Air Conditioning System

AC-1
AIR CONDITIONING SYSTEM
AC-2
AIR CONDITIONING SYSTEM GENERAL DESCRIPTION
GENERAL DESCRIPTION
NEW AIR CONDITIONING SYSTEM WITH R134a
Refrigerant R12(CFC12), previously used in automobile air conditioning systems is believed to contribute towards the depletion the earths ozone layer. The ozone layer help to protect us against the harmful ultraviolet rays of the sun. A newly developed refrigerant, R134a (HFC 134a), does not the destroy the ozone layer.
AN1-M
PRECAUTIONS FOR SERVICING R134a AIR CONDITIONINGS

1. USE OF NEW REFRIGERANT R134a The very different characteristics of refrigerants R134a and R12 have determined the design of their respective air conditioning systems. Under no circumstances allow R12 to enter an R134a system, or vice versa, because serious damage could occur. 2. USE OF PROPER COMPRESSOR OIL Compressor oil used in conventional R12 air conditioning systems cannot be used in R134a air conditioning systems. Always use genuine Toyota R134a air conditioning oil ND - OIL 9, made expressly for use with R134a.
If even a small amount of the wrong oil is changed, it will result in clouding of the refrigerant. A large amount will cause the compressor to seize up.
AC-3
3. USE OF PROPER O-RINGS AND SEALS O-rings and seals used for conventional R12 air conditioning systems cannot be used for R134a air conditioning systems. Always use genuine Toyota R134a system O-rings and seals for R134a air conditioning systems.
If O-rings and/or seals for R12 air conditioning systems are used by mistake in the connections of an R 134a air conditioning system, the O-ring and seals will foam and swell resulting in leakage of refrigerant.
4. TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent leaking of refrigerant gas. Apply a few drops of compressor oil to O-ring fittings for easy tightening and to prevent leaking of refrigerant gas.
CAUTION: Apply only ND-OIL 9 compressor oil
Tighten the nuts using 2 wrenches to avoid twisting the tube. Tighten the O-ring fittings or the bolted type fittings to the specified torque. 5. INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS Insert a plug immediately in the disconnected parts to prevent the ingress of moisture and dust. 6. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL IMMEDIATELY BEFORE INSTALLATION
7. WHEN DISCONNECTING THE PLUG, TAKE CARE SO THAT OIL WILL NOT AGAIN
AC-4
SERVICE TOOLS FOR R134a AIR CONDITIONING

When servicing R134a air conditioning systems always use the R134a dedicated manifold gauges, gas leak detector and vacuum pump adaptor.
1. USE MANIFOLD GAUGES FOR R134a AIR CONDITIONING Always use R134a dedicated manifold gauges to prevent R12 and R12 compressor oil contaminating the R134a system.
2. USE R134a GAS LEAK DETECTOR Similarly, always use an R134a dedicated leak detector. The R12 leak detector is not sufficiently sensitive.
3. USE VACUUM PUMP ADAPTER By connecting a vacuum pump adapter, the vacuum pump can be used for both R134a and R12 air conditioning systems. The vacuum pump adaptor has an internal magnetic valve. When evacuation is completed and the vacuum pump switch is turned off, the magnetic valve opens allow. ing the introduction of atmospheric air into the manifold gauges to prevent the back flow of oil from the vacuum pump into the gauge hose.
CAUTION: Be sure to turn off the manifold gauge valve immediately after evacuating the system. Then you may switch off the vacuum pump. If this order is reversed, the line wilI be temporarily open to atmosphere.
AC-5
HANDLING PRECAUTIONS FOR REFRIGERANT

1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL THAT LIQUID REFRIGERANT DOES NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cool water.
CAUTION: Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin. (c) GO immediately to a physician or hospital for professional treatment.
HANDLING PRECAUTIONS FOR REFRIGERANT CONTAINER

1. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 2. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT
CHARGING AND LEAK-CHECK METHODS Evacuate the refrigeration system according to the following procedures.
10 min.
Leave for 5 min.
Start Evacuation
Stop Evacuation
Airtight Check
Refrigerant Charge
Gas Leak Check
Refrigerant Charge
Check and correct pipe joints
Abnormal indication of manifold gauges
Fill refrigerant in gas state until gauge pressure reads 1 kg/cm2
AC-6
CAUTION:
Be sure to connect both the high and low pressure quick-connectors onto the A/C system when evacuating. If only one side is connected, the system would be open to atmosphere through the other connector, making it impossible to maintain vacuum. Be sure to turn off the manifold gauge valve immediately after evacuating the system. Then you may switch off the vacuum pump.
PRECAUTIONS WHEN CHARGING REFRIGERANT

1. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT CYCLE If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this. 2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILST COMPRESSOR IS OPERATING If the high pressure valve is opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the low pressure valve only. 3. BE CAREFUL NOT TO OVERCHARGE WITH REFRIGERANT IN SYSTEM If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.
ELECTRICAL PARTS
Before removing and inspecting the electrical parts, set the ignition switch to the LOCK position and disconnect the negative (-) terminal cable from battery.
CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.
AC-7
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

Failure to carry out service operations in the correct sequence could cause the airbag system to deploy, possibly leading to a serious accident. During removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the RS section before performing the operation.
AC-8
AIR CONDITIONING SYSTEM DESCRIPTION
DESCRIPTION
PARTS LOCATION
AC-9
WIRING DIAGRAM
USA
AC-10
Canada
AC-1 1
DAMPERS POSITION
AC-12
AIR CONDITIONING SYSTEM PREPARATION
PREPARATION
SST (SPECIAL SERVICE TOOLS)
07110-58060 Air Conditioner Service Tool Set
(07117-58060) Refrigerant Drain Service Valve
(07117-58070) T-Joint
(07117-58080) Quick Coupler
Discharge (diam. 16 mm)
(07117-58090) Quick Coupler
Suction (diam. 13 mm)
(07117-78050) Refrigerant Charging Gauge
(07117-88060) Refrigerant Charging Hose
Discharge (Red)
Suction (Blue)
Utility (Green)
07112-66040 Magnetic Clutch Remover
07112-76060 Magnetic Clutch Stopper
07114-84020 Snap Ring Pliers
07116-38360 Gas Leak Detector Assembly
AC-13
AIR CONDITIONING SYSTEM PREPARATION
RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set
LUBRICANT
Item Compressor oil When replacing receiver When replacing condenser When replacing evaporator When replacing compressor 10 cc (2.9 fl.oz.) 40 cc (1.4 fl.oz.) 40 cc (1.4 fl.oz.) 120 cc (4.1 fl.oz.) Capacity Classification ND-OIL 8
AC-14
AIR CONDITIONING SYSTEM USE OF MANIFOLD GAUGE SET
USE OF MANIFOLD GAUGE SET

MANIFOLD GAUGE SET INSTALLATION
1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand.
CAUTION: Do not connect the wrong hoses.
2. CONNECT QUICK CONNECTORS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE
5. CONNECT QUICK CONNECTORS TO SERVICE VALVES HINT: Push the quick connector onto the service valve, then slide the sleeve of the quick connector downward to lock it.
MANIFOLD GAUGE SET REMOVAL

1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 2. DISCONNECT QUICK CONNECTORS. FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick connector upward to unlock the connector and remove it from the service valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIGERANT LINE
AC-15
AIR CONDITIONING SYSTEM TROUBLESHOOTING
TROUBLESHOOTING
You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts.
AC-22
AC-61
AC-23
AC-51
AC-64
AC-52
AC-46
See Page
Inspect cooling system for refrigerant
Inspect A/C control lever adjustment
Blower speed control switch
Condenser fan relay No. 2
Inspect volume of refrigerant
Radiator fan main relay
Part Name
Inspect engine coolant volume
Condenser fan relay No. 3
AC-54 AC-55 AC-54 AC-55 Condenser fan fuse
Inspect drive belt tension
Inspect outlet air control
Trouble
No blower operation No air temperature control No compressor operation Compressor operates immediately No condenser fan operation No cool air cones out Cool air comes out immediately Cool air comes out only at high engine rpm Insufficient cooling No engine idle up when A/C switch on No warm air comes out
Condenser fan motor
Heater main relay
Blower resistor
Blower motor
AC-47
AC-16
High pressure switch Engine coolant temperature switch Inspect refrigerant lines Compressor Magnetic clutch Condenser Receiver Evaporator Expansion valve Inspect refrigeration control A/C fuse A/C switch Magnetic clutch relay Dual pressure switch Thermistor A/C amplifier Wiring and wiring connections Vacuum switching valve (VSV) Heater radiator
AC-60
AC-34 AC-34 AC-42

AIR CONDITIONING SYSTEM
AC-41 AC-44 AC-48
AC-63 AC-53 AC-60 AC-57 AC-66
TROUBLESHOOTING
AC-49
AC-17
REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET

This is a method in which the trouble is located by using a manifold gauge set. (See USE OF MANIFOLD GAUGE SET on page AC-14 ) Read the manifold gauge pressure when the following conditions are established: (a) Temperature at the air inlet with the switch set at RECIRC is 30 - 35_C (86 - 95F) (b) Engine running at 1,500 rpm (c) Blower speed control switch set at high (d) Temperature control set at max. cool HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions. 1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM
Gauge reading: Low pressure side: 0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2) High pressure side: 1.37 - 1.57 MPa (14 - 16 kgf/cm2)
AC-18
2. MOISTURE PRESENT IN REFRIGERATION SYSTEM
Condition: Periodically cools and then fails to cool
Symptom seen in refrigeration system S During operation, pressure on low pressure side sometimes becomes a vacuum and sometimes normal
Probable cause S 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 S Drier in oversaturated state S Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant
Remedy (1) Replace receiver/drier (2) Remove moisture in cycle through repeatedly evacuating air (3) Charge new refrigerant to proper amount
3. INSUFFICIENT REFRIGERANT
Condition: Insufficient cooling
Symptom seen in refrigeration system S Pressure low on both low and high pressure sides S Bubbles seen in sight glass continuously S Insufficient cooling performance
Probable cause S Gas leakage at some place in refrigeration system
Diagnosis
Remedy
S Insufficient refrigerant (1) Check for gas leakage with leak detector in system and repair if necessary (2) Charge refrigerant to S Refrigerant leaking proper amount (3) If pressure indicated value is near 0 when connected to gauge, create the vacuum after inspecting and repairing the location of the leak
AC-19
4. POOR CIRCULATION OF REFRIGERANT
Symptom seen in refrigeration system S Pressure low on both low and high pressure sides S Frost on tubes from receiver to unit
Probable cause S Refrigerant flow obstructed by dirt in receiver
Diagnosis S Receiver clogged
Remedy S Replace receiver
5. REFRIGERANT DOES NOT CIRCULATE
Condition: Does not cool (Cools from time to time in some cases)
Symptom seen in refrigeration system S Vacuum indicated on low pressure side, very low pressure indicated on high pressure side S Frost or dew seen on piping before and after receiver/drier or expansion valve
Probable cause
Diagnosis
Remedy
S Refrigerant flow obS Refrigerant does not cir- (1) Check heat sensing structed by moisture or tube, expansion valve culate dirt in refrigeration sysand EPR tem (2) Clean out dirt in expanS Refrigerant flow obsion valve by blowing structed by gas leakage with air from expansion valve If not able to remove heat sensing tube dirt, replace expansion valve (3) Replace receiver (4) Evacuate air and charge new refrigerant to proper amount. For gas leakage from heat sensing tube, replace expansion valve.
AC-20
6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER
Condition: Does not cool sufficiently
Symptom seen in refrigeration system S Pressure too high on both low and high pressure sides S No air bubbles seen through the sight glass even when the engine rpm is lowered.
Probable cause
Diagnosis
Remedy
(1) Clean condenser S Unable to develop suffi- S Excessive refrigerant in cycle refrigerant over- (2) Check fan motor opercient performance due to ation charged excessive refrigerant in S Condenser cooling insuf- (3) !f (1) and (2) are in norsystem mal state, check ficient condenser fins S Insufficient cooling of amount of refrigerant clogged or fan motor condenser Charge proper amount faulty of refrigerant
7. AIR PRESENT IN REFRIGERATION SYSTEM
Condition: Does not cool down sufficiently
NOTE: These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging.
Symptom seen in refrigeration system
Probable cause
Diagnosis
Remedy
S Pressure too high on S Air entered in refrigeraboth low and high tion system pressure sides S The low pressure piping is hot to the touch S Bubbles seen insight glass
S Air present in refrigera- (1) Check compressor oil tion system to see if dirty or insuffi cient S Insufficient vacuum (2) Evacuate air and purging charge new refrigerant
AC-21
8. EXPANSION VALVE IMPROPERLY MOUNTED/HEAT SENSING TUBE DEFECTIVE (OPENS TOO WIDE)
Symptom seen in refrigeration system S Pressure too high on both low and high pressure sides S Frost or large amount of dew on piping on low pressure side
Probable cause S Trouble in expansion valve or heat sensing tube not installed correctly
Diagnosis S Excessive refrigerant in low pressure piping S Expansion valve opened too wide
Remedy (1) Check heat sensing tube installed condition (2) If (1) is normal, check expansion valve Replace if defective
9. DEFECTIVE COMPRESSION COMPRESSOR
Condition: Does not cooI
Symptom seen in refrigeration system S Pressure too high on low pressure side S Pressure too low on high pressure side
Probable cause S Internal leak in compressor
Diagnosis S Compression defective Valve leaking or broken, sliding parts
Remedy S Repair or replace compressor
AC-22
AIR CONDITIONING SYSTEM REFRIGERANT VOLUME
REFRIGERANT VOLUME
REFRIGERANT VOLUME INSPECTION
1. RUN ENGINE AT APPROX. 1,500 RPM 2. SET TEMPERATURE CONTROL AT MAX. COOL 3. SET BLOWER SWITCH AT HI 4. SET AIR INLET CONTROL AT RECIRC 5. TURN A/C SWITCH ON 6. FULLY OPEN DOORS 7. INSPECT AMOUNT OF REFRIGERANT Observe the sight glass on the liquid tube.
Item
Symptom
Amount of refrigerant
Remedy (1) Check for gas leakage with gas leak tester and repair if necessary (2) Add refrigerant until bubbles disappear Refer to items 3 and 4 (1) Check for gas leakage with gas leak tester and repair if necessary (2) Add refrigerant until bubbles disappear
Bubbles present in sight glass
Insufficient*
No bubbles present in sight glass No temperature difference between compressor inlet and outlet
None, sufficient or too much
Empty or nearly empty
Temperature between compressor inlet Correct or too much and outlet is noticeably different Immediately after air conditioning is turned off, refrigerant in sight glass stays clear When air conditioning is turned off, refrigerant foams and then stays clear
Refer to items 5 and 6 (1) Recover refrigerant (2) Evacuate air and charge proper amount of purified refrigerant
Too much
Correct
* Bubbles in the sight glass with ambient temperatures higher can be considered normal if cooling is sufficient.
REFRIGERANT CHARGE VOLUME

Specified amount: 700 50 g (24.69 1.76 oz.)
AC-23
AIR CONDITIONING SYSTEM DRIVE BELT TENSION
DRIVE BELT TENSION

DRIVE BELT TENSION INSPECTION
1. MAKE SURE THAT DRIVE BELT IS INSTALLED CORRECTLY Check that the drive belt fits properly in the ribbed groves.
2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Belt tension gauge: Nippondenso BTG-20 (9550600020) or Borroughs No. BT-33-73F
Drive belt tension: New belt 160 25 lbf Used belt 100 20 lbf
HINT: New belt refers to a belt which has been used less than 5 minutes on a running engine. Used belt refers to a belt which has been used on a running engine for 5 minutes or more. After installing the drive belt, check that it fits properly in the ribbed grooves.
AC-24
AIR CONDITIONING SYSTEM IDLE-UP SPEED
IDLE-UP SPEED
IDLE UP SPEED INSPECTION
1. WARM UP ENGINE 2. SET VEHICLE IN FOLLOWING CONDITION Blower switch high position A/C switch on Magnetic clutch on 3. INSPECT IDLE UP SPEED
Standard: 950 50 RPM
IDLE-UP SPEED ADJUSTMENT

ADJUST IDLE-UP SPEED Adjust idle-up speed with the idle adjusting screw of the VSV.
AC-25
AIR CONDITIONING SYSTEM REFRIGERANT LINES
REFRIGERANT LINES
LOCATIONS
AC-26
AIR CONDITIONING SYSTEM REFRIGERANT LINES
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak tester, check for leakage of refrigerant.
REFRIGERANT LINES REPLACEMENT

1. RECOVER REFRIGERANT IN REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE HINT: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE: Connections should not be torque tighter than the specified torque.
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT

5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refrigerant. 6. INSPECT AIR CONDITIONING OPERATION
AC-27
AIR CONDITIONING SYSTEM COOLING UNIT
COOLING UNIT
COOLING UNIT REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
2. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 3. DISCONNECT SUCTION TUBE FROM COOLING UNIT OUTLET FITTING 4. DISCONNECT LIQUID TUBE FROM COOLING UNIT INLET FITTING HINT: Cap the open fittings immediately to keep moisture out of the system. 5. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 6. DISCONNECT CONNECTOR FROM WIRE HARNESS 7. REMOVE EARTH WIRE
8. REMOVE A/C AMPLIFIER (a) Disconnect the connector from the A/C amplifier. (b) Remove the 3 screws and the A/C amplifier.
9. REMOVE COOLING UNIT Remove the 3 screws, nuts and the cooling unit.
AC-28
COOLING UNIT DISASSEMBLY
1. REMOVE UPPER AND LOWER CASE (a) Disconnect and remove the wire harness. (b) Remove the 2 clips and the 4 screws. (c) Remove the upper and the lower case. (d) Remove the A/C main relay from the upper case. (e) Remove the blower resistor from the lower case.
AC-29
2. REMOVE THERMISTOR FROM EVAPORATOR
3. REMOVE EXPANSION VALVE, SUCTION AND LIQUID TUBES FROM EVAPORATOR
COOLING UNIT ASSEMBLY

1. CONNECT EXPANSION VALVE, SUCTION AND LIQUID TUBES TO EVAPORATOR Torque the bolts.
Torque: 5.4 N-m (55 kgf-cm. 48 in.-Ibf)
2. INSTALL THERMISTOR 3. INSTALL UPPER AND LOWER CASE TO EVAPORATOR (a) Install the blower resistor to the lower case. (b) Install the A/C main relay to the upper case. (c) Install the upper and lower case to the evaporator. (d) Install the 2 clips and 4 tapping screws. (e) Connect the connectors of wire harness.
AC-30
COOLING UNIT INSTALLATION

1. INSTALL COOLING UNIT Install the cooling unit with the 3 nuts and 4 screws. 2. INSTALL A/C AMPLIFIER (a) Install the A/C amplifier to the cooling unit with the 2 screws. (b) Connect the connector to the A/C amplifier. 3. INSTALL EARTH WIRE TO BODY 4. CONNECT CONNECTOR TO WIRE HARNESS OF VEHICLE SIDE 5. INSTALL INSTRUMENT LOWER FINISH PANEL
6. CONNECT LIQUID TUBE TO COOLING UNIT INLET FITTING Torque the nut.
Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf)
7. CONNECT SUCTION TUBE TO COOLING UNIT OUTLET FITTING Torque the nut.
Torque: 32 N-m (330 kgf-cm, 24 ft-Ibf)
8. IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR

Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 9
9. CONNECT NEGATIVE (-) CABLE TO BATTERY 10. EVACUATE AIR FROM REFRIGERATION SYSTEM 11. CHARGE SYSTEM WITH REFRIGERANT AND INSPECT FOR LEAKAGE OF REFRIGERANT
AC-31
AIR CONDITIONING SYSTEM BLOWER UNIT
BLOWER UNIT
BLOWER UNIT REMOVAL
1. REMOVE COOLING UNIT (See page AC-25 ) 2. REMOVE BLOWER UNIT (a) Disconnect the connector from the blower motor. (b) Disconnect the air inlet damper control cable from the blower motor. (e) Remove the nut, 2 screws and the blower unit.
BLOWER UNIT INSTALLATION

1. INSTALL BLOWER UNIT (a) Install the blower unit with the nut and 2 screws. (b) Connect the air inlet damper control cable to the blower unit. HINT: For installing the control cable, refer to Adjustment of A/C Control Cables. (c) Connect the connector to the blower motor. 2. INSTALL COOLING UNIT (See page AC-30 )
AC-32
AIR CONDITIONING SYSTEM HEATER UNIT
HEATER UNIT
HEATER UNIT REMOVAL
1. REMOVE SAFETY PAD See Instrument Panel on BO section. 2. REMOVE COOLING UNIT (See page AC-25 ) 3. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 4. DISCONNECT WATER HOSES FROM HEATER RADIATOR PIPES (a) Grip the claws of the hose clip with pliers and slide the clip along the hose to a place where it dose not clamp the hose to the pipe. (b) Disconnect the water hoses. 5. REMOVE PIPE GROMMETS 6. REMOVE A/C CONTROL ASSEMBLY (See page AC-64 ) 7. REMOVE HEATER TO REGISTER CENTER DUCT Remove the 3 screws and the duct.
8. REMOVE INSTRUMENT PANEL REINFORCEMENT NO. 1 BRACE Remove the 2 nuts, 2 bolts and the No. 1 brace. 9. REMOVE INSTRUMENT PANEL REINFORCEMENT NO. 2 BRACE Remove the 2 nuts, a bolts and the No. 2 brace.
10. REMOVE HEATER UNIT Remove the screw, nut and the heater unit.
AC-33
AIR CONDITIONING SYSTEM HEATER UNIT
HEATER UNIT INSTALLATION

Install by following the removal procedure in reverse order. HINT: Push the water hose onto the heater radiator pipe as far as the ridge on the pipe. Install the hose clip in a position, as shown to the left.
AC-34
AIR CONDITIONING SYSTEM COMPRESSOR
COMPRESSOR
ON-VEHICLE INSPECTION Magnetic Clutch:
INSPECT MAGNETIC CLUTCH FOR FOLLOWING (a) Inspect the pressure plate and the rotor for signs of oil. (b) Check the clutch bearings for noise and grease leakage. (c) Connect the positive (+) lead from the battery to the terminal on the magnetic clutch connector and the negative (-) lead to the body ground. (d) Check that the magnetic clutch is energized. If the magnetic clutch is not energized, replace the magnetic clutch.
Compressor:
1. INSTALL MANIFOLD GAUGE SET 2. RUN ENGINE AT APPROX. 2,000 RPM 3. INSPECT COMPRESSOR FOR FOLLOWING (a) High pressure gauge reading is not lower and low pressure gauge reading is not higher than normal. (b) Check that the metallic sound. (c) Check that the leakage from shaft seal.
AC-35
COMPRESSOR REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10 MINUTES 2. STOP ENGINE 3. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
4. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 5. REMOVE UNDER COVER 6. DISCONNECT CONNECTOR FROM MAGNETIC CLUTCH 7. DISCONNECT 2 HOSES FROM COMPRESSOR SERVICE VALVE Cap the open fitting immediately to keep moisture and dust out of the system.
AC-36
8. REMOVE COMPRESSOR (a) Loosen the compressor drive belt. (b) Remove the compressor mounting bolts and the compressor.
MAGNETIC CLUTCH DISASSEMBLY
1. REMOVE PRESSURE PLATE (a) Using a socket and SST, remove the shaft nut. SST 07112-76060
(b) Install SST to the pressure plate. SST 07112 - 66040
AC-37
(c) Using SST and the socket, remove the pressure plate. SST 07112-76060, 07112-66040
(d) Remove the shims from the shaft.
2. REMOVE ROTOR (a) Using SST, remove the snap ring. SST 07114-84020
(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) Using a screwdriver and disconnect the stator lead wires from the compressor housing.
AC-38
(b) Using SST, remove the snap ring. SST 07114-84020
(c) Remove the stator.
MAGNETIC CLUTCH ASSEMBLY

1. INSTALL STATOR (a) Install the stator on the compressor. (b) Using SST, install a new snap ring. SST 07114-84020
NOTICE: The snap ring should be installed so that its beveled side faces up.
(c) Connect the stator lead wires to the compressor housing.
AC-39
2. INSTALL ROTOR (a) Install the rotor on the compressor shaft. (b) Using SST, install a new snap ring. SST 07114-84020
NOTICE: The snap ring should be installed so that its beveled side faces up.
3. INSTALL PRESSURE PLATE (a) Adjust the clearance between the pressure plate and rotor by putting shims on the compressor shaft.
Standard clearance: 0.5 0.15 mm (0.020 0.0059 in.)
If the clearance is not within tolerance, change the number of shims to obtain the standard clearance.
(b) Using SST and torque wrench, install the shaft nut. SST 07112-76060
Torque: 14 N-m (140 kgf-cm, 10 ft-lbf)
AC-40
4. INSPECT CLEARANCE OF MAGNETIC CLUTCH (a) Set the dial-gauge to the pressure plate of the magnetic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor, when connect the negative (-) terminal of the battery.
Standard clearance: 0.5 0.15 mm (0.020 0.0059 in.)
If the clearance is not within standard clearance adjust the clearance using shims to obtain the standard clearance.
COMPRESSOR INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING BOLTS
2. INSTALL DRIVE BELT See Drive Belt Tension Adjustment on page AC-23 . 3. CONNECT 2 HOSES TO COMPRESSOR SERVICE VALVES
Torque: Discharge line 10 N-m (100 kgf-cm, 8 ft-lbf) Suction line 10 N-m (100 kgf-cm. 8 ft-lbf)
4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS 5. CONNECT NEGATIVE (-) CABLE TO BATTERY 6. EVACUATE AIR FROM REFRIGERATION SYSTEM 7. CHARGE SYSTEM WITH REFRIGERANT AND IN. SPECT FOR LEAKAGE OF REFRIGERANT
AC-41
AIR CONDITIONING SYSTEM RECEIVER
RECEIVER
INSPECT SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR LEAKAGE Use a gas leak tester. Repair as necessary.
RECEIVER REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT (-) NEGATIVE CABLE FROM BATTERY
3. REMOVE FRONT GRILLE 4. DISCONNECT 2 LIQUID TUBES FROM RECEIVER HINT: Cap the open fittings immediately to keep moisture out of the system. 5. REMOVE RECEIVER FROM RECEIVER HOLDER
RECEIVER INSTALLATION
1. INSTALL RECEIVER IN RECEIVER HOLDER HINT: Do not remove the blind plugs until ready for connection. 2. CONNECT 2 LIQUID TUBES TO RECEIVER Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
3. INSTALL FRONT GRILLE 4. CONNECT NEGATIVE (-) CABLE TO BATTERY 5. IF RECEIVER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR
Add 20 cc (0.71 fl.oz.) Compressor oil: ND-OIL 9
6. EVACUATE AIR FROM REFRIGERATION SYSTEM 7. CHARGE SYSTEM WITH REFRIGERANT AND INSPECT FOR LEAKAGE OF REFRIGERANT
AC-42
AIR CONDITIONING SYSTEM CONDENSER
CONDENSER
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air.
NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER FITTINGS FOR LEAKAGE Repair as necessary.
CONDENSER REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
3. REMOVE FOLLOWING PARTS Front grille Horn Hood lock Center brace Condenser fan 4. DISCONNECT LIQUID TUBE AND DISCHARGE HOSE FROM CONDENSER FITTING HINT: Cap the open fittings immediately to keep moisture out of the system. 5. REMOVE RECEIVER WITH RECEIVER BRACKET FROM CONDENSER 6. REMOVE RADIATOR SUPPORT BRACKETS 7. REMOVE CONDENSER (a) Remove the 2 condenser mounting bolts. (b) Remove the 2 condenser brackets.
AC-43
(c) Pull the condenser out.
CONDENSER INSTALLATION
1. INSTALL CONDENSER Install the condenser with the 2 condenser brackets and the 2 mounting bolts.
2. INSTALL RADIATOR SUPPORT 3. INSTALL RECEIVER WITH RECEIVER BRACKET TO CONDENSER 4. CONNECT LIQUID TUBE TO RECEIVER Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
5. CONNECT LIQUID TUBE AND DISCHARGE HOSE TO CONDENSER Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
6. INSTALL FOLLOWING PARTS Condenser fan Center brace Hood lock Horn Front grille 7. CONNECT NEGATIVE (-) CABLE TO BATTERY 8. IF CONDENSER WAS REPLACED, ADD COMPRESSOR OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.) Compressor oil: ND-OIL 9
9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM 10. CHARGE SYSTEM WITH REFRIGERANT AND INSPECT FOR LEAKAGE OF REFRIGERANT
AC-44
EVAPORATOR INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES Repair as necessary.
REMOVAL AND INSTALLATION OF EVAPORATOR

See item of cooling unit.
AC-45
AIR CONDITIONING SYSTEM HEATER RADIATOR
HEATER RADIATOR
HEATER RADIATOR REMOVAL
1. REMOVE HEATER UNIT (See page AC-32 ) 2. REMOVE HEATER RADIATOR (a) Remove the 2 screws and the 2 plates. (b) Pull the heater radiator out.
HEATER RADIATOR INSPECTION

INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air.
HEATER RADIATOR INSTALLATION

1. INSTALL HEATER RADIATOR (a) Insert the heater radiator to the heater unit. (b) Install the 2 plates with the 2 screws. 2. INSTALL HEATER UNIT (See page AC-33 )
AC-46
AIR CONDITIONING SYSTEM BLOWER MOTOR
BLOWER MOTOR
MOTOR REMOVAL
2. REMOVE A/C AMPLIFIER Remove the 3 screws and the A/C amplifier with the connector connected.
3. REMOVE BLOWER MOTOR (a) Disconnect the connector from the blower motor. (b) Remove the 3 screws and the blower motor.
MOTOR INSPECTION
INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 1 and the negative (-) lead to terminal 2, then check that the motor operation is smooth.
MOTOR INSTALLATION
1. INSTALL BLOWER MOTOR (a) Install the blower motor with the 3 screws. (b) Connect the connector to blower motor. 2. INSTALL A/C AMPLIFIER Install A/C amplifier with the 3 screws. 3. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-47
AIR CONDITIONING SYSTEM CONDENSER FAN
CONDENSER FAN
INSPECT CONDENSER FAN MOTOR (a) Using the wire harness, apply battery positive voltage to the connector. (b) Confirm smooth rotation of the motor within the specified current flow.
Standard current: 9.5 1.5 A
If current is not as specified, replace the motor.
CONDENSER FAN REMOVAL

2. REMOVE FOLLOWING COMPONENTS Front grille Hood lock Center brace 3. REMOVE CONDENSER FAN (a) Disconnect the connector from fan motor. (b) Remove the 2 bolts and the condenser fan.
CONDENSER FAN INSTALLATION

1. INSTALL CONDENSER FAN (a) Install the condenser fan with the 2 bolts. (b) Connect the connector to the fan motor. 2. INSTALL FOLLOWING PARTS Center brace Hood lock Front grille 3. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-48
AIR CONDITIONING SYSTEM EXPANSION VALVE
EXPANSION VALVE
1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. INSTALL MANIFOLD GAUGE SET 3. RUN ENGINE Run the engine at 2,000 RPM for at least 5 minutes. Then check that the high pressure reading is 1,275 1,471 kPa (13 - 15 kgf/cm2, 185 - 213 psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kPa (0 kgf/cm2, 0 psi), otherwise it is OK. HINT: When the low pressure drops to 0 kPa (0 kgf/ cm2, 0 psi), feel the receivers IN and OUT sides for no temperature difference.
EXPANSION VALVE REMOVAL AND INSTALLATION

AC-49
AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV)
VACUUM SWITCHING VALVE (VSV)

VACUUM HOSE CIRCUIT
VSV INSPECTION
1. DISCONNECT VACUUM HOSES AND CONNECTOR FROM VSV
2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY BLOWING AIR INTO PIPES (a) Connect the VSV terminals to the battery terminals as illustrated. (b) Blow into pipe A and check that air comes out of pipe B.
(c) Disconnect the battery. (d) Blow into pipe A and check that air does not come out pipe B. If a problem is found, replace the VSV.
3. CHECK FOR SHORT CIRCUIT Using an ohmmeter, check that there is no continuity between each terminal and the VSV body. If there is continuity, replace the VSV.
AC-50
AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV)
4. CHECK FOR OPEN CIRCUIT Using an ohmmeter, the resistance between the 2 terminals.
Resistance: 30 - 34 W at 20 C (68 F)
If the resistance is not within specification, replace the VSV.
AC-51
AIR CONDITIONING SYSTEM BLOWER RESISTOR
BLOWER RESISTOR
BLOWER RESISTOR REMOVAL
2. REMOVE BLOWER RESISTOR (a) Disconnect the connector from the blower resistor. (b) Remove the 2 screws and the blower resistor.
BLOWER RESISTOR INSPECTION

INSPECT BLOWER RESISTOR Continuity
Terminal Condition Constant
If continuity is not as specified, replace the blower resistor.
BLOWER RESISTOR INSTALLATION

1. INSTALL BLOWER RESISTOR (a) Install the blower resistor with the 2 screws. (b) Connect the connector to the blower resistor. 2. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-52
AIR CONDITIONING SYSTEM HEATER MAIN RELAY
HEATER MAIN RELAY

RELAY REMOVAL
2. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 3. DISCONNECT HEATER MAIN RELAY FROM A/C RELAY BLOCK
RELAY INSPECTION
INSPECT HEATER MAIN RELAY Continuity
Condition Constant Apply B + between terminals 1 and 3. Tester connection to terminal number 1-3 2-4 4-5 Specified value Continuity Continuity
If continuity is not as specified, replace the relay.
RELAY INSTALLATION
1. CONNECT HEATER MAIN RELAY TO A/C RELAY BLOCK 2. INSTALL INSTRUMENT LOWER FINISH PANEL 3. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-53
AIR CONDITIONING SYSTEM MAGNETIC CLUTCH RELAY
MAGNETIC CLUTCH RELAY

RELAY REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY CAUTION: Work must be started after 90 seconds from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. 2. REMOVE INSTRUMENT LOWER FINISH PANEL (See page BO-46 ) 3. REMOVE MAGNETIC CLUTCH RELAY Remove a screw and disconnect the relay from the connector.
RELAY INSPECTION
INSPECT MAGNETIC CLUTCH RELAY Continuity
Condition Constant Apply B+ between terminals 1 and 3. Tester connection to terminal number 1-3 2-4 Specified value Continuity Continuity
RELAY INSTALLATION
1. INSTALL MAGNETIC CLUTCH RELAY Connect the relay to the connector and install it to the cooling unit with the screw. 2. INSTALL INSTRUMENT LOWER FINISH PANEL 3. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-54
AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N0.3 (USA)
CONDENSER FAN RELAY NO.2 AND NO.3 (USA)

RELAYS REMOVAL
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 FROM RELAY BLOCK NO. 2
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO. 2 Check the relay the same way as for the heater main relay. 2. INSPECT CONDENSER FAN RELAY NO. 3 Check the relay the same way as for the magnetic clutch relay.
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 TO RELAY BLOCK NO. 2 2. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-55
AIR CONDITIONING SYSTEM CONDENSER FAN RELAY NO.2 AND NO.3 (Canada)
CONDENSER FAN RELAY NO.2 AND NO.3 (Canada)

RELAYS REMOVAL
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 FROM RELAY BLOCK NO. 5
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO.2 Continuity
Condition Constant Apply B + between terminals 1 and 2. Tester connection to terminal number 1-2 3-4 3-5
Specified value Continuity Continuity
If continuity is not as specified, replace the relay. 2. INSPECT CONDENSER FAN RELAY NO.3 Continuity
Condition Constant Apply B+ between terminals 1 and 2. Tester connection to terminal number 1-2 3-5 Specified value Continuity Continuity
AC-56
AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N 0.3(Canada)
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND NO. 3 TO RELAY BLOCK NO.5 2. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-57
AIR CONDITIONING SYSTEM THERMISTOR
THERMISTOR
THERMISTOR REMOVAL AND INSTALLATION
THERMISTOR INSPECTION
INSPECT THERMISTOR RESISTANCE (a) Measure the resistance between terminals at 25 C (77 F).
Resistance: 1,500 W at 25C (77F)
(b) Place the thermistor in cold water. While varying the temperature of the water, measure the resistance at the connector and at the same time, measure the temperature of the water with a thermometer. (c) Compare the 2 readings on the chart. If the resistance valve is not as specified, replace the thermistor.
AC-58
AIR CONDITIONING SYSTEM REVOLUTION DETECTING SENSOR (w Power Steering)
REVOLUTION DETECTING SENSOR (w Power Steering)

SENSOR INSPECTION
MEASURE SENSOR RESISTANCE Measure the resistance between terminals 3 and 4.
Standard resistance: 240 80 at 20C (68F)
If resistance value is not as specified, replace the sensor.
SENSOR REMOVAL
1. REMOVE COMPRESSOR (See page AC-35 ) 2. REMOVE REVOLUTION DETECTING SENSOR (a) Remove the bolt. (b) Remove the revolution detecting sensor.
SENSOR INSTALLATION
1. INSTALL REVOLUTION DETECTING SENSOR Using a torque wrench, tighten the bolt.
Torque: 11 N .m (110 kgf-cm, 8 ft-lbf)
2. INSTALL COMPRESSOR (See page AC-40 )
AC-59
AIR CONDITIONING SYSTEM REFRIGERANT TEMPERATURE SWITCH
REFRIGERANT TEMPERATURE SWITCH

SWITCH REMOVAL AND INSTALLATION
See Discharge Valve Removal or Installation on page AC-35 or 40.
SWITCH INSPECTION
INSPECT REFRIGERANT TEMPERATURE SWITCH Check refrigerant temperature switch operation.
Oil Temperature 120C (248F) 180C (356F) Specified Value Continuity No continuity
If operation is not as specified, replace the switch. HINT: After inspection, throughly clean the switch before assembly.
AC-60
AIR CONDITIONING SYSTEM TRIPLE PRESSURE SWITCH
TRIPLE PRESSURE SWITCH

1. DISCONNECT CONNECTOR FROM TRIPLE PRESSURE SWITCH 2. INSTALL MANIFOLD GAUGE SET 3. RUN ENGINE AT APPROX. 2,000 RPM
4. INSPECT TRIPLE PRESSURE SWITCH (Magnetic Clutch Control) (a) Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 2. (b) Check continuity between terminals when refrigerant pressure is changed, as shown. If operation is not as specified, replace the pressure switch.
SWITCHES REMOVAL
1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM 2. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
3. REMOVE TRIPLE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the triple pressure switch.
SWITCHES INSTALLATION
1. INSTALL TRIPLE PRESSURE SWITCH TO LIQUID TUBE Tighten the triple pressure switch then connect the connector to it.
2. CONNECT NEGATIVE (-) CABLE TO BATTERY 3. EVACUATE AIR FROM REFRIGERATION SYSTEM 4. CHARGE SYSTEM WITH REFRIGERANT AND INSPECT FOR LEAKAGE OF REFRIGERANT
AC-61
AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH
BLOWER SPEED CONTROL SWITCH

SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) GABLE FROM BATTERY
2. REMOVE A/C CONTROL PANEL (See page BO-47 ) 3. REMOVE AUDIO AND ASH TRAY (See page BO-46 ) 4. REMOVE BLOWER SPEED CONTROL SWITCH (a) Remove the illumination light from the A/C control assembly. (b) Using a screwdriver, pry loose the clip and push out the blower speed control switch to rear of the A/C control assembly. (c) Disconnect the connector from the blower speed control switch.
SWITCH INSPECTION
INSPECT BLOWER SPEED CONTROL SWITCH Continuity
Terminal Switch position OFF
Illumination
If continuity is not as specified, replace the blower speed control switch.
AC-62
AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH
SWITCH INSTALLATION
1. INSTALL BLOWER SPEED CONTROL SWITCH (a) Connect the connector to the blower speed control switch. (b) Install the illumination light to the A/C control assembly. (c) Install the blower speed control switch to the A/C control assembly. 2. INSTALL AUDIO AND ASH TRAY 3. INSTALL A/C CONTROL PANEL 4. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-63
AIR CONDITIONING SYSTEM AIR CONDITIONING SWITCH
AIR CONDITIONING SWITCH

SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE PROM BATTERY
2. REMOVE A/C SWITCH Using a screwdriver, pry loose the clips and remove the A/C switch. HINT: Tape the screwdriver tip before use.
SWITCH INSPECTION
INSPECT A/C SWITCH Continuity
Condition A/C Switch OFF A/C Switch ON Illumination circuit 4-5 4-6 1-3 Tester connection to terminal number Specified value No continuity Continuity Continuity
If continuity is not as specified, check the bulb or replace the switch.
SWITCH INSTALLATION
1. INSTALL A/C SWITCH Push in the A/C switch to the A/C control assembly. 2. CONNECT NEGATIVE (-) CABLE TO BATTERY
AC-64
AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY
AIR CONDITIONING CONTROL ASSEMBLY

INSPECT A/C CONTROL LEVERS OPERATION Move the control levers left and right and check for stiffness and binding through the full range of the levers.
A/C CONTROL CABLES ADJUSTMENT
1. ADJUST AIR INLET DAMPER CONTROL CABLE Set the air inlet damper on RECIRC position, install the control cable and lock clamp.
2. ADJUST MODE DAMPER CONTROL CABLE Set the air inlet damper on FACE position, install the control cable and lock the clamp.
3. ADJUST AIR MIX DAMPER CONTROL CABLE Set the air mix damper on COOL position, install the control cable and lock the clamp.
AC-65
AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY
A/C CONTROL ASSEMBLY REMOVAL

1. REMOVE SAFETY PAD See Instrument Panel on BO section. 2. REMOVE A/C CONTROL ASSEMBLY (a) Disconnect the control cables from the heater unit and the blower unit. (b) Remove the blower switch and remove the A/C control assembly.
A/C CONTROL ASSEMBLY INSTALLATION

1. INSTALL A/C CONTROL ASSEMBLY (a) Install the blower switch to the A/C control assembly. (b) Wire the control cables, as shown the illustration. (c) Connect the control cables to the heater unit and blower unit. HINT: For installing the control cables, refer to Adjustment of A/C Control Cables. 2. INSTALL SAFETY PAD
AC-66
AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER
AIR CONDITIONING AMPLIFIER

AMPLIFIER REMOVAL
REMOVE A/C AMPLIFIER (a) Disconnect the connector from the amplifier. (b) Remove the 3 screws and the amplifier.
AMPLIFIER INSPECTION
INSPECT A/C AMPLIFIER CONNECTOR ON WIRE HARNESS SIDE Test conditions: Ignition switch ON Temperature control lever to MAX COOL Blower switch ON w/o Power Steering
Tester connection to terminal number 1 - Ground 1 - Ground 7 - Ground 7 - Ground 8 - Ground 8 - Ground Tester connection to terminal number 2- 13 9-13 Tester connection to terminal number 5 -7 12 - Ground Constant Constant Constant Constant Start the engine Stop the engine
Condition
Specified value (Voltage) Approx. 10 to 14 V No voltage Battery positive voltage No voltage Battery positive voltage No voltage
Blower switch ON Blower switch OFF A/C switch ON A/C switch OFF Condition
Specified value (Resistance) Approx. 1.5 kW at 25C (77F) Approx. 240W
Condition
Specified value (Continuity) Continuity Continuity
w/ Power Steering
Tester connection to terminal number 1 - Ground 1 - Ground 7 - Ground 7 - Ground 8 - Ground 8 - Ground Start the engine Stop the engine Blower switch ON Blower switch OFF A/C switch ON A/C switch OFF
Condition
Specified value (Voltage) Approx. 10 to 14 V No voltage Battery positive voltage No voltage Battery positive voltage No voltage
AC-67
AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER
Tester connection to terminal number 2 - 12 Tester connection to terminal number 5-7 12 - Ground Constant Constant Constant
Condition
Specified value (Resistance) Approx. 1.5 kW at 25C (77F)
Condition
Specified value (Continuity) Continuity Continuity
If continuity is not as specified, replace the A/C amplifier.
AC-68
AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
Refrigerant charge volume Drive belt tension New belt Used belt Idle-up speed Magnetic clutch clearance 160 25 lbf 100 20 lbf 1,450 50 RPM 0.5 0.15 mm (0.02 0.0059 in.) 700 50 g (24.69 1.76 oz.)
TORQUE SPECIFICATIONS
Part tightened Compressor x Suction hose Compressor x Discharge hose Compressor x Compressor bracket Receiver x Liquid tube Condenser x Liquid tube Cooling unit x Liquid tube Cooling unit x Suction tube 5.5 5.5 140 330 N-m kgf-cm 100 100 250 48 in.-lbf 48 in.-lbf ft-lbf

Air Conditioning System

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Air Conditioning System

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AC-1

AIR CONDITIONING SYSTEM

PRECAUTIONS FOR SERVICING R134a AIR CONDITIONINGS

SERVICE TOOLS FOR R134a AIR CONDITIONING

HANDLING PRECAUTIONS FOR REFRIGERANT

HANDLING PRECAUTIONS FOR REFRIGERANT CONTAINER

Leave for 5 min.

Gas Leak Check

Check and correct pipe joints

Abnormal indication of manifold gauges

Fill refrigerant in gas state until gauge pressure reads 1 kg/cm2

PRECAUTIONS WHEN CHARGING REFRIGERANT

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)

(07117-58060) Refrigerant Drain Service Valve

(07117-58080) Quick Coupler

Discharge (diam. 16 mm)

(07117-58090) Quick Coupler

Suction (diam. 13 mm)

(07117-78050) Refrigerant Charging Gauge

(07117-88060) Refrigerant Charging Hose

(07117-88070) Refrigerant Charging Hose

(07117-88080) Refrigerant Charging Hose

07112-66040 Magnetic Clutch Remover

07112-76060 Magnetic Clutch Stopper

07114-84020 Snap Ring Pliers

07116-38360 Gas Leak Detector Assembly

USE OF MANIFOLD GAUGE SET

MANIFOLD GAUGE SET REMOVAL

Inspect cooling system for refrigerant

Inspect A/C control lever adjustment

Blower speed control switch

Condenser fan relay No. 2

Inspect volume of refrigerant

Radiator fan main relay

Inspect engine coolant volume

Condenser fan relay No. 3

AC-54 AC-55 AC-54 AC-55 Condenser fan fuse

Inspect drive belt tension

Inspect outlet air control

Condenser fan motor

Heater main relay

AC-34 AC-34 AC-42

AC-41 AC-44 AC-48

AC-63 AC-53 AC-60 AC-57 AC-66

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET

2. MOISTURE PRESENT IN REFRIGERATION SYSTEM

Condition: Periodically cools and then fails to cool

Condition: Insufficient cooling

Probable cause S Gas leakage at some place in refrigeration system

4. POOR CIRCULATION OF REFRIGERANT

Condition: Insufficient cooling

Probable cause S Refrigerant flow obstructed by dirt in receiver

Diagnosis S Receiver clogged

Remedy S Replace receiver

5. REFRIGERANT DOES NOT CIRCULATE

6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER

Condition: Does not cool sufficiently

7. AIR PRESENT IN REFRIGERATION SYSTEM

Condition: Does not cool down sufficiently

Symptom seen in refrigeration system

Condition: Insufficient cooling

9. DEFECTIVE COMPRESSION COMPRESSOR

Condition: Does not cooI