there continuity between the harness side

connector terminal No.I20–11 and No.B26–4? — Go to Step 10 Go to Step 9

9 Repair an open circuit between No .I20–11 and B26–4.

Is the action complete? — Verify repair —

10 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Chart B: Failure on the Intake Control

Step Action Value(s) Yes No

1 Is the fuse No.C–14 normal? — Go to Step 2 Replace the

fuse

2 Is the fuse No.F–5 normal? — Go to Step 3 Replace the

fuse

3 Is the relay No.X–6 normal? — Go to Step 4 Replace the

relay

4 Turn on the ignition switch. (the engine is run.)

Is the intake actuator stopped? — Go to Step 6 Go to Step 5

5 Replace or repair the auto air conditioner control unit.

Is the action complete? — Verify repair —

6 Is there continuity between the harness side

connector terminal No.B26–5 and No.I44–11? — Go to Step 8 Go to Step 7

7 Repair an open circuit between terminal No.B26–5

and No.I44–11.

Is the action complete? — Go to Step 6 —

8 Is there continuity between the harness side

connector terminal No.B26–6 and No.I44–12? — Go to Step 10 Go to Step 9

9 Repair an open circuit between terminal No.B26–6

and No.I44–12.

Is the action complete? — Go to Step 8 —

10 Is there continuity between the harness side

connector terminal No.B26–1 and No.I44–13? — Go to Step 12 Go to Step 11

11 Repair an open circuit between terminal No.B26–1

and I44-13.

Is the action complete? — Go to Step 10 –

12 Is there continuity between the harness side

connector terminal No.B26–2 and No.I44–14? — Go to Step 14 Go to Step 13

13 Repair an open circuit between harness No.B26–2

and No.I44–14.

Is the action complete? — Go to Step 12 —

14 1. Disconnect the intake actuator connector No.B–

26.

2. Is the battery voltage applied between harness

side connector terminal

No.B26–6 and ground?

No.B26–2 and ground?

No.B26–1 and ground?

— Go to Step 15 Go to Step 16

15 Replace or repair the intake actuator.

Is the action complete? — Verify repair —

16 Replace or repair the air conditioner control unit.

Is the action complete? — Verify repair —

Inspection of the Mix Actuator System

D08RX229

Condition Possible cause Correction

Does not work at all — Refer to Chart A

Control failure — Ref er to Chart B

Chart A: Does Not work At All

Step Action Value(s) Yes No

1 1. Turn on the ignition switch (the engine is run).

2. Disconnect the mix actuator connector (C–45).

3. Short-circuit the chassis harness side connector

terminal No.C45–2 and No.C45–7.

4. Using the temperature control lever, select FH for

the temperature.

Is the battery voltage applied on a regular interval

basis between the harness side connector terminal

No.C45–8 (-) and No.C45–6 (+)? — Go to Step 3 Go to Step 2

2 Replace the auto air conditioner control unit.

—Varify repair —

3 Using the temperature control lever, select FC for the

temperature.

Is the battery voltage applied on a regular interval

basis between the harness side connector terminal

No.C45–8 (+) and No.C45–6 (-)? — Go to Step 5 Go to Step 4

4 Replace the auto air conditioner control unit.

— Verify repair —

5 Is there continuity between the harness side

connector terminal No.I20–6 and No.C45–8? — Go to Step 7 Go to Step 6

6 Repair an open circuit between terminal No.I20–6 and

No.C45–8.

Is the action complete? — Go to Step 5 —

7 Is there continuity between the harness side

connector terminal No.I20–5 and No.C45–6? — Go to Step 9 Go to Step 8

8 Repair an open circuit between terminal No.I20–5 and

No.C45–6.

Is the action complete? — Verify repair —

9 Replace the mix actuator.

Is the action complete? — Verify repair —

Chart B: Mix Actuator Control Failure

Step Action Value(s) Yes No

1 Turn the ignition switch (the engine is run).

Dose th e mix ac tuat or fu ll y stroke when FH a nd FC of

the temperature control lever? — Go to Step 3 Go to Step 2

2 Repair or replace the air mix door or the link unit.

Is the action complete? — Varify repair —

3 Is there continuity between the harness side

connector terminal No.C45–2 and No.I44–11? — Go to Step 5 Go to Step 4

4 Repair an open circuit between terminal No.C45–2

and No.I44–11.

Is the action complete? — Go to Step 3 —

5 Is there continuity between harness side connector

terminal No.C45–7 and No.I44–5? — Go to Step 7 Go to Step 6

6 Repair an open circuit between terminal No.C45–7

and No.I44–5.

Is the action complete? — Go to Step 5 —

7 Is there continuity between the harness side

connector terminal No.C45–3 and No.I44–15? — Go to Step 9 Go to Step 8

8 Repair an open circuit between terminal No.C45–3

and No.I44–15.

Is the action complete? — Go to Step 7 —

9 Is sum of the voltage between the following chassis

harness side connector terminals approximately 5V?

No.I44–15 and No.I52–5, No.I44–5 and No.I44–11 — Go to Step 11 Go to Step 10

10 Replace the actuator.

Is the action complete? — Verify repair —

11 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Inspection of the Mode Actuator System

D08RX228

Condition Possible cause Correction

Does not work at all — Refer to Chart A

Control failure — Ref er to Chart B

Chart A: Does Not Work At All

Step Action Value(s) Yes No

1 1. Turn on the ignition switch (the engine is run).

2. Disconnect the mode actuator connector (C–48)

3. Select VENT pressing the mode actuator.

Is the battery voltage provided on a regular interval

between the harness side connector terminal

No.C48–1 (+) and No.C48–5 (-)? — Go to Step 3 Go to Step 2

2 Replace the auto air conditioner control unit.

Is the action complete? — Varify repair —

3 Turn on the DEF mode switch.

Is the battery voltage provided on a regular interval

between the chassis side connector terminal No.C48–

5 (+) and No.C48–1 (-)? — Go to Step 5 Go to Step 4

4 Replace the auto air conditioner control unit.

—Varify repair —

5 Is there continuity between the harness side

connector terminal No.C48–1 and No.I20–4? — Go to Step 7 Go to Step 6

6 Repair an open circuit between terminal No.C48–1

and No.I20–4.

Is the action complete? — Go to Step 5 —

7 Is there continuity between the harness side

connector terminal No.C48–5 and No.I20–3? — Go to Step 9 Go to Step 8

8 Repair an open circuit between terminal No.C48–5

and No.I20–3.

Is the action complete? — Verify repair —

9 Replace the mode actuator.

— Verify repair —

Chart B: Mode Actuator Control Failure

Step Action Value(s) Yes No

1 Turn on the ignition switch (the engine is run).

Dose th e mode actuator fully stroke when the defrost

mode and the vent mode are selected? — Go to Step 3 Go to Step 2

2 Repair or replace the mode door or the link unit.

Is the action complete? — Go to Step 1 —

3 Is there continuity between the harness side

connector terminal No.C48–9 and No.I44–11? — Go to Step 5 Go to Step 4

4 Repair an open circuit between terminal No.C48–9

and No.I44–11.

Is the action complete? — Go to Step 3 —

5 Is there continuity between the harness side

connector terminal No.C48–3 and No.I44–10? — Go to Step 7 Go to Step 6

6 Repair an open circuit between terminal No.C48–3

and No.I44–10.

Is the action complete? — Go to Step 5 —

7 Is there continuity between harness side connector

terminal No.C48–4 and No.I44–8? — Go to Step 9 Go to Step 8

8 Repair an open circuit between terminal No.C48–4

and No.I44–8.

Is the action complete? — Go to Step 7 —

9 Is sum of the voltage between the following harness

side connector terminal approximately 5V? Voltage

between No.I44–8 and No.I44–10 plus voltage

between No.I44–8 and No.I44–11 5V Go to Step 11 Go to Step 10

10 Replace the actuator.

Is the action complete? — Verify repair —

11 Dose the mode actuator work normally through

manual operation? — Go to Step 13 Go to Step 12

12 Replace the sensor.

Is the action complete? — Verify repair —

13 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Inspection of the Fan Motor System

D08RX227

Chart A: Fan Does Not Rotate At All

Condition Possible cause Correction

The fa n dose not rotate at all — Refer to Chart A

The fan dose not rotate in the MAX–

HI mode — Refer to Chart B

The fan dose not rotate in any mode

other than MAX–HI — Refer to Chart C

The fa n dose not stop — Refer to Chart D

Step Action Value(s) Yes No

1 Are the fuse No.F–4 and No.F–5 normal? — Go to Step 2 Replace the

fuse

2 Are the relay No.X–6 and No.B–25 normal? — Go to Step 3 Replace the

relay

3 Turn on the ignition switch (the engine is run).

Is the battery voltage applied between the harness

side connector terminal No.B5–2 and ground? — Go to Step 5 Go to Step 4

4 Repair an ope n circuit between terminal No.B5–2 and

No.F–4 fuse.

Is the action complete? — Go to Step 3 —

5 Is there continuity between the harness side

connector terminal No.B5–1 and ground (No.B–8)? — Go to Step 7 Go to Step 6

6 Repair an ope n circuit between terminal No.B5–1 and

ground.

Is the action complete? —

7 Is the battery voltage applied between the harness

side connector terminal No.B5–1 and No.B5–2? — Go to Step 8 Go to Step 9

8 Replace the blower motor.

Is the action complete? — Verify repair —

9 Refer to chart B and C.

Is the action complete? — Verify repair —

Chart B: Fan Does Not Rotate in MAX HI Mode

Step Action Value(s) Yes No

1 Is the MAX-HI relay (B–25) normal? — Go to Step 2 Replace the

relay

2 1. Turn on the ignition switch (the engine is run).

2. Set the fan switch to the MAX-HI.

Is there continuity between the harness side

connector terminal No.B5–1 and No.B25–2? — Go to Step 4 Go to Step 3

3 Repair an ope n circuit between terminal No.B5–1 and

No.B25–2.

Is the action complete? — Go to Step 3 —

4 Is there continuity between the harness side

connector terminal No.B25–4 and ground (No.B–8)? — Go to Step 6 Go to Step 5

5 Repair an open circuit between terminal No.B25–4

and ground (No.B–8).

Is the action complete? — Go to Step 4 —

6 Is the battery voltage applied between the harness

side connector terminal No.B25–1 and ground? — Go to Step 8 Go to Step 7

7 Repair an open circuit between terminal No.B25–1

and No.F–5 fuse.

Is the action complete? — Go to Step 6 —

8 Is the battery voltage applied between the harness

side connector terminal No.I20–12 and ground? — Go to Step 10 Go to Step 9

9 Repair an open circuit between terminal No.B25–3

and No.I20–12.

Is the action complete? — Verify repair —

10 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI

Chart D: Fan Does Not Stop

Step Action Value(s) Yes No

1 Is the power transistor performanc e normal ? (Refer to

the later section on “individual inspection") — Go to Step 2 Replace the

power transistor

2 Is there continuity between the harness side

connector terminal No.B5–1 and No.B35–1, No.B5–1

and No.I44–17? — Go to Step 4 Go to Step 3

3 Repair an open circuit between terminal.

No.B5–1 and B35–1

No.B5–1 and I44–17

— Go to Step 2 —

4 Is there continuity between the harness side

connector terminal No.B35–3 and ground (No.B–8)? — Go to Step 6 Go to Step 5

5 Repair an open circuit between terminal No.B35–3

and ground.

Is the action complete? — Go to Step 4 —

6 Is there continuity between the harness side

connector terminal No.B35–2 and No.I44–19? — Go to Step 8 Go to Step 7

7 Repair an open circuit between terminal No.B35–2

and No.I44–19.

Is the action complete? — Go to Step 6 —

8 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Step Action Value(s) Yes No

1 1. Disconnect the max high relay, the power

transistor connector B–35 and the auto A/C

control unit connector I–44.

2. Turn on the ignition switch.

Does the blower motor stop? — Go to Step 3 Go to Step 2

2 Repair a short circuit between connector No .B5–1 and

No.B25–2, No.B5–1 and No.B35–1, or No.B5–1 and

I44–17.

Is the action complete? — Verify repair —

3 Is the max high relay normal? (Refer to the later

section on “individual inspection".) — Go to Step 4 Replace the

relay

4 Reinstall the max high relay.

Does the blower motor start operating? — Go to Step 6 Go to Step 5

5 Repair a short circuit between connector No.B25–3

and No.I20–12.

Is the action complete? — Go to Step 4 —

6 Is the power transistor normal? (Refer to the later

section on “individual inspection".) — Go to Step 7 Replace the

power transistor

7 Reinstall the power transistor.

Does the blower motor start operating? —

Replace the

auto A/C control

unit —

Inspection of the Magnetic Clutch System

6VD1 Engine

D08RX226

Chart A: Magnetic Clutch Does Not work

Condition Possible cause Correction

Magnetic clutch does not work — Refer to Chart A

Step Action Value(s) Yes No

1 Is the fuse No.F–5 normal? — Go to Step 2 Replace the

fuse

2 Is the relay No.X–4 (compressor relay) No.X–5 (A/C

thermo relay) and No.X–6 (heater relay) normal? — Go to Step 3 Replace the

fuse

3 Is the thermo unit normal? — Go to Step 4 Replace the

thermo unit

4 Is the pressure switch normal? — Go to Step 5 Replace the

pressure switch

5 1. Turn the ignition switch on. (the engine is run.)

2. Push the air conditioner switch on.

Is the battery voltage applied between the harness

side connector terminal No.E3–1 and the ground? — Go to Step 6 Go to Step 7

6 Repair or replace the magnetic clutch.

Is the action complete? — Verify repair —

7 Is there continuity between the harness side

connector terminal No.X4–1 and No.E3–1? — Go to Step 9 Go to Step 8

8 Repair an ope n circuit between terminal No.X4–1 and

No.E3–1.

Is the action complete? — Go to Step 7 —

9 Is the battery voltage applied between the harness

side con nector ter minal No. X4–5 and ground , No.X4–

2 and ground? — Go to Step 11 Go to Step 10

10 Re pair an ope n circuit between ter min al No.X4–5 and

fuse No.F–5, No.X4–2 and fuse No.F–5.

Is the action complete? — Go to Step 9 –

11 Is the battery voltage applied between the harness

side connector terminal No.I44–18 and ground? — Go to Step 13 Go to Step 12

12 Repair an open circuit between terminal No.I44–18

and No.X4–4.

Is the action complete? — Go to Step 11 —

13 Is the battery voltage applied between the harness

side connector terminal No.C11–2 and ground? — Go to Step 15 Go to Step 14

14 Repair an open circuit between terminal No.C11–2

and fuse No.F–5.

Is the action complete? — Go to Step 13 —

15 Is the battery voltage applied between the harness

side con nector ter minal No. X5–2 and ground , No.X5–

5 and ground? — Go to Step 17 Go to Step 16

16 Re pair an ope n circuit between ter min al No.X5–2 and

No.C11–1, No.X5–5 and fuse No.F–5.

Is the action complete? — Go to Step 15 —

17 Is the battery voltage applied between the harness

side connector terminal No.I20–14 and ground? — Go to Step 19 Go to Step 18

18 Re pair an ope n circuit between ter min al No.X5–4 and

I20–14.

Is the action complete? — Go to Step 17 —

Chart A: Magnetic Clutch Does Not work (Cont’d)

CAUTION: There are conditions which air

conditioner system dose not operate except trouble

as follows.

1. The throttle is griater than 90%.

2. The ignition voltage is below 10.5 volts.

3. The engine speed greater than 4500 RPM for 5

seconds or 5400 RPM.

4. The engine coolant temperature (ECT) is greater

than 125°

°°

°C (257°

°°

°F).

5. The intake air temperature (IAT) is less than 5°

°°

°C

(41°

°°

°F).

6. The power steering pressure switch signals a high

pressure condition.

Step Action Value(s) Yes No

19 Is there continuity between the harness side

connector terminal No.I44–4 and ground? — Go to Step 21 Go to Step 20

20 Repair an open circuit between terminal No.I44–4 and

No.E19–1.

Is the action complete? — Go to Step 20 —

21 Dose the the rmo relay “ON" when connecting ground

to the harness connector terminal No.H17–5? — Go to Step 23 Go to Step 22

22 Failure on the auto air conditioner control unit.

Is the action complete? — Verify repair —

Condenser Fan Diagnosis

While the air conditioning is ON, the cycling switch in

the triple pressure switch senses the refrigerant

pressure, and activates the condenser fan to improve

the cooling capacity of the condenser when the

refri gerant pressure exceeds a set pressure value. The

conden ser fan stops when the air co nditionin g is tur ned

“OFF" or when the pressure goes down below the set

pressure value.

D08RX255

Condition Possible cause Correction

Condenser fan does not run. — Refer to Chart A

Condenser fan does not stop. — Refer to Chart B

Chart “A" Condenser Fan Does Not Run

Step Action Value(s) Yes No

1 Is the fusible link No.FL–2 normal? — G o to Step 2 Replace the

fusible link wire

2 Is the fuse No.F–5 normal? — Go to Step 3 Replace the

fuse

3 Is the heater relay (No.X–6) and condenser fan relay

(No.X–9) normal? — Go to Step 4 Replace the

relay

4 1. Disconnect the condenser fan motor connector

No.C–24.

2. Connect the motor side connector terminal

No.C24–1 to the battery positive terminal and

No.C24–2 to the battery negative terminal.

Dose the f an operate? — Go to Step 6 Go to Step 5

5 Repair or replace the condenser fan motor.

Is the action complete? — Go to Step 4 —

6 Is there continuity between the harness side

connector terminal No.C24–2 and ground (C–16)? — Go to Step 8 Go to Step 7

7 Repair an open circuit between terminal No.C24–2

and No.C–16.

Is the action complete? — Go to Step 6 —

8 Is there continuity between the harness side

connector terminal No.C24–1 and No.X9–1? — Go to Step 10 Go to Step 9

9 Repair an open circuit between terminal No.C24–1

and No.X9–1.

Is the action complete? — Verify repair —

10 Is the battery voltage applied between the harness

side connector terminal No.X9–5 and ground? — Go to Step 12 Go to Step 11

11 Re pair an ope n circuit between ter min al No.X9–5 and

No.FL–2.

Is the action complete? — Go to Step 10 —

12 Is the battery voltage applied between the harness

side connector terminal No.C11–3 and ground? — Go to Step 14 Go to Step 13

13 Re pair an ope n circuit between ter min al No.X9–4 and

No.C11–3.

Is the action complete? — Go to Step 12 —

14 Is there continuity between the harness side

connector terminal No.C11–4 and No.I20–14? — Go to Step 16 Go to Step 15

15 Repair an open circuit between terminal No.C11–4

and No.I20–14.

Is the action complete? — Verify repair —

16 Connect the harness side connector terminal

No.C24–1 to the battery terminal and No.C24–2 to the

battery negative terminal.

Is the battery voltage between the pressure switch

side connector terminal No.C24–4 and ground? — Go to Step 18 Go to Step 17

17 Replace the triple pressure switch.

Is the action complete? — Verify repair —

18 Replace the auto air conditioner control unit.

Is the action complete? — Verify repair —

Chart “B" Condenser Fan Does Not Stop

Step Action Value(s) Yes No

1 1. Turn on the ignition switch “ON" (the engine is

run).

2. Air conditioning switch “OFF".

3. Disconnect the triple pressure switch.

Does the condenser fan stop? — Go to Step 2 Go to Step 3

2 Replace the triple pressure switch.

Is the action complete? — Verify repair —

3 Disconnect the relay.

Is there continuity between the harness side

connector terminal No.X9–4 and ground? — Go to Step 4 Go to Step 5

4 Repair short circuit between terminal No.X9–4 and

No.C11–3.

Is the action complete? — Verify repair —

5 Replace the relay condenser fan.

Is the action complete? — Verify repair —

Individual Inspection

In Car Sensor

1. Disconnect the in car sensor connector (I–4).

2. Measure resistance between the in car sensor side

terminal No.I4–3 and No.I4–4.

865RX007

Sun Sensor

1. Disconnect the sun sensor connector (I–50).

2. Measure the current value on the sun sensor when

placed it approximately 15 cm away from 60W

incandescent lamp.

C01RX013

Ambient Sensor

1. Disconnect the connector (C–8) on the ambient

sensor.

2. Measure resistance between the ambient sensor

side terminals.

C01RX012

Power Transistor

1. Remove the power t ransistor co nne ct or (B–35 ) from

the evaporator assembly.

2. Check the c onduction bet ween the power transistor

side terminals.

C01RX015

MAX HI Relay

1. Remove the MAX – HI relay connector (B–25) from

the blower assembly.

2. Check the conduction between the MAX – HI relay

side terminals.

C01RX014

In Car Sensor

1. Turn on the ignition switch (the engine is started).

Start the air conditioner in “Full Auto".

2. Make sure that the interior sensor suctions cigarette

smokes an d such.

In Car Sensor

1.Dismount the in car sensor from the automatic

heater/air conditioner control unit. Connect (+)

end and (-) end of the battery to the aspirator motor

side terminals No.I4–1 and No.I4–2, respectively,

then check if the motor runs normally.

C01RW020

Heater (X–6), Thermostat (X–5), Condenser

Fan (X–9) And Compressor (X–4) Relay

1.Disconnect relays and check for continuity and

resistance between relay terminals.

•For handling of these relays, refer to Heater Relay

in this section.

901RX071

Condenser Fan

1. Disconnect the condenser fan connector.

2. Connect the battery positive terminal to the

condens er fan side c onnector ter minal No.C24 -2

and negative to the No.C24-1.

3. Check that conden se r fan is r otat ing corre ctl y.

875RW010

Triple Pressure Switch (V6, A /T)

1. Disconnect the connector and check for continuity

between pressure s witch side connector terminals

(1) and (2).

2. Reco nnect the conne ct or to activate the A/C switch,

and check to see if there is continuity between the

chassis side connector ter minal (3) and (4) and the

fan operates.

875RX009

On-Vehicle Service

Power Transistor

874RY00029

EndOFCallout

Removal

1.Remove glove box.

2.Remove passenger knee bolster reinforcement.

3.Disconnect the power transistor connector.

4.Remove power transistor.

Installation

To install, follow the removal step in the reverse order.

Automatic Heater/Air Conditioner

Control Unit

865RW016

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove instrument lower cover.

3.Remove meter cluster assembly.

•Refer to Instrument Panel Assembly in Body

Structure section.

4. Remove the auto ma tic he ater /a ir c ond iti one r co ntrol

unit attaching screws.

5. Pull the automatic heater/air conditioner unit out and

disconnect the connectors.

Installation

To install, follow the removal step in the reverse order.

Legend

(1) Power Transistor

(2) Passenger knee bolster Reinforcement

(3) Power Transistor Connector

(4) Glove Box

Legend

(1) Connector

(2) Automatic Ai r Control Unit

(3) Meter Cluster Assembly

(4) Instrument Center Cluster

(5) Instrument Lower Cover

In Car Sensor

865RW014

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove the automatic heater/air conditioner control

unit.

•Refer to the automatic heater/air conditioner

control unit section.

3.Remove in car sensor.

Installation

To install, follow the removal step in the reverse order.

Ambient Sensor

875RY00022

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove radiator grille.

•Refer to Radiator Grille in Body Structure section.

3. Disconnect the ambient sensor connector.

4. Remove the amb ien t sensor.

Installation

To install, follow the removal step in the reverse order.

Legend

(1) In Car Sensor

(2) Automatic Air Control Unit

Legend

(1) Ambient Sensor

(2) Radiator Grille

Sun Sensor

865RW009

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove the sun sensor.

3.Disconnect the sun sensor connector.

Installation

To install, follow the removal step in the reverse order.

Electronic Thermostat

874RW027

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove evaporator assembly.

•Refer to Evaporator Assembly section.

3. Remove ele ct ronic thermo stat.

Installation

To install, follow the removal step in the reverse order.

Legend

(1) Sun Sensor

Legend

(1) Duct Sensor

(2) Evapolator Assembly

(3) Thermostat Assembly

Mode Actuator

860RW030

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove the A/T control unit.

•The connector shall remain connected.

3.Remove the actuator rod.

4.Remove the mode actuator.

Installation

To install, follow the remove step in the reverse order.

Mix Actuator

860RW033

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove the instrument panel assembly.

•Refer to the Instrument Panel Assembly in Body

Structure section.

3. Remove the instrument panel center cluster.

4. Remove the ac tuato r rod.

5. Remove the mix actuator.

Installation

To install, follow the remove step in the reverse order.

Legend

(1) A/T Control Unit

(2) Mode Actuator

(3) A ct uato r Rod

Legend

(1)Instrument Panel Assembly

(2) Instrument Panel Center Cluster

(3) Actuator Rod

(4) Mix Actuator

Intake Actuator

860RX018

EndOFCallout

Removal

1.Disconnect the battery ground cable.

2.Remove the blower assembly.

•Refer to Blower Assembly section.

3. Disconnect the intake actuator connector.

4. Remove the intake actuator.

Installation

To install, follo w the remove step in the reverse order.

Legend

(1) Evaporator Assembly

(2) Intake Actuator

(3) Intake Actuator Connector