AC- 1

AIR CONDITIONING SYSTEM

Page

.................................... AC-2 AIR CONDITIONING SYSTEM CIRCUIT ................. AC-4 SYSTEM COMPONENTS ..................................... AC-8 GENERAL DESCRIPTION ..................................... AC-9 SPECIAL TOOLS AND EQUIPMENT ...................... AC-14 TROUBLESHOOTING .......................................... AC-15
GENERAL INFORMATION Checking of Refrigeration System w i t h Manifold Gauge ...........................................

................................... REFRIGERATION SYSTEM ................................... Checking of Refrigerant Volume ....................... . Installation of Manifold Gauge Set .................... COMPRESSOR ................................................... RECEIVER ......................................................... CONDENSER ..................................................... CONDENSER FAN MOTORS ................................ HEATER BLOWER RESISTOR ............................... RELAYS ............................................................ PRESSURE SWITCH ........................................... WATER TEMPERATURE SWITCH ......................... COOLING UNIT .................................................. Evaporator ..................................................... REFRIGERANT LINES .......................................... THERMISTOR .................................................... A/C CONTROL PANEL ASSEMBLY ....................... AMPLIFIERS ...................................................... SENSORS .......................................................... FUNCTIONAL TEST AND ADJUSTMENT ..............
ON-VEHICLE INSPECTION

AC-2

AIR CONDITIONING SYSTEM - General Information

GENERAL INFORMATION
ELECTRICAL PARTS
Before removing and inspecting the electrical parts, set the ignition switch t o the LOCK position and disconnect the negative ( - ) terminal cable from the battery.

CAUTION: Work must not be started until after at least 20 seconds or longer from the time the negative (-1 terminal cable is disconnected. SRS

AIRBAG SYSTEM
Failure t o carry out service operations in the correct sequence could cause the airbag system t o deploy, possibly leading t o a serious accident. When removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer t o the precautionary notices in the AB section before performing the operation.

COOLING SYSTEM
1. WHEN HANDLING REFRIGERANT (R-12), FOLLOWING PRECAUTIONS MUST BE OBSERVED;
(a) Do not handle refrigerant in an enclosed area or near an open flame. Be careful that liquid refrigerant does not get in your eyes or on your skin.

(b) Always wear eye protection.

(c)

If liquid refrigerant gets in your eyes or on your skin; Do not rub. Wash the area w i t h lots of cool water. Apply clean petroleum jelly t o the skin. Go immediately t o a physician or hospital for professional treatment. Do not attempt t o treat yourself.

2. WHEN REPLACING PARTS IN REFRIGERANT LINE;

(a) (b)
(c)

Discharge the refrigerant in the line slowly before replacement. Insert a plug immediately in disconnected parts t o prevent the entry of moisture and dust. DO not leave a new condenser or receiver, etc., lying around w i t h the plug removed.

AIR CONDITIONING SYSTEM - General Information

AC-3

( d ) Discharge the refrigerant f r o m the charging valve before installing a n e w compressor.

Charging Valve

If the refrigerant is n o t discharged first, compressor oil will spray o u t w i t h the refrigerant gas w h e n t h e plug is removed. (e) D o n o t use a torch for tube bending or lengthening operations.

If tubes are heated w i t h a torch, a layer of oxidation forms inside t h e tube, causing the same kind o f trouble as an accumulation of dust.

3.
Below 4 0 " ~

WHEN HANDLING REFRIGERANT CONTAINER (SERVICE CAN);

(a) The container m u s t never be heated. (b) (c) Containers m u s t be kept below 40C (104OF) If warming a service can w i t h h o t water, be careful t h a t the valve o n t o p of the service can is never immersed i n the water, as the water m a y permeate the refrigerant cycle. Empty service cans m u s t never be re-used.

Wrong

Correct

(d)

4.

WHEN A/C IS ON AND REFRIGERANT GAS IS BEING REPLENISHED;

(a) If there is n o t enough refrigerant gas in the refrigera n t cycle, oil lubrication will be insufficient and compressor burnout may occur, so take care t o avoid this. If t h e valve o n t h e high pressure side is opened, refrigerant f l o w s i n the reverse direction and could cause t h e service can t o rupture, so open and close t h e valve o n the l o w pressure side only. If the service can is inverted and refrigerant is loaded i n a liquid state, the liquid is compressed and causes the compressor t o break down, so the refrigerant must be i n a gaseous state. Be careful n o t t o load too much refrigerant gas, as this causes trouble such as inadequate cooling, poor fuel economy, engine overheating, etc.

(b)

(c)

(dl

5. WHEN USING GAS-CYLINDER TYPE GAS LEAK TESTER;

(a) A s a naked flame is used, first make sure t h a t there are n o flammable substances nearby before using it.

( b ) Be careful, as a poisonous gas is produced w h e n refrigerant gas comes in contact w i t h heated parts.

AC-4

AIR CONDITIONING SYSTEM - Air Conditioning System Circuit

AIR CONDITIONING SYSTEM CIRCUIT

7M-GTE Engine

AIR CONDITIONING SYSTEM - Air Conditioning System Circuit

AC-5

Fan Motor

Fan Motor
No 2

Ambient S e n s o r

12 HR

27 ST25 S T *

22 : -4H SG

B FACE
7

WL

19'00T 16 6 DEF F/C

Panel Assembly

@ ~ ~ e c lC i onnectar

@ ~ e l a y Bcx

AC-6

AIR CONDITIONING SYSTEM - Air Conditioning System Circuit

AIR CONDITIONING SYSTEM CIRCUIT (Cont'd)

7M-GE Engine

AIR CONDITIONING SYSTEM - Air Conditioning System Circuit

AC-7

AC-8

AIR CONDITIONING SYSTEM - System Components

SYSTEM COMPONENTS

Cooling Unit

High Pressure Switch

7M-GT-E E/G Condenser 1 Ambient Sensor

Condenser Fan No. 3

Receiver

' - 4 7

in-car Sensor

Solar Sensor

Fitting size 0.31 in. Tube 0.50 in. Tube 0.62 in. Tube "Ited
Type

Torque 135 (10. 13) 225 (16, 22) 325 (24,32) 250 (18, 25) 250 (18, 25)

Control Servo Motor

.\

(For Compressor) (For Condenser)

AC1708

AIR CONDITIONING SYSTEM

General Description

AC-9

Discharge Port

Suction Port

GENERAL DESCRIPTION
REFRIGERATION CYCLE
1.
The compressor discharges high temperature and high pressure refrigerant containing t h e heat absorbed f r o m t h e evaporator plus the heat created b y the compressor in a discharge stroke. This gaseous refrigerant f l o w s into the condenser. In the condenser, t h e gaseous refrigerant condenses into liquid refrigerant. This liquid refrigerant f l o w s into t h e receiver w h i c h stores and filters the liquid refrigerant till t h e evaporator requires the refrigerant.

2.

3.

4.

The liquid refrigerant is changed b y the expansion valve into a l o w temperature, l o w pressure liquid and gaseous mixture. This cold and foggy refrigerant f l o w s t o the evaporator. Vaporizing the liquid i n t h e evaporator, the heat f r o m the w a r m air stream passing through t h e evaporator core is transferred t o t h e refrigerant. All t h e liquid is changed into the gaseous refrigerant in the evaporator and only heat-laden gaseous refrigerant is d r a w n into t h e compressor. Then t h e process is repeated again.

5.

Blower

E V A P O R A T O R . In whlch
released r e f r l g e r a n t expands and flows through t h e evapor a t o r tubes It then removes evaporator cores, causlng a drop In pressure and consequent drop In temperature

heat f r o m t h e aw blow~ng across t h e flns and tubes. and evaporates, causlng t h e temperature ~ n s ~ dte he car t o be gradually lowered

t
J , COMPRESSOR
draws o f f

gaseous refrlgerant from t h e

evaporator and compresses ~t Thls causes the r e f r ~ g erant gas temperature and pressure t o rlse rapldly

I\
The

I\

f a CONDENSER,
hquld

through whlch t h e heated refrlgerant

7
J

gas glves o f f heat t o t h e englne coollng alr

r e h g e r a n t gas cools o f f and once agaln becomes a

i-

I \
removes any

2, RECEIVER

t r a c e s of rnolsture and

fllters out d r t In t h e system It also serves as a reservou f o r excess refrlgerant

AC-10

AIR CONDITIONING SYSTEM - General Description

1.

PRINCIPLE OF A/C ELECTRICAL CIRCUIT

Ignition Switch (ACC)

A/C Fuse

A/C Switch

1
T

lqnition &itch ( l G ON)

Blower >Motor Dual Pressure A/C Switch Amolif ier Blower Switch

Battery

Thermistor

@ - - TEMP. ----

2. HOW IS THE MAGNETIC CLUTCH ENERGIZED?

The general process until t h e magnetic clutch is energized is s h o w n below.

8
($

1 lgnition S w i t c h "ON"

2 Blower S w i t c h "ON" AIC S w i t c h "ON"

--

Heater Relay "ON"

(Blower M o t o r "RUN") (AIC A m p . Main Power Supply)

AIC Amplifier "ON"

? 9
h

4 Dual Pressure S w i t c h "ON": Refrigerant Condition ( 2 . 1 k g l c m 2 ( 3 0 psi, 2 0 6 kPa) less than 2 7 k g / c m 2 ( 3 8 4 psi, 2 , 6 4 8 kPa))
Thermistor supplies temperature signal of evaporator t o AIC amplifier. E/G Idle-up

I
7 9

6 VSV "ON"

7 Magnetic Clutch Relay "ON"

8 Temperature Sensor "ON": Temperature of Temperature Sensor is less than 1 8 0 C ( 3 5 6 F ) . Magnetic Clutch " O N f r

10 Revolution Detecting Sensor supplies RPM signal of compressor t o AIC amplifier.

If compressor is n o t locked, magnetic clutch is continuously energized.

AIR CONDITIONING SYSTEM - General Description

AC-11

PRINCIPLE OF AUTOMATIC AIR CONDITIONING SYSTEM

1. WHAT'S AUTOMATIC AIR CONDITIONING SYSTEM?
Automatic air conditioning system automatically controls the interior room temperature, the blower speed, the air vent mode, etc, according t o setting temperature of hope. It keeps good air condition at all seasons.

2. HOW FUNCTIONS DOES AUTOMATIC AIR CONDITIONING SYSTEM HAVE?

Automatic air conditioning system has four main functions as follows.

( 1 ) Interior Room Temperature Control System & Blower Speed Control System

- - - - - Max. Cool Position

Block Water Valve

Water Valve Diaphram

Heater Relay lower Motor

There is water temperature switch under heater core. * System Amplifier is built in AIC panel control assembly.

AC-12

AIR CONDITIONING SYSTEM - General Description

lnterior Room Temperature Control System & Blower Speed Control System (Cont'd)

( ; ; ; )

Heater Control Assembly

I
1

1 Temp.
Resistor
Amplifier

7 1

I
Servo

(a)

lnterior Room Temperature Control System For example, n o w interior room temperature is rising.

In-Car Sensor

Sensor
Sensor

Resistance value of in-car sensor decreases. Voltage of V i decreases. System amplifier rotates a motor in air m i x control servo motor

Air m i x control servo motor shaft moves t o w a r d s max. cool side. Resistance value of potentiometer increases. Voltage of V i increases in original condition. Air m i x control servo motor shaft stops.

* W h e n air m i x control servo m o t o r shaft moves at m a x . cool position, water valve VSV is o f f . A n d
water valve is close. A s aforeside, according t o moving of air m i x control servo motor, blower speed is controlled.

( b ) Blower Speed Control System

Warm-up S y s t e m

condition:

Blower S w i t c h

/AUTO\position.

Air M o d e S w i t c h is

v l
+

or

position

This system has a function that t h e blower unit b l o w s cold air t o your feet.
Water Temperature Less than 20C (68F) 20C - 40C (68" F - 104" F ) Water Temperature Switch 20C ( 6 8 " ~Switch ) 20C (68F) Switch ~ o ' c ( I o ~ ' F ) switch OFF ON OFF ON Blower Motor OFF Low Only

+
-+

ore than 4 0 ' ~(104F)

40C (104F) Switch

Automatic Control

AIR CONDITIONING SYSTEM - General Description

(2) Air V e n t M o d e Control S y s t e m & RECIRCIFRESH Control System
OutsideAir RECIRC/FRESH Control Damper Air Mix Control Damper

AC-13

Blower Motor Cool Air By-Pass Control Damper Cool Air By-Pass Duct Air Flow Control Damper

Side Ventilator

Center Ventilator

side Ventilator

~ o h e Ventilator r
AC1371

(a)

Air V e n t M o d e Control S y s t e m Air-flow changes as follows. Air m i x control servo motor shaft moves. Program s w i t c h is changed. (Signal is transmitted t o relay b o x ) Relay box rotates a motor in air vent mode control servo motor. Servo motor links move. Each damper moves. A s aforeside, t h e air f l o w s as s h o w n l e f t illustration.

VENT

BI-LEVEL

HEAT

23 Cool Air

DEF Warm Air

AC-14

AIR CONDITIONING SYSTEM

General Description, Special Tools and Equipment, S S M ( S ~ e c i aService l Materials)

RECIRC/FRESH Control Dampers RECIRCIFRESH :rol Servo

( b ) RECIRCIFRESH Control S y s t e m RECIRC and FRESH changes as follows.

@ @
@)

RECIRC/FRESH control switch is pushed. System amplifier rotates a motor i n RECIRCIFRESH control servo motor. RECIRCIFRESH control dampers moves as s h o w n left illustration.

SPECIAL TOOLS AND EQUIPMENT

Tool
Manifold gauge set Ohmmeter Voltage meter Ammeter Magnetic clutch stopper Magnetic clutch remover Snap ring pliers (External type)

SST NO.

Use
To evacuate and charge system To perform electrical diagnosis T o perform electrical diagnosis T o perform electrical diagnosis T o remove and install pressure plate T o remove pressure plate To remove and install rotor and stator

SSM (SPECIAL SERVICE MATERIALS)

I
DENSOOIL 6,

Part Name

Part No.

Use etc.
Compressor

07 1 17 - 6 8 0 4 0

SUNlSO No.5GS or qeuivalent

1
-

Fuses

/ AC-4,6
AC-4,6

Main Relay

Wiring Connection
-. -

AC-4,6 AC-17 AC-3 1

Refrigerant in System 3 4 Heater Relay Blower Motor

-- -

Blower Resistor Water Temp. SW 20c (68OF)

-

AC-30

+AC-32 Water Temp. SW 40c ( 1 0 4 ~ ~ ) Dual Pressure Switch High Pressure Switch

I Magnetic Clutch
A/C Amplifier

I AC-22

Clutch Relay

I compressor

1 Condenser
Receiver

I AC-22

Evaporator Expansion Valve

-

/ Thermistor I Drive Belt

A/C Switch

/ AC-37 I AC-20
AC-38

Blower Switch Temp. Control System Air Vent Mode Switch RECIF RE Control Switch In-Car Sensor Ambient Sensor Solar Sensor Potentiometer Program Switch
---

Air Mix Control Servo Air Vent Mode Control Servo REC/F RE Control Servo System Amplifier Water Valve VSV Water Valve Diaphram Water Valve Leak in System Excessive Moisture in System Air in System Air or Excessive Compressor Oil in System Air Inlet Blocked Air Leakage from Cooling Unit or Air Duct Servo Motor Links

AIR CONDITIONING SYSTEM - Troubleshooting

AC-17

Checking of Refrigeration System with Manifold Gauge

This is a method in which the trouble is located by using a manifold gauge. Read the manifold gauge pressure with the following conditions are established: (a) Temperature at the air inlet is 3 0 - 35OC (86 - 95OF) (b) Engine running at 1,500 rpm
(c)

Blower fan speed switch set at high speed It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.

(d) Temperature control lever set at cool side HINT:

NORMALLY FUNCTIONING REFRIGERATION SYSTEM

Gauge reading:

Low pressure side

1 . 5 - 2 . 0 kglcm2 ( 2 1 - 2 8 psi, 1 4 7 - 1 9 6 kPa) High pressure side 1 4 . 5 - 1 5 . 0 kg/cm2 ( 2 0 6 - 2 1 3 psi, 1 , 4 2 2 - 1.47 1 kPa) Each pointer of manifold gauge point to position A

Trouble Moisture present in refrigeration system

Condition Periodically cools and then fails to cool Insufficient cooling Insufficient cooling

Position of Pointers Between Aand B

1 1

Insufficient refrigerant Poor circulation of refrigerant

1
1

Refrigerant overcharge or insufficient cooling of condenser Expansion valve improperly mounted, heat sensing tube defective (opens too wide) Air present in refrigeration system Refrigerant does not circulate

Does not cool sufficiently

lnsufficient cooling Does not cool sufficiently Does not cool (Cools from time to time in some cases) Does not cool Low is D High is [Y

1 1
7

l nsufficient compression

AC-18

AIR CONDITIONING SYSTEM - Troubleshooting

Checking of Refrigeration System with Manifold Gauge (Cont'd)

No. Symptom seen in refrigeration system During operation, pressure at low pressure side sometimes becomes a vacuum and sometimes normal Probable cause Moisture entered in refrigeration system freezes at expansion valve orifice and temporarily stops cycle, but normal state is restored after a time when the ice melts Diagnosis Drier in oversaturated state Remedy (1) Replace receiver and drier (2) Remove moisture in cycle through repeated vacuum purging (3) Charge refrigerant t o proper amount

3.
Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Insufficient refrigerant in system

; Pressure low at both low

and high pressure sides

Gas leakage at some place in refrigeration system

(1) Check with leak de. tector and repair (2) Charge refrigerant to proper amount

.1
2 Bubbles seen in sight I glass I lnsufficient cooling performance
--

Refrigerant leaking

Pressure low at both low and high pressure sides 3

I

Refr~gerant flow obstructed by dirt in recelver

Receiver clogged

Replace receiver

Frost on tubes from receiver to unit

I

Pressure too high a t both low and high pressure sides

Unable to develop sufficient performance due to excessive refrigerant in system Condenser cooling insufficient

Excess refrigerant in cycle + refrigerant overcharged

Condenser cooling insufficient + condenser fins clogged or fan motor faulty

Clean condenser Check fan motor operation If (1) and (2) are normal, check refrigerant amount

HINT: Vent out refrigerant through gauge manifold low pressure side by gradually opening valve.
I

1 Pressure too high a t both

low and high pressure sides Frost or large amount of dew on piping a t low pressure side Pressure too high at both low and high pressure sides

Trouble in expansion valve or heat sensing tube not installed correctly Refrigerant flow out

Excessive refrigerant in low pressure piping

1
Expansion valve opened too wide

( 1 ) Check heat sensing tube installed condition

(2) I f (1) is normal, t e s t expansion valve in unit (3) Replace if defective ( 1) Replace receiver and drier (2) Check compressor oil to see if dirty or insufficient (3) Vacuum purge and charge new refrigerant

Air entered refrigeration system

Air present in refrigeration system

J
lnsufficient vacuum purging

"Note a t No. 6 These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging.

AIR CONDITIONING SYSTEM - Troubleshootina

AC-19

Checking of Refrigeration System with Manifold Gauge (Cont'd)

Symptom seen in refrigeration system Vacuum indicated at low pressure side, very low pressure indicated at high pressure side Probable cause Refrigerant flow obstructed by moisture or dirt in refrigerant freezing or adhering to expansion valve orifice Refrigerant flow obstructed by gas leakage from expansion valve heat sensing tube Diagnosis Expansion valve orifice clogged Remedy Allow t o stand for soml time and then restart operation t o determine if trouble is caused by moisture or dirt. If caused by moisture refer t o procedures Stel 2 on page AC-18. If caused by dirt, remoj expansion valve and cle off dirt by blowing wit1 air. I f unable to removl dirt, replace valve. Vacuum purge and chat new refrigerant to prop amount. For gas leakage from ht sensing tube, replace ex pansion valve. Pressure too high at low pressure side Pressure too low a t high pressure side Internal leak in compres sor Compression defective Repair or replace compressor

4
Refrigerant does not flow

Frost or dew seen on piping before and after receiver and drier or expansion valve

4
Valve leaking or broken sliding parts (Piston, cylinder, gasket, etc.) broken

Discharging of Refrigeration System Evacuating and Charging of Refrigeration System

(See Air Conditioning Fundamentals and Repairs Pub. No. 36950E3

AC-20

AIR CONDITIONING SYSTEM - On-Vehicle Inspection

ON-VEHICLE INSPECTION
CHECK CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, clean them with pressurized water.

CAUTION:
CORRECT WRONG WRONG

Be careful not t o damage the fins.

MAKE SURE THAT DRIVE BELT IS INSTALLED CORRECTLY

After installing the drive belt, check that i t fits properly in the ribbed grooves.

CHECK DRIVE BELT TENSION

Nippondenso Borroughs

Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG-20(95506-00020) or No.BT-33-73F Borroughs

Drive belt tension: New belt 1 6 0 Used belt 1 0 5

+ 2 0 Ib + 1 0 1b

HINT: "New belt" refers t o a belt which has been used less than 5 minutes on a running engine. "Used belt" refers t o a belt which has been used on a running engine for 5 minutes or more.

START ENGINE TURN ON A/C SWITCH

Check that the A/C operates at each. position of the blower switch.

CHECK MAGNETIC CLUTCH OPERATION

If magnetic clutch does not engage, check the A/C fuse.

CHECK THAT IDLE INCREASES

When the magnetic clutch engages, engine revolution should increase.

Standard idle-up rpm:

M I T (N range) 7M-GTE EIG 7M-GE EIG 9 0 0 rpm 9 0 0 rpm A I T (D range) 7 0 0 rpm 6 5 0 rpm

CHECK CONDENSER FAN MOTOR ROTATES CHECK AMOUNT OF REFRIGERANT

If you can see bubbles in the sight glass, additional refrigerant is needed. (See page AC-21)

10. IF NO COOLING OR IT IS INSUFFICIENT, INSPECT FOR LEAKAGE

Using a gas leak detector, inspect each component of the refrigeration system.

AIR CONDITIONING SYSTEM - Refrigeration System

AC-21

REFRIGERATION SYSTEM Checking of Refrigerant Volume

1. 2.

RUN ENGINE AT APPROX. 2,000 RPM OPERATE AIR CONDITIONER AT MAXIMUM COOLING FOR A FEW MINUTES CHECK AMOUNT OF REFRIGERANT
Observe the sight glass on the receiver.

3.

l tem

Symptom Bubbles present in sight glass No bubbles present in sight glass No temperature difference between compressor inlet and outlet Temperature between compressor inlet and outlet is noticeably different Immediately after the air conditioner is turned off, refrigerant in sight glass stays clear When the air conditioner is turned off, refrigerant foams and then stays clear

Amount of refrigerant Insufficient Empty, proper or t o o much Empty or nearly empty

Remedy Check for leak w i t h gas leak detector Refer t o items 3 and 4 Evacuate and charge system. Then check for leak with gas leak detector Refer to items 5 and 6

Proper or too much

Too much

Discharge the excess refrigerant t o specified amount

Proper

Installation of Manifold Gauge Set

i i g h Pressure 2harging Valve Low Pressure Charging Valve

1.

CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET INSTALL CHARGING HOSES OF GAUGE SET TO CHARGING VALVES
Connect the low pressure hose (Blue) t o the l o w pressure charging valve and the high pressure hose (Red)t o the high pressure charging valve. Tighten the hose nuts by hand.

2.

HINT: Do not apply compressor oil t o the seat of the connection.

AC-22

AIR CONDITIONING SYSTEM

Compressor

COMPRESSOR
ON-VEHICLE INSPECTION
1. INSTALL MANIFOLD GAUGE SET (See page AC-21)

2. 3.

RUN ENGINE AT APPROX. 1 , 5 0 0 RPM CHECK COMPRESSOR FOR FOLLOWING:

(a) (b)
(c)

High pressure gauge reading is not lower and l o w pressure gauge reading is n o t higher than normal. Metallic sound Leakage f r o m shaft seal

If defects are found, repair the compressor

4.

CHECK MAGNETIC CLUTCH

(a) Inspect the pressure plate and the rotor for signs of oil. ( b ) Check the clutch bearings for noise and grease leakage.

(c)

Using an ohmmeter, measure the resistance of the stator coil between the clutch lead wire and ground.

Standard resistance:

2 . 7 - 3 . 1 Q at 2 0 C (68OF)

If resistance value is n o t as specified, replace t h e coil.

(d)

Connect the positive ( + ) lead f r o m the battery t o terminal 1, check that the magnetic clutch is energized.

If magnetic clutch is not energized, replace the coil.

NOTICE: Do not short the positive ( + ) lead wire on the vehicle by applying battery voltage.

AIR CONDITIONING SYSTEM - Compressor

AC-23

Compressor

Drive Belt

Bolt

kg-cm (ft-lb,

~4 : Spec~f~e torque d
REMOVAL OF COMPRESSOR

AC1814

RUN ENGINE AT IDLE SPEED WITH AIR CONDITIONING ON FOR 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE AND POSITIVE CABLE FROM BATTERY REMOVE BATTERY DISCONNECT CLUTCH LEAD WIRE FROM WIRING HARNESS DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM DISCONNECT TWO HOSES FROM COMPRESSOR SERVICE VALVES
Cap t h e open fitting immediately t o keep moisture o u t of the system.

REMOVE COMPRESSOR
(a)
Loosen the drive belt.

(b) Remove the compressor mounting bolts and the compressor.

AC-24

AIR CONDITIONING SYSTEM - Compressor

Bolt

I
Pressure Plate

Snap Ring

Non-reusable part

AC1812

DISASSEMBLY OF MAGNETIC CLUTCH

1.

REMOVE PRESSURE PLATE (a) Using SST and socket, remove the shaft bolt.
SST 071 12-76060

(b)

Install SST t o the pressure plate.

SST 071 12-66040

(c) Using SST and the socket, remove the pressure plate.
SST 071 12-76060

AIR CONDITIONING SYSTEM - Compressor

(dl Remove the shims from the pressure plate.

AC-25

2.

REMOVE ROTOR
(a) Using SST, remove the snap ring

SST 07 1 14-84020

(b) Using a plastic hammer, tap the rotor off the shaft.

NOTICE: Be careful not to damage the pulley when tapping on the rotor.

3.

REMOVE STATOR
(a) Disconnect the stator lead wire from the compressor housing.

(b) Using SST, remove the snap ring.

SST 07 1 14-84020

AC-26

AIR CONDITIONING SYSTEM - Compressor

(c) Remove the stator.

ASSEMBLY OF MAGNETIC CLUTCH

1.

INSTALL STATOR
(a) Install the stator o n the compressor.

(b)

Using SST, install the n e w snap ring.

SST 07 1 14-84020

(c)

Connect the stator lead wires t o the compressor housing.

2.

INSTALL ROTOR
(a) Install the rotor on the compressor shaft. Using SST, install the n e w snap ring. (b)

SST

SST 07 1 14-84020

AIR CONDITIONING SYSTEM - Compressor

AC-27

3.

INSTALL PRESSURE PLATE (a) Install t h e shims t o the pressure plate.

(b)

Using SST and torque wrench, install the shaft bolt. 1 4 0 kg-cm ( 1 0 ft-lb, 1 4 Nmm)

SST 07 1 12-76060
Torque:

4.

CHECK CLEARANCE OF MAGNETIC CLUTCH Check the clearance between the pressure plate and rotor using thickness gauge. Standard clearance: 0.5

+ 0.15 m m (0.020 + 0.006 in.)

If t h e clearance is n o t w i t h i n tolerance, change the number o f shims t o obtain the standard clearance.
Thickness Gauge

INSTALLATION OF COMPRESSOR
(See page AC-23) 1. INSTALL COMPRESSOR WlTH FOUR MOUNTING BOLTS Torque: 2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m)

2.

INSTALL DRIVE BELT (See steps 2 and 3 on page AC-20) CONNECT TWO HOSES TO COMPRESSOR SERVICE VALVES Torque: Discharge line Suction line 2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m) 2 5 0 kg-cm ( 1 8 ft-lb, 2 5 Nmm)

3.

4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS

5. 6. 7. PLACE BATTERY CONNECT NEGATIVE CABLE TO BATTERY EVACUATE AIR FROM AIR CONDITIONING SYSTEM REFRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 6 5 0 - 7 5 0 g (1.4

8. CHARGE AIR CONDITIONING SYSTEM WlTH

1.7 Ib)

AC-28

AIR CONDITIONING SYSTEM - Receiver. Condenser

RECEIVER
(See page AC-8)

ON-VEHICLE INSPECTION
CHECK SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR LEAKAGE
Use a gas leak detector. Repair as necessary.

REMOVAL OF RECEIVER
1. 2. DISCHARGE REFRIGERATION SYSTEM DISCONNECT TWO LIQUID TUBES FROM RECEIVER
HINT: Cap the open fittings immediately t o keep moisture out of the system.

3. REMOVE RECEIVER FROM RECEIVER HOLDER

INSTALLATION OF RECEIVER
1. INSTALL RECEIVER IN RECEIVER HOLDER
HINT: Do not remove the blind plugs until ready for connection.

2. CONNECT TWO LIQUID TUBES TO RECEIVER

Torque: 5 5 kg-cm ( 4 ft-lb, 5 N - m )

3.

IF RECEIVER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 2 0 cc (0.7 fl.oz.1 Compressor oil: DENSOOIL 6, SUNlSO No.5GS or equivalent

4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM

5. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 6 5 0 - 7 5 0 g (1.4 - 1.7 Ibl

CONDENSER
(See page AC-8)

ON-VEHICLE INSPECTION
1. CHECK CONDENSER FINS FOR BLOCKAGE OR DAMAGE
If the fins are clogged, wash them with water and dry with compressed air.

NOTICE:

Be careful not t o damage the fins.

If the fins are bent, straighten them with a screwdriver or pliers.

2.

CHECK CONDENSER FITTINGS FOR LEAKAGE

Repair as necessary.

REMOVAL OF CONDENSER
1. DISCHARGE REFRIGERATION SYSTEM

AIR CONDITIONING SYSTEM - Condenser 2. REMOVE FOLLOWING COMPONENTS:

(a) Hood lock brace (b) Center brace w i t h horn
(c) Washer tank w i t h bracket

AC-29

(d) (e) (f)

Engine under cover (7M-GTE E/G only) Intercooler (7M-GTE E/G only) Oilcooler (7M-GTE E/G only)

(g) Condenser fan (7M-GTE E/G and AIT model only)

3.
7M-GT EIG Onlv

DISCONNECT DISCHARGE HOSE AND SUCTION HOSE DISCONNECT LIQUID TUBE AND SUCTION TUBE
HINT: Cap the open fittings immediately t o keep moisture out of the system.

\ \

4.

5.

REMOVE CONDENSER
Remove t w o nuts and t w o bolts.

l nte

INSTALLATION OF CONDENSER
1.

INSTALL CONDENSER (See page AC-8) CONNECT DISCHARGE HOSE AND SUCTION HOSE Torque: Discharge hose Suction hose 2 5 0 kg-cm ( 1 8 ft-lb, 2 5 N.m) 3 2 5 kg-cm ( 2 4 ft-lb, 3 2 N - m )

2.

3.

CONNECT LIQUID TUBE AND SUCTION TUBE Torque: Liquid tube Suction tube 1 3 5 kg-cm ( 1 0 ft-lb, 1 3 N - m ) 3 2 5 kg-cm ( 2 4 ft-lb, 3 2 N - m )

(7M-GT EIG and

4.

INSTALL FOLLOWING COMPONENTS:

(a) Hood lock brace (b) Center brace w i t h horn
(c) Washer tank w i t h bracket

(d) Engine under cover (7M-GTE E/G only) (e) (f) Intercooler (7M-GTE E/G only) Oilcoolr (7M-GTE E/G only)

(g) Condenser fan (7M-GTE EIG and AIT model only)

5.

IF CONDENSER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 4 0 - 5 0 cc (1.4 - 1.7 fl.oz.1 Compressor oil: DENSOOIL 6, SUNISO No.5GS or equivalent

6.

EVACUATE AIR FROM AIR CONDITIONING SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 6 5 0 - 7 5 0 g (1.4 - 1.7 Ib)

7.

AC-30 AIR CONDITIONING SYSTEM - Condenser Fan Motors, Heater Blower Resistor, Relays

CONDENSER FAN MOTORS

INSPECTION OF CONDENSER FAN MOTORS
1. DISCONNECT NEGATIVE CABLE FROM BATTERY

2. DISCONNECT CONNECTOR OF FAN MOTOR

3. CHECK FAN MOTOR
(a) Using t h e wire harness, apply battery voltage ( 1 2V) t o the connector.

7M-GTE E/G and A/T Model Only

( b ) Confirm smooth rotation of the motor within the specified current f l o w .

Standard current: Fan motor No.1 and No.2 0.8 A (7M-GTE E/G and M / T model) 8.0 0.7 A 7M-GTE E/G and AIT model or 6.7 (7M-GE EIG model

+ +

Fan motor No.3 6.7 0.7 A

(7M-GTE E/G and A/T model only)

If defective, replace the motor.

4.

CONNECT CONNECTOR OF FAN MOTOR

5. CONNECT NEGATIVE CABLE TO BATTERY

HEATER BLOWER RESISTOR

INSPECTION OF RESISTOR
INSPECT RESISTOR RESISTANCE
Check t h a t there is continuity between terminals 4 and 6.

If there is n o continuity, replace t h e resistor.

RELAYS
INSPECTION OF RELAYS
1. REMOVE RELAYS

AIR CONDITIONING SYSTEM - Relays

AC-31

fl
Fan Relay No. 3

INSPECT RELAY CONTINUITY

(Magnetic Clutch Relay)
Clutch

ci t , !

(Fan Relay No. I ) (Fan Relay No.2 ; 7M-GTE EIG and A / T Model)
: Continuity

Fan Relay No. 1 & Fan Relay No. 2

BE0908

I
I

Constant Apply battery voltage t o terminal 2 and 4

I
I

I+I0
I I
I

(Fan Relay N o . 3 ; 7M-GTE EIG and A / T Model)

Terminals Condition Constant Apply battery voltage to terminal 1 and 2

I
(a) (b)
(c)

No continuity

If continuity is n o t as specified, replace the relay (Heater Relay) Check that there is continuity between terminals 1 and 3. Check that there is continuity between terminals 2 and 4. Check that there is n o continuity between terminals 4 and 5.

If continuity is n o t as specified, replace the relay

Continuity

3.

INSPECT RELAY OPERATION

(Heater Relay) (a) Apply battery voltage t o terminals 1 and 3. ( b ) Check that there is continuity between terminals 4 and 5.
(c)

Check that there is n o continuity between terminals 2 and 4.

If operation is n o t as specified, replace the relay.

AC-32

AIR CONDITIONING SYSTEM - Pressure S w i t c h , W a t e r T e m p e r a t u r e S w i t c h

PRESSURE SWITCH
(See page AC-8)

ON-VEHICLE INSPECTION
1.

DISCONNECT CONNECTOR OF PRESSURE SWITCH INSPECT PRESSURE SWITCH

(a) (b) (c) Install t h e m a n i f o l d gauge set. (See page A C - 2 1 ) Observe t h e gauge reading. C h e c k t h e c o n t i n u i t y b e t w e e n t w o terminals o f t h e pressure s w i t c h s h o w n i n t h e b e l o w .

2.

Dual Pressure Switch

2.1 kg/cm2 (30 psi, 206 kPa) (Continuity)

27 kg/cm2 (384 psi, 2,648 kPa)

OFF
(NO continuity)

2.35 kglcm2 (33 psi, 230 kPa)

OFF 21.0 kg/cm2 (299 psi, 2,059 kPa)

If defective, replace t h e pressure s w i t c h .

WATER TEMPERATURE SWITCH

HINT: T h e w a t e r t e m p e r a t u r e s w i t c h i s u n d e r t h e heater radiator.

INSPECTION OF WATER TEMPERATURE SWITCH NO. 1

'

Heater Unit

INSPECT SWITCH CONTINUITY

15C ( 5 9 O ~or ) below

OFF

L . J
35C 45C ON

1
0

NO

continuity

I
0

25C ( 7 7 " ~or ) more 45C (11 3 " ~ or ) more

-1

OFF

AIR CONDITIONING SYSTEM - Water Temperature Switch, Cooling Unit

7M-GTE E/G Onl

AC-33

INSPECTION OF WATER TEMPERATURE SWITCH N0.2, N0.3 (7M-GTE EIG MODEL ONLY)
INSPECT SWITCH CONTINUITY
Inspect the switch continuity between each terminal at each water temperature.

7M-GTE E/G Only Water Temp. S W No. 2 Water Temp. SW No. 3

t
1 12C (234F)

OFF

If defective, replace the switch.

COOLING UNlT
(See page AC-8)

ON-VEHICLE INSPECTION OF EXPANSION VALVE

1.

CHECK QUANTITY OF REFRIGERANT GAS DURING REFRIGERATION CYCLE INSTALL MANIFOLD GAUGE SET (See page AC-2 1) RUN ENGINE
Run the engine at 2,000 rpm for at least 5 minutes.

2.
3.

4.

CHECK EXPANSION VALVE If the expansion valve is clogged, the l o w pressure reading will drop t o 0 kgicm2 (0 psi, 0 kPa), otherwise i t is OK.

REMOVAL OF COOLING UNlT

1.

DISCONNECT NEGATIVE CABLE FROM BATTERY DISCHARGE REFRIGERATION SYSTEM REMOVE CHARCOAL CANISTER WITH BRACKET DISCONNECT SUCTION TUBE FROM COOLING UNlT OUTLET FITTING DISCONNECT LIQUID TUBE FROM COOLING UNlT INLET FITTING
HINT: Cap the open fittings immediately t o keep moisture out of the system.

2.
3.
4.

5.

AC-34
I

AIR CONDITIONING SYSTEM - Cooling U n i t

1
Cooling Unit

6.

REMOVE GROMMETS FROM INLET AND OUTLET FITTINGS REMOVE GLOVE BOX AND UNDER COVER REMOVE GLOVE BOX COVER AND REINFORCEMENT REMOVE EFI AND A.B.S. COMPUTER

7.
8. 9.

10. DISCONNECT CONNECTOR

ncoe.90

11. REMOVE COOLING UNlT

Remove four screws and three nuts

DISASSEMBLY OF COOLING UNlT

Upper Unit Case

3r

Drain

7
Case Wire Harness

1.

REMOVE LOWER AND UPPER CASE

(a)
(c)

Remove connector of thermistor f r o m unit case. Remove four screws. Remove upper unit case. Remove thermistor w i t h thermistor holder. Remove lower unit case.

(b) Remove three clips.

(d) (e) (f)

AIR CONDITIONING SYSTEM - Cooling Unit

Hexagonal

AC-35

2.

REMOVE EXPANSION VALVE

(a) (b) Remove the packing and heat sensing tube from suction and liquid tubes. Remove the expansion valve f r o m the evaporator.

Evaporator
INSPECTION OF EVAPORATOR
1.

CHECK EVAPORATOR FINS FOR BLOCKAGE

If the fins are clogged, clean them w i t h compressed air.

NOTICE:

Never use water t o clean the evaporator.

2.

CHECK FITTINGS FOR CRACKS OR SCRATCHES

Repair as necessary.

ASSEMBLY OF COOLING UNlT

INSTALL COMPONENTS ON EVAPORATOR
(a) Connect the expansion valve, suction and liquid tubes t o the evaporator. Torque the bolt.

Torque:

5 5 kg-cm (47.7 in.-lb, 5 . 4 Nmm)

HINT: Be sure that the O-rings are positioned o n the tube fitting.
Expansion Valve

(b)
A C 1859

lnstall the holder t o the suction and liquid tubes w i t h heat sensing tube. lnstall the lower unit case t o the evaporator. lnstall the thermistor t o the evaporator. lnstall the upper unit case. lnstall the four screws. lnstall three clips. lnstall the connector of thermistor.

(c) (d) (e) (f) (g) (h)

INSTALLATION OF COOLING UNlT

1.
Cooling Unit

INSTALL COOLING UNlT

lnstall the cooling unit w i t h four screws and three nuts.

2.

CONNECT CONNECTOR OF THERMISTOR INSTALL EFI AND A.B.S. COMPUTER INSTALL GLOVE BOX COVER AND REINFORCEMENT INSTALL GLOVE BOX AND UNDER COVER INSTALL GROMMETS ON INLET AND OUTLET FITTINGS

3.
4.

5.
6.

AC-36

AIR CONDITIONING SYSTEM - Coolling Unit, Refrigerant Lines 7. CONNECT LIQUID TUBE TO COOLING UNlT INLET FITTING
Torque the nut.

Torque: 8.

1 3 5 kg-cm ( 1 0 ft-lb, 1 3 N - m )

CONNECT SUCTION TUBE TO COOLING UNlT OUTLET FITTING

Torque t h e n u t .

Torque:

325 kg-cm ( 2 4 ft-lb, 32 N - m )

9.

IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR Add 4 0 - 5 0 cc (1.4 - 1.7 f l . ~ ~ . ) Compressor oil: DENSOOIL 6, SUNlSO No.5GS or equivalent

10. INSTALL CHARCOAL CANISTER WlTH BRACKET 11. CONNECT NEGATIVE CABLE TO BATTERY

12. EVACUATE AIR FROM AIR CONDITIONING SYSTEM

13. CHARGE AIR CONDITIONING SYSTEM WlTH REFRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: .7 Ib) 6 5 0 - 7 5 0 g (1.4 - I

REFRIGERANT LINES
(See page AC-8)

ON-VEHICLE INSPECTION
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.

2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT LOOSE

Tighten or replace as necessary.

REPLACEMENT OF REFRIGERANT LINES

1. 2. DISCHARGE REFRIGERATION SYSTEM REPLACE FAULTY TUBE OR HOSE

HINT: Cap the open fitting immediately t o keep moisture o u t o f t h e system.

AIR CONDITIONING SYSTEM - Refrigerant Lines, Thermistor 3.

AC-37

TIGHTENING TORQUE FOR O-RING AND BOLTED TYPE FITTINGS (See page AC-8) EVACUATE AIR FROM AIR CONDITIONING SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 6 5 0 - 7 5 0 g (1.4 - 1.7 Ib)

4. 5.

THERMI
1.

'OR

REMOVAL AND INSPECTION OF THERMISTOR

DISCONNECT NEGATIVE CABLE FROM BATTERY

2. REMOVE GLOVE BOX AND UNDER COVER

3. CHECK THERMISTOR INSTALLED OPERATION
Using an ohmmeter, measure the resistance at the connector.

Resistance:

1.500 fl at 25OC (77OF)

If resistance value is n o t as specified, replace t h e thermistor.

4.

REMOVE THERMISTOR
(a) Disconnect the connector. ( b ) Remove the screw and thermistor f r o m t h e cooling unit.

Thermometer
n /

1
5.

Ice

CHECK THERMISTOR OPERATION

(a) Place t h e thermistor i n cold water. While varying the temperature of the water, measure the resistance at the connector and, at the same time, measure the temperature of t h e water w i t h a thermometer.

( b ) Compare the t w o readings o n the chart.

10 cm (3.94 in.)
AC0175

If the intersection is not between the t w o lines, replace the thermistor.

30

32 34 36 Temperature

38 4 0 " ~
~ ~ 0 5 4 8

AC-38

AIR CONDITIONING SYSTEM - A/C Control Panel Assembly

A/C CONTROL PANEL ASSEMBLY

INSPECTION OF A/C CONTROL PANEL ASSEMBLY
1. 2.

REMOVE A/C CONTROL PANEL ASSEMBLY MEASURE OUTPUT VOLTAGE

(a) Connect the positive ( + ) lead from the battery t o terminals 1, 2 and the negative ( - 1 lead t o terminal 1 0 .

Blower Speed REC

FR\S

Mode LO HI Control O F F M I

( b ) Connect the negative ( - ) lead from the voltage meter t o terminal 1 0 and the positive ( + ) lead t o each terminal @ w i t h the resistance. ( c ) Check that the output voltage is as shown in the chart below.

HINT: Confirm t h a t each indicator lights are lit w i t h butt o n pushed in.
Button AlC Mode Control Blower Speed

OFF AUTO

d f 2
Resistance @

AUTO 12 or more

620

1 ;; 1
14

12 or more 1 or less 1.5 or less 12 or more

OFF

13 6
DEF

1 2 o r more

1 or less
12 or more

FOOT
BI-LEVE

620

12 or more 1 or less 12 or more 1 or less

FACE AUTO AUTO

AIR CONDITIONING SYSTEM - A/C Control Panel Assembly

Control Button
Mode Control Speed

AC-39
t

1 or less
12 or more lorless
I

Resistance

t"

AUTO

AUTO

620

19
8

1 2 or more

If the voltage is n o t as specified, replace the AIC control panel assembly.

AC-40
Wire Harness Side

AIR CONDITIONING SYSTEM - Amplifiers

AMPLIFIERS
INSPECTION OF AMPLIFIER
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect t h e connector o n the wire harness side as s h o w n in the chart below. Test conditions: ( 1 ) Ignition switch: ON (2) Temperature control lever: (3) Blower s w i t c h : HI

M A X COOL

Check for Continuity Voltage Resistance

Tester connection 10 - Ground 2-10 Constant

Condition Turn A/C switch on.

Specified value Continuity Battery voltage No voltage (77F) Approx. 1.5 k f l a t 2 5 O ~

6-9

Turn A/C switch off. Constant

INSPECTION OF SYSTEM AMPLIFIER (In AIC Control Panel Assembly)

1.
A Interior room temperature is very low. lnterior room temperature is very high.

False Signal Input t o System Amplifier

False Signal
-

Condition

SYSTEM AMPL.I FI ER

SYSTEM AMPL.IFIER

I N-CA R SENSOR

I-\?
SENSOR

Your Work

Remove in-car sensor connector

Remove in-car sensor and ground the numl 1 pin of in-car sensor female connector

AIR CONDITIONING SYSTEM - A m p l i f i e r s

2.
S y s t e m Operation W h e n I n p u t False Signal Condition:

AC-41

System Main Parts

False Signal

~
1

S e t t i n g Temperature is a t 25OC (77OF)

Motion

Air Mix Control Servo Motor

A B

Air mix control servo motor shaft mover towards max. hot side. Air mix control servo motor shaft moves towards max. cool side. Air Vent Mode Damper

Air Vent Mode Control Servo Motor

VENT A B A Close Open

BI-LEVEL Close Close

HEAT Open Close

DEF Close Close

Blower Motor B A Water Valve

Blower motor rotates at high speed.

I
1

OPEN CLOSE

I1

FREiREC Control Servo Motor

I
1

FRE Switch ON REC Switch ON

1
I

Fresh air is ventilated. Recirculation air is ventilated. If necessary, replace t h e s y s t e m amplifier.

AC-42

AIR CONDITIONING SYSTEM - Sensors

SENSORS
1.

IN-CAR SENSOR
Check t h e sensor resistance. HINT: If there is an open circuit in t h e sensor, t h e syst e m will operate at m a x i m u m heating. Conversely, if there is a short in the system, i t will operate at m a x i m u m cooling. If resistance is n o t as specified, replace the sensor

Thermistor
I

lknl

2.

AMBIENT SENSOR
Check the sensor resistance. If resistance is n o t as specified, replace t h e sensor.

Thermistor

[kRl

0.62

3.

SOLAR SENSOR
Using an ohmmeter, check the continuity. HINT: There is t h e solar sensor o n the safety pad of t h e assistant side. If there is n o continuity, replace t h e sensor.

AIR CONDITIONING SYSTEM - Functional Test and Adjustment

AC-43

FUNCTIONAL TEST AND ADJUSTMENT Automatic Temperature Control System

ON-VEHICLE INSPECTION

DISCONNECT SHORT CIRCUIT CONNECTOR MAKE SHORT TERMINALS 1 AND 3 FOR TEST SET TEMPERATURE CONTROL AT 25OC (77OF) RUN ENGINE AT IDLING TURN ON BLOWER SWITCH TO AUTO POSITION

Servo Motor

CHECK AUTOMATIC TEMPERATURE CONTROL SYSTEM

(a) Verify that the guide plate o n the servo motor is positioned at the mark "0" (between the "R" and "W"). If t h e guide plate position is n o t at t h e mark " O H , adjust as follows.

(b)

(c)

If the guide plate position is over t h e "W" area, conn e c t t h e wire harness RG and BrY.

(dl

If t h e guide plate position is over the "R" n e c t the wire harness RG and W B .

area, con-

CONNECT SHORT CIRCUIT CONNECTOR

AC-44

AIR CONDITIONING SYSTEM - Functional Test and Adjustment

RECIRCIFRESH Control Servo Motor

INSPECTION OF RECIRCIFRESH CONTROL SERVO MOTOR
(Operation) (a) Connect the positive ( ) lead from the battery t o terminal 1 and the negative ( - ) lead t o terminal 2. A t this time, check for continuity between terminals 3 and 4 as s h o w n in the illustration.

(b) Check t h a t the arm rotates smoothly.

(c)

( d ) Connect the positive ( + ) lead f r o m the battery t o terminal 2 and the negative ( - ) lead t o terminal 1 . (e) (f) Check that t h e arm rotates smoothly. A t this time, check for continuity between terminals 5 and 6 as s h o w n in the illustration.

If operation is n o t as specified, replace t h e servo motor.

Air Vent Mode Control Servo Motor

INSPECTION OF AIR VENT MODE CONTROL SERVO MOTOR
(Operation) (a) Connect the positive ( + ) lead f r o m the battery t o terminal 1 and t h e negative ( - ) lead t o terminal 4.

( b ) Check that the arm rotates smoothly.

(c)

Connect the positive ( + ) lead from the battery t o terminal 4 and t h e negative ( - ) lead t o terminal 1 . Check that the arm rotates smoothly.

(dl

(Continuity) Check for continuity between terminal as s h o w n below.

\

Terminals Arm position FACE BI-LEVEL FOOT FOOT-DEF DEF

1 1 2

' K 1 1

1 1 0 ~ 1 1

Pi-PFW-1
I

I MTWT

If operation or continuity is n o t as specified, replace the servo motor.

AIR CONDITIONING SYSTEM - Functional Test and Adjustment

AC-45

Air Mix Control Servo Motor

INSPECTION OF AIR MIX CONTROL SERVO MOTOR
(Operation) (a) Connect the positive ( + lead from the battery t o terminal 10 and the negative ( - ) lead t o terminal 1 1 .

( b ) Check that the lever moves smoothly from W A R M t o COOL.

(c)

Connect the positive ( + ) lead from the battery t o terminal 1 1 and the negative ( - ) lead t o terminal 10. Check that the lever moves smoothly f r o m COOL t o WARM.

(d)

(Resistance) While operating the servo motor f r o m either points (a) or ( b ) , measure the resistance values of terminals 5 and 6.

I
I I
COOL
WARM
BE1168

Position

I
I I

Resistance

(n)

I
I I

COOL
WARM

1,900

+ 100 200 + 50

The resistance values f r o m COOL t o W A R M will successively decrease. If operation or resistance is n o t as specified, replace the servo motor.

- MEMO -