Air conditioning system

AIR CONDITIONING SYSTEM

AC-1

A¿¿N1-M

PRECAUTIONS FOR SERVICING R134a AIRCONDITIONINGS1. USE OF NEW REFRIGERANT R134aThe very different characteristics of refrigerantsR134a and R12 have determined the design of theirrespective air conditioning systems. Under no circum-stances allow R12 to enter an R134a system, or viceversa, because serious damage could occur.

GENERAL DESCRIPTIONNEW AIR CONDITIONING SYSTEM WITH R134aRefrigerant R12(CFC12), previously used in automo-bile air conditioning systems is believed to contributetowards the depletion the earth’s ozone layer. Theozone layer help to protect us against the harmfulultraviolet rays of the sun.

2. USE OF PROPER COMPRESSOR OILCompressor oil used in conventional R12 air condi-tioning systems cannot be used in R134a air condi-tioning systems.Always use genuine Toyota R134a air conditioning oilND - OIL 9, made expressly for use with R134a.

If even a small amount of the wrong oil is changed, itwill result in clouding of the refrigerant.A large amount will cause the compressor to seize up.

A newly developed refrigerant, R134a (HFC 134a),does not the destroy the ozone layer.

-AIR CONDITIONING SYSTEM GENERAL DESCRIPTIONAC-2

4. TIGHTEN CONNECTING PARTS SECURELYSecurely tighten the connecting parts to prevent leak-ing of refrigerant gas.• Apply a few drops of compressor oil to O-ring

fittings for easy tightening and to prevent leakingof refrigerant gas.

CAUTION: Apply only ND-OIL 9 compressor oil

• Tighten the nuts using 2 wrenches to avoid twist-ing the tube.

• Tighten the O-ring fittings or the bolted typefittings to the specified torque.

5. INSERT PLUG IMMEDIATELY IN DISCONNECTEDPARTSInsert a plug immediately in the disconnected parts toprevent the ingress of moisture and dust.6. DO NOT REMOVE PLUG FROM NEW PARTS UNTILIMMEDIATELY BEFORE INSTALLATION

3. USE OF PROPER O-RINGS AND SEALSO-rings and seals used for conventional R12 airconditioning systems cannot be used for R134a airconditioning systems.Always use genuine Toyota R134a system O-ringsand seals for R134a air conditioning systems.

If O-rings and/or seals for R12 air conditioning sys-tems are used by mistake in the connections of an R134a air conditioning system, the O-ring and sealswill foam and swell resulting in leakage of refrigerant.

7. WHEN DISCONNECTING THE PLUG, TAKE CARESO THAT OIL WILL NOT AGAIN


3. USE VACUUM PUMP ADAPTERBy connecting a vacuum pump adapter, the vacuumpump can be used for both R134a and R12 air conditioningsystems.The vacuum pump adaptor has an internal magneticvalve.When evacuation is completed and the vacuum pumpswitch is turned off, the magnetic valve opens allow.ing the introduction of atmospheric air into the manifoldgauges to prevent the back flow of oil from thevacuum pump into the gauge hose.

CAUTION:Be sure to turn off the manifold gauge valve immediatelyafter evacuating the system. Then you may switch offthe vacuum pump. If this order is reversed, the line wilIbe temporarily open to atmosphere.

SERVICE TOOLS FOR R134a AIRCONDITIONINGWhen servicing R134a air conditioning systemsalways use the R134a dedicated manifold gauges, gasleak detector and vacuum pump adaptor.

1. USE MANIFOLD GAUGES FOR R134a AIR CONDI-TIONINGAlways use R134a dedicated manifold gauges to pre-vent R12 and R12 compressor oil contaminating theR134a system.

2. USE R134a GAS LEAK DETECTORSimilarly, always use an R134a dedicated leak detec-tor. The R12 leak detector is not sufficiently sensitive.


3. BE CAREFUL THAT LIQUID REFRIGERANT DOESNOT GET IN YOUR EYES OR ON YOUR SKINIf 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 profes-sional treatment.

HANDLING PRECAUTIONS FORREFRIGERANT CONTAINER1. NEVER HEAT CONTAINER OR EXPOSE IT TONAKED FLAME2. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT

HANDLING PRECAUTIONS FORREFRIGERANT1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSEDAREA OR NEAR AN OPEN FLAME2. ALWAYS WEAR EYE PROTECTION

CHARGING AND LEAK-CHECK METHODSEvacuate the refrigeration system according to thefollowing procedures.

Fill refrigerant in gas state untilgauge pressure reads 1 kg/cm2

Abnormal indication ofmanifold gauges

Check and correctpipe joints

RefrigerantCharge

RefrigerantCharge

StartEvacuation

StopEvacuation

Leave for 5 min.

Gas LeakCheck

AirtightCheck

10 min.


CAUTION:

• Be sure to connect both the high and low pressurequick-connectors onto the A/C system when eva-cuating. If only one side is connected, the systemwould be open to atmosphere through the otherconnector, making it impossible to maintainvacuum.

• Be sure to turn off the manifold gauge valve imme-diately after evacuating the system. Then you mayswitch off the vacuum pump.

PRECAUTIONS WHEN CHARGINGREFRIGERANT1. DO NOT OPERATE COMPRESSOR WITHOUTENOUGH REFRIGERANT IN REFRIGERANT CYCLEIf there is not enough refrigerant in the refrigerantsystem, oil lubrication will be insufficient and com-pressor burnout may occur, so take care to avoid this.2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVEWHILST COMPRESSOR IS OPERATINGIf the high pressure valve is opened, refrigerant flowsin the reverse direction and could cause the chargingcylinder to rupture, so open and close the low pres-sure valve only.3. BE CAREFUL NOT TO OVERCHARGE WITH RE-FRIGERANT IN SYSTEMIf refrigerant is overcharged, it causes problems suchas insufficient cooling, poor fuel economy, engineoverheating etc.

ELECTRICAL PARTSBefore removing and inspecting the electrical parts,set the ignition switch to the LOCK position anddisconnect the negative (-) terminal cable from bat-tery.

CAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the ”LOCK”position and the negative (-) terminal cable is discon-nected from the battery.


SUPPLEMENTAL RESTRAINT SYSTEM(SRS)Failure to carry out service operations in the correctsequence could cause the airbag system to deploy,possibly leading to a serious accident.During removal or installation of the parts and theyellow wire harness and connector for the airbag isnecessary, refer to the precautionary notices in the RSsection before performing the operation.


DESCRIPTIONPARTS LOCATION

-AIR CONDITIONING SYSTEM DESCRIPTIONAC-8

WIRING DIAGRAM

USA


Canada


DAMPERS POSITION

-AIR CONDITIONING SYSTEM DESCRIPTIONAC-1 1

PREPARATIONSST (SPECIAL SERVICE TOOLS)

(07117-88070) Refrigerant Charging Hose

(07117-78050) Refrigerant Charging Gauge


(07117-58080) Quick Coupler


(07117-58090) Quick Coupler

(07117-58070) T-Joint

(07117-58060) Refrigerant Drain Service Valve

Suction (Blue)

Suction (diam. 13 mm)

Discharge (Red)

Utility (Green)

Discharge (diam. 16 mm)

07110-58060 Air Conditioner Service Tool Set

07116-38360 Gas Leak Detector Assembly

07112-66040 Magnetic Clutch Remover

07112-76060 Magnetic Clutch Stopper

07114-84020 Snap Ring Pliers

-AIR CONDITIONING SYSTEM PREPARATIONAC-12

RECOMMENDED TOOLS09082-00050 TOYOTA Electrical Tester Set

LUBRICANT

When replacing compressor

When replacing evaporator

When replacing condenser

When replacing receiver

40 cc (1.4 fl.oz.)

40 cc (1.4 fl.oz.)

120 cc (4.1 fl.oz.)

10 cc (2.9 fl.oz.)

Compressor oil

Classification

ND-OIL 8

CapacityItem

-AIR CONDITIONING SYSTEM PREPARATIONAC-13

USE OF MANIFOLD GAUGE SETMANIFOLD GAUGE SET INSTALLATION1. CONNECT CHARGING HOSES TO MANIFOLDGAUGE SETTighten the nuts by hand.

CAUTION: Do not connect the wrong hoses.

2. CONNECT QUICK CONNECTORS TO CHARGINGHOSESTighten the nuts by hand.3. CLOSE BOTH HAND VALVES OF MANIFOLDGAUGE SET4. REMOVE CAPS FROM SERVICE VALVES ON RE-FRIGERANT LINE

MANIFOLD GAUGE SET REMOVAL1. CLOSE BOTH HAND VALVES OF MANIFOLDGAUGE SET2. DISCONNECT QUICK CONNECTORS. FROM SER-VICE VALVES ON REFRIGERANT LINEHINT: Slide the sleeve of the quick connector upwardto unlock the connector and remove it from the ser-vice valve.3. INSTALL CAPS TO SERVICE VALVES ON REFRIG-ERANT LINE

5. CONNECT QUICK CONNECTORS TO SERVICEVALVESHINT: Push the quick connector onto the servicevalve, then slide the sleeve of the quick connectordownward to lock it.

-AIR CONDITIONING SYSTEM USE OF MANIFOLD GAUGE SETAC-14

TROUBLESHOOTINGYou will find the troubles easier using the table well shown below. In this table, each numbershows the priority of causes in troubles. Check each part in order. If necessary, replace theseparts.

Cool air comes out only at highengine rpm

No engine idle up when A/Cswitch on

Insp

ect A

/C c

ontr

ol le

ver

adju

stm

ent

Insp

ect c

oolin

g sy

stem

for

refr

iger

ant

Compressor operates immediately

Insp

ect e

ngin

e co

olan

t vol

ume

Cool air comes out immediately

Insp

ect v

olum

e of

ref

riger

ant

No air temperature control

No condenser fan operation

Blo

wer

spe

ed c

ontr

ol s

witc

h

Con

dens

er fa

n re

lay

No.

2

Con

dens

er fa

n fu

se

Con

dens

er fa

n re

lay

No.

3

Insp

ect d

rive

belt

tens

ion

Insp

ect o

utle

t air

cont

rol

No compressor operation

No warm air comes out

Rad

iato

r fa

n m

ain

rela

y

No cool air cones out

Part Name

No blower operation

Con

dens

er fa

n m

otor

Insufficient cooling

Hea

ter

mai

n re

lay

Blo

wer

res

isto

r

Blo

wer

mot

or

AC

-54

AC

-55

AC

-54

AC

-55

See Page

Trouble

AC

-61

AC

-23

AC

-47

AC

-51

AC

-52

AC

-22

AC

-46

AC

-64

-AIR CONDITIONING SYSTEM TROUBLESHOOTINGAC-15

Engine coolant temperature switch

Wiring and wiring connections

Vacuum switching valve (VSV)

Inspect refrigeration control

Inspect refrigerant lines

Magnetic clutch relay

High pressure switch

Dual pressure switch

Expansion valve

Magnetic clutch

Heater radiator

A/C amplifier

A/C switch

Compressor

Thermistor

Condenser

Evaporator

AC-49

AC-66

A/C fuse

Receiver

AC-60

AC-60

AC-53

AC-63

AC-41

AC-48

AC-34

AC-44

AC-42

AC-57

AC-34

-A

IR C

ON

DIT

ION

ING

SY

ST

EM

TR

OU

BLE

SH

OO

TIN

GA

C-16

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SETThis 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 - 95°F)(b) Engine running at 1,500 rpm(c) Blower speed control switch set at high(d) Temperature control set at max. coolHINT: It should be noted that the gauge indications may vary slightly due to ambient temperatureconditions.1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM

Gauge reading:Low pressure side:0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm 2)High pressure side:1.37 - 1.57 MPa (14 - 16 kgf/cm 2)


(1) Check for gas leakage with leak detector and repair if necessary(2) Charge refrigerant to 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

� Drier in oversaturated state ↓� Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant

� 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

(1) Replace receiver/drier(2) Remove moisture in cycle through repeat- edly evacuating air(3) Charge new refrigerant to proper amount

� Pressure low on both low and high pressure sides� Bubbles seen in sight glass continuously� Insufficient cooling performance

� During operation, pressure on low pressure side sometimes becomes a vacuum and sometimes normal

2. MOISTURE PRESENT IN REFRIGERATION SYSTEM

� Insufficient refrigerant in system ↓� Refrigerant leaking

Condition: Periodically cools and then fails to cool

� Gas leakage at some place in refrigeration system

3. INSUFFICIENT REFRIGERANT

Symptom seen inrefrigeration system

Condition: Insufficient cooling

Symptom seen inrefrigeration system Probable cause

Probable cause Diagnosis

Diagnosis

Remedy

Remedy


(1) Check heat sensing tube, expansion valve and EPR(2) Clean out dirt in expansion valve by blowing with air If not able to remove 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.

� Refrigerant flow ob- structed by moisture or dirt in refrigeration system� Refrigerant flow ob- structed by gas leakage from expansion valve heat sensing tube

� Vacuum indicated on low pressure side, very low pressure indicated on high pressure side� Frost or dew seen on piping before and after receiver/drier or expansion valve

5. REFRIGERANT DOES NOT CIRCULATE

Condition: Does not cool (Cools from time to time in some cases)

� Pressure low on both low and high pressure sides� Frost on tubes from receiver to unit

4. POOR CIRCULATION OF REFRIGERANT

� Refrigerant flow ob- structed by dirt in receiver

� Refrigerant does not circulate




Probable cause

� Replace receiver� Receiver clogged

Probable cause

Diagnosis

Diagnosis

Remedy

Remedy


6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER

(1) Clean condenser(2) Check fan motor operation(3) !f (1) and (2) are in normal state, check amount of refrigerant Charge proper amount of refrigerant

NOTE: These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without vacuum purging.

� Excessive refrigerant in cycle → refrigerant overcharged� Condenser cooling insufficient → condenser fins clogged or fan motor faulty

� Pressure too high on both low and high pressure sides� No air bubbles seen through the sight glass even when the engine rpm is lowered.

� Pressure too high on both low and high pressure sides� The low pressure piping is hot to the touch� Bubbles seen insight glass

� Unable to develop sufficient performance due to excessive refrigerant in system� Insufficient cooling of condenser

(1) Check compressor oil to see if dirty or insufficient(2) Evacuate air and charge new refrigerant

� Air present in refrigeration system ↓� Insufficient vacuum purging

7. AIR PRESENT IN REFRIGERATION SYSTEM

Condition: Does not cool down sufficiently

Condition: Does not cool sufficiently

� Air entered in refrigeration system


Symptom seen inrefrigeration system Probable cause

Probable cause

Diagnosis

Diagnosis

Remedy

Remedy


8. EXPANSION VALVE IMPROPERLYMOUNTED/HEAT SENSING TUBE DEFECTIVE(OPENS TOO WIDE)

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

(1) Check heat sensing tube installed condition(2) If (1) is normal, check expansion valve Replace if defective

� Excessive refrigerant in low pressure piping ↓� Expansion valve opened too wide

� Compression defective ↓ Valve leaking or broken, sliding parts

� Pressure too high on low pressure side� Pressure too low on high pressure side

� Trouble in expansion valve or heat sensing tube not installed cor- rectly

9. DEFECTIVE COMPRESSION COMPRESSOR

� Internal leak in compressor

� Repair or replace compressor




Condition: Does not cooI

^

Diagnosis

Probable cause

Probable cause

Diagnosis Remedy

Remedy


REFRIGERANT VOLUMEREFRIGERANT VOLUME INSPECTION1. RUN ENGINE AT APPROX. 1,500 RPM2. SET TEMPERATURE CONTROL AT MAX. COOL3. SET BLOWER SWITCH AT ’HI’4. SET AIR INLET CONTROL AT ’RECIRC’5. TURN A/C SWITCH ON6. FULLY OPEN DOORS7. INSPECT AMOUNT OF REFRIGERANTObserve the sight glass on the liquid tube.

REFRIGERANT CHARGE VOLUMESpecified amount:700 ±50 g (24.69 ± 1.76 oz.)

* Bubbles in the sight glass with ambient tempera-tures higher can be considered normal if cooling issufficient.

(1) Check for gas leakage with gas leak tester and repair if necessary(2) Add refrigerant until bubbles disap- pear

(1) Check for gas leakage with gas leak tester and repair if necessary(2) Add refrigerant until bubbles disap- pear

(1) Recover refrigerant(2) Evacuate air and charge proper amount of purified refrigerant

Immediately after air conditioning isturned off, refrigerant in sight glassstays clear

When air conditioning is turned off, re-frigerant foams and then stays clear

No temperature difference betweencompressor inlet and outlet

Temperature between compressor inletand outlet is noticeably different

No bubbles present in sight glass

Bubbles present in sight glass

None, sufficient or too much

Empty or nearly empty

Amount of refrigerant

Refer to items 3 and 4

Refer to items 5 and 6Correct or too much

Insufficient*

Symptom

Too much

Remedy

Correct

Item

-AIR CONDITIONING SYSTEM REFRIGERANT VOLUMEAC-22

2. INSPECT DRIVE BELT TENSIONUsing a belt tension gauge, check the drive belt ten-sion.Belt tension gauge: Nippondenso BTG-20 (95506-00020) or Borroughs No. BT-33-73F

Drive belt tension:New belt 160 ± 25 lbfUsed 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.

DRIVE BELT TENSIONDRIVE BELT TENSION INSPECTION1. MAKE SURE THAT DRIVE BELT IS INSTALLEDCORRECTLYCheck that the drive belt fits properly in the ribbedgroves.

-AIR CONDITIONING SYSTEM DRIVE BELT TENSIONAC-23

IDLE-UP SPEEDIDLE UP SPEED INSPECTION1. WARM UP ENGINE2. SET VEHICLE IN FOLLOWING CONDITION• Blower switch high position• A/C switch on• Magnetic clutch on3. INSPECT IDLE UP SPEED

Standard:950 ± 50 RPM

IDLE-UP SPEED ADJUSTMENTADJUST IDLE-UP SPEEDAdjust idle-up speed with the idle adjusting screw ofthe VSV.

-AIR CONDITIONING SYSTEM IDLE-UP SPEEDAC-24

REFRIGERANT LINESLOCATIONS

-AIR CONDITIONING SYSTEM REFRIGERANT LINESAC-25

REFRIGERANT LINES REPLACEMENT1. RECOVER REFRIGERANT IN REFRIGERATIONSYSTEM2. REPLACE FAULTY TUBE OR HOSEHINT: Cap the open fittings immediately to keep mois-ture or dirt out of the system.3. TORQUE CONNECTIONS TO SPECIFIED TORQUE

NOTICE: Connections should not be torque tighter thanthe specified torque.

4. EVACUATE AIR IN REFRIGERATION SYSTEM ANDCHARGE WITH REFRIGERANT

Specified amount:700 ± 50 g (24.69 ± 1.76 oz.)

5. INSPECT FOR LEAKAGE OF REFRIGERANTUsing a gas leak tester, check for leakage of refriger-ant.6. INSPECT AIR CONDITIONING OPERATION

ON-VEHICLE INSPECTION1. INSPECT HOSE AND TUBE CONNECTIONS FORLOOSENESS2. INSPECT HOSES AND TUBES FOR LEAKAGEUsing a gas leak tester, check for leakage of refriger-ant.

-AIR CONDITIONING SYSTEM REFRIGERANT LINESAC-26

COOLING UNITCOOLING UNIT REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY

CAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the ’LOCK’position and the negative (-) terminal cable is discon-nected from the battery.

2. RECOVER REFRIGERANT FROM REFRIGERATIONSYSTEM3. DISCONNECT SUCTION TUBE FROM COOLINGUNIT OUTLET FITTING4. DISCONNECT LIQUID TUBE FROM COOLING UNITINLET FITTINGHINT: Cap the open fittings immediately to keep mois-ture out of the system.5. REMOVE INSTRUMENT LOWER FINISH PANEL(See page BO-46 )6. DISCONNECT CONNECTOR FROM WIRE HARNESS7. 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 UNITRemove the 3 screws, nuts and the cooling unit.

-AIR CONDITIONING SYSTEM COOLING UNITAC-27

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.

COOLING UNIT DISASSEMBLY


2. INSTALL THERMISTOR3. INSTALL UPPER AND LOWER CASE TO EVAPORA-TOR(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.

COOLING UNIT ASSEMBLY1. CONNECT EXPANSION VALVE, SUCTION ANDLIQUID TUBES TO EVAPORATORTorque the bolts.

Torque: 5.4 N-m (55 kgf-cm. 48 in.-Ibf)

3. REMOVE EXPANSION VALVE, SUCTION ANDLIQUID TUBES FROM EVAPORATOR

2. REMOVE THERMISTOR FROM EVAPORATOR


6. CONNECT LIQUID TUBE TO COOLING UNIT INLETFITTINGTorque the nut.

Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf)

7. CONNECT SUCTION TUBE TO COOLING UNITOUTLET FITTINGTorque the nut.

Torque: 32 N-m (330 kgf-cm, 24 ft-Ibf)

8. IF EVAPORATOR WAS REPLACED, ADD COMPRES-SOR OIL TO COMPRESSOR

Add 40 - 50 cc (1.4 - 1.7 fl.oz.)Compressor oil:ND-OIL 9

9. CONNECT NEGATIVE (-) CABLE TO BATTERY10. EVACUATE AIR FROM REFRIGERATION SYSTEM11. CHARGE SYSTEM WITH REFRIGERANT AND IN-SPECT FOR LEAKAGE OF REFRIGERANT


COOLING UNIT INSTALLATION1. INSTALL COOLING UNITInstall 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 2screws.(b) Connect the connector to the A/C amplifier.3. INSTALL EARTH WIRE TO BODY

4. CONNECT CONNECTOR TO WIRE HARNESS OF VE-HICLE SIDE5. INSTALL INSTRUMENT LOWER FINISH PANEL


BLOWER UNITBLOWER UNIT REMOVAL1. 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 theblower motor.(e) Remove the nut, 2 screws and the blower unit.

BLOWER UNIT INSTALLATION1. INSTALL BLOWER UNIT(a) Install the blower unit with the nut and 2 screws.(b) Connect the air inlet damper control cable to theblower unit.HINT: For installing the control cable, refer to ”Adjust-ment of A/C Control Cables”.(c) Connect the connector to the blower motor.2. INSTALL COOLING UNIT(See page AC-30 )

-AIR CONDITIONING SYSTEM BLOWER UNITAC-31

4. DISCONNECT WATER HOSES FROM HEATER RA-DIATOR PIPES(a) Grip the claws of the hose clip with pliers and slide theclip along the hose to a place where it dose not clampthe hose to the pipe.(b) Disconnect the water hoses.5. REMOVE PIPE GROMMETS6. REMOVE A/C CONTROL ASSEMBLY(See page AC-64 )

HEATER UNITHEATER UNIT REMOVAL1. REMOVE SAFETY PADSee ”Instrument Panel” on BO section.2. REMOVE COOLING UNIT(See page AC-25 )3. DRAIN ENGINE COOLANT FROM RADIATORHINT: It is not necessary to drain out all the coolant.

8. REMOVE INSTRUMENT PANEL REINFORCEMENTNO. 1 BRACERemove the 2 nuts, 2 bolts and the No. 1 brace.9. REMOVE INSTRUMENT PANEL REINFORCEMENTNO. 2 BRACERemove the 2 nuts, a bolts and the No. 2 brace.

7. REMOVE HEATER TO REGISTER CENTER DUCTRemove the 3 screws and the duct.

10. REMOVE HEATER UNITRemove the screw, nut and the heater unit.

-AIR CONDITIONING SYSTEM HEATER UNITAC-32

HEATER UNIT INSTALLATIONInstall by following the removal procedure in reverseorder.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.

-AIR CONDITIONING SYSTEM HEATER UNITAC-33

COMPRESSORON-VEHICLE INSPECTIONMagnetic Clutch:INSPECT MAGNETIC CLUTCH FOR FOLLOWING(a) Inspect the pressure plate and the rotor for signs ofoil.(b) Check the clutch bearings for noise and grease leak-age.(c) Connect the positive (+) lead from the battery to theterminal on the magnetic clutch connector and thenegative (-) lead to the body ground.(d) Check that the magnetic clutch is energized.If the magnetic clutch is not energized, replace themagnetic clutch.

Compressor:1. INSTALL MANIFOLD GAUGE SET2. RUN ENGINE AT APPROX. 2,000 RPM3. INSPECT COMPRESSOR FOR FOLLOWING(a) High pressure gauge reading is not lower and lowpressure gauge reading is not higher than normal.(b) Check that the metallic sound.(c) Check that the leakage from shaft seal.

-AIR CONDITIONING SYSTEM COMPRESSORAC-34

1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10MINUTES2. STOP ENGINE3. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


4. RECOVER REFRIGERANT FROM REFRIGERATIONSYSTEM5. REMOVE UNDER COVER6. DISCONNECT CONNECTOR FROM MAGNETICCLUTCH7. DISCONNECT 2 HOSES FROM COMPRESSOR SER-VICE VALVECap the open fitting immediately to keep moisture anddust out of the system.

COMPRESSOR REMOVAL


8. REMOVE COMPRESSOR(a) Loosen the compressor drive belt.(b) Remove the compressor mounting bolts and the com-pressor.

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

MAGNETIC CLUTCH DISASSEMBLY


3. REMOVE STATOR(a) Using a screwdriver and disconnect the stator leadwires from the compressor housing.

(b) Using a plastic hammer, tap the rotor off the shaft.NOTICE: Be careful not to damage the pulley when tapp-ing on the rotor.

(c) Using SST and the socket, remove the pressure plate.SST 07112-76060, 07112-66040

2. REMOVE ROTOR(a) Using SST, remove the snap ring.SST 07114-84020

(d) Remove the shims from the shaft.


MAGNETIC CLUTCH ASSEMBLY1. INSTALL STATOR(a) Install the stator on the compressor.(b) Using SST, install a new snap ring.SST 07114-84020

(c) Connect the stator lead wires to the compressor hous-ing.

NOTICE: The snap ring should be installed so that itsbeveled side faces up.

(b) Using SST, remove the snap ring.SST 07114-84020

(c) Remove the stator.


3. INSTALL PRESSURE PLATE(a) Adjust the clearance between the pressure plate androtor 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 thenumber of shims to obtain the standard clearance.

2. INSTALL ROTOR(a) Install the rotor on the compressor shaft.(b) Using SST, install a new snap ring.SST 07114-84020

(b) Using SST and torque wrench, install the shaft nut.SST 07112-76060

Torque: 14 N-m (140 kgf-cm, 10 ft-lbf)

NOTICE: The snap ring should be installed so that itsbeveled side faces up.


COMPRESSOR INSTALLATION1. INSTALL COMPRESSOR WITH 4 MOUNTINGBOLTS


2. INSTALL DRIVE BELTSee Drive Belt Tension Adjustment on page AC-23 .3. CONNECT 2 HOSES TO COMPRESSOR SERVICEVALVES

Torque:Discharge line10 N-m (100 kgf-cm, 8 ft-lbf)Suction line10 N-m (100 kgf-cm. 8 ft-lbf)

4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS5. CONNECT NEGATIVE (-) CABLE TO BATTERY6. EVACUATE AIR FROM REFRIGERATION SYSTEM7. CHARGE SYSTEM WITH REFRIGERANT AND IN.SPECT FOR LEAKAGE OF REFRIGERANT

Specified amount:700 ±50 g (24.69 ± 1.76 oz.)

4. INSPECT CLEARANCE OF MAGNETIC CLUTCH(a) Set the dial-gauge to the pressure plate of the mag-netic clutch.(b) Connect the magnetic clutch lead wire to the positive(+) terminal of the battery.(c) Check the clearance between the pressure plate androtor, when connect the negative (-) terminal of thebattery.

Standard clearance:0.5 ± 0.15 mm (0.020 ± 0.0059 in.)

If the clearance is not within standard clearanceadjust the clearance using shims to obtain the stand-ard clearance.


RECEIVER REMOVAL1. RECOVER REFRIGERANT FROM REFRIGERATIONSYSTEM2. DISCONNECT (-) NEGATIVE CABLE FROM BAT-TERY

CAUTION: Work must be started after 90 seconds fromthe time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable is discon-nected from the battery.

3. REMOVE FRONT GRILLE4. DISCONNECT 2 LIQUID TUBES FROM RECEIVERHINT: Cap the open fittings immediately to keep mois-ture out of the system.5. REMOVE RECEIVER FROM RECEIVER HOLDER

RECEIVER INSTALLATION1. INSTALL RECEIVER IN RECEIVER HOLDERHINT: Do not remove the blind plugs until ready forconnection.2. CONNECT 2 LIQUID TUBES TO RECEIVERTorque the bolt.

Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)

3. INSTALL FRONT GRILLE4. CONNECT NEGATIVE (-) CABLE TO BATTERY5. IF RECEIVER WAS REPLACED, ADD COMPRESSOROIL TO COMPRESSOR

Add 20 cc (0.71 fl.oz.)Compressor oil:ND-OIL 9

6. EVACUATE AIR FROM REFRIGERATION SYSTEM7. CHARGE SYSTEM WITH REFRIGERANT AND IN-SPECT FOR LEAKAGE OF REFRIGERANT


RECEIVERON-VEHICLE INSPECTIONINSPECT SIGHT GLASS, FUSIBLE PLUG AND FIT-TINGS FOR LEAKAGEUse a gas leak tester. Repair as necessary.

-AIR CONDITIONING SYSTEM RECEIVERAC-41

3. REMOVE FOLLOWING PARTS• Front grille• Horn• Hood lock• Center brace• Condenser fan4. DISCONNECT LIQUID TUBE AND DISCHARGEHOSE FROM CONDENSER FITTINGHINT: Cap the open fittings immediately to keep mois-ture out of the system.5. REMOVE RECEIVER WITH RECEIVER BRACKETFROM CONDENSER6. REMOVE RADIATOR SUPPORT BRACKETS7. REMOVE CONDENSER(a) Remove the 2 condenser mounting bolts.(b) Remove the 2 condenser brackets.

CONDENSERON-VEHICLE INSPECTION1. INSPECT CONDENSER FINS FOR BLOCKAGE ORDAMAGEIf the fins are clogged, wash them with water and drywith compressed air.

NOTICE: Be careful not to damage the fins.

If the fins are bent, straighten them with a screwdriveror pliers.2. INSPECT CONDENSER FITTINGS FOR LEAKAGERepair as necessary.

CONDENSER REMOVAL1. RECOVER REFRIGERANT FROM REFRIGERATIONSYSTEM2. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


-AIR CONDITIONING SYSTEM CONDENSERAC-42

2. INSTALL RADIATOR SUPPORT3. INSTALL RECEIVER WITH RECEIVER BRACKET TO

CONDENSER4. CONNECT LIQUID TUBE TO RECEIVERTorque the bolt.

Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)

5. CONNECT LIQUID TUBE AND DISCHARGE HOSETO CONDENSERTorque 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 grille7. CONNECT NEGATIVE (-) CABLE TO BATTERY8. IF CONDENSER WAS REPLACED, ADD COMPRES-SOR OIL TO COMPRESSOR

Add 40 - 50 cc (1.4 - 1.7 fl.oz.)Compressor oil:ND-OIL 9

9. EVACUATE AIR FROM AIR CONDITIONINGSYSTEM10. CHARGE SYSTEM WITH REFRIGERANT AND IN-SPECT FOR LEAKAGE OF REFRIGERANT


CONDENSER INSTALLATION1. INSTALL CONDENSERInstall the condenser with the 2 condenser bracketsand the 2 mounting bolts.

(c) Pull the condenser out.


EVAPORATOR INSPECTION1. CHECK EVAPORATOR FINS FOR BLOCKAGEIf the fins are clogged, clean them with compressedair.

NOTICE: Never use water to clean the evaporator.

2. CHECK FITTINGS FOR CRACKS OR SCRATCHESRepair as necessary.

REMOVAL AND INSTALLATION OFEVAPORATORSee item of cooling unit.


HEATER RADIATORHEATER RADIATOR REMOVAL1. 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 INSPECTIONINSPECT FINS FOR BLOCKAGEIf the fins are clogged, clean them with compressedair.

HEATER RADIATOR INSTALLATION1. 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 )

-AIR CONDITIONING SYSTEM HEATER RADIATORAC-45

BLOWER MOTORMOTOR REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


MOTOR INSTALLATION1. INSTALL BLOWER MOTOR(a) Install the blower motor with the 3 screws.(b) Connect the connector to blower motor.2. INSTALL A/C AMPLIFIERInstall A/C amplifier with the 3 screws.3. CONNECT NEGATIVE (-) CABLE TO BATTERY

MOTOR INSPECTIONINSPECT BLOWER MOTOR OPERATIONConnect the positive (+) lead from the battery toterminal 1 and the negative (-) lead to terminal 2,then check that the motor operation is smooth.

3. REMOVE BLOWER MOTOR(a) Disconnect the connector from the blower motor.(b) Remove the 3 screws and the blower motor.

2. REMOVE A/C AMPLIFIERRemove the 3 screws and the A/C amplifier with theconnector connected.

-AIR CONDITIONING SYSTEM BLOWER MOTORAC-46

CONDENSER FAN REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


2. REMOVE FOLLOWING COMPONENTS• Front grille• Hood lock• Center brace3. REMOVE CONDENSER FAN(a) Disconnect the connector from fan motor.(b) Remove the 2 bolts and the condenser fan.

CONDENSER FAN INSTALLATION1. 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 grille3. CONNECT NEGATIVE (-) CABLE TO BATTERY

CONDENSER FANON-VEHICLE INSPECTIONINSPECT CONDENSER FAN MOTOR(a) Using the wire harness, apply battery positive voltageto the connector.(b) Confirm smooth rotation of the motor within the spe-cified current flow.

Standard current:9.5 ±1.5 A

If current is not as specified, replace the motor.

-AIR CONDITIONING SYSTEM CONDENSER FANAC-47

EXPANSION VALVEON-VEHICLE INSPECTION1. CHECK QUANTITY OF GAS DURING REFRIGERA-TION CYCLE2. INSTALL MANIFOLD GAUGE SET3. RUN ENGINERun 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 VALVEIf the expansion valve is faulty, the low pressurereading will drop to 0 kPa (0 kgf/cm2, 0 psi), otherwiseit is OK.HINT: When the low pressure drops to 0 kPa (0 kgf/cm2, 0 psi), feel the receiver’s IN and OUT sides for notemperature difference.

EXPANSION VALVE REMOVAL ANDINSTALLATIONSee item of cooling unit.

-AIR CONDITIONING SYSTEM EXPANSION VALVEAC-48

2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BYBLOWING AIR INTO PIPES(a) Connect the VSV terminals to the battery terminals asillustrated.(b) Blow into pipe ”A” and check that air comes out ofpipe ”B”.

(c) Disconnect the battery.(d) Blow into pipe ”A” and check that air does not comeout pipe ’B’.If a problem is found, replace the VSV.

3. CHECK FOR SHORT CIRCUITUsing an ohmmeter, check that there is no continuitybetween each terminal and the VSV body.If there is continuity, replace the VSV.

VSV INSPECTION1. DISCONNECT VACUUM HOSES AND CONNECTORFROM VSV

VACUUM SWITCHING VALVE (VSV)VACUUM HOSE CIRCUIT

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

4. CHECK FOR OPEN CIRCUITUsing an ohmmeter, the resistance between the 2terminals.

Resistance:30 - 34 � at 20� C (68� F)

If the resistance is not within specification, replacethe VSV.

-AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV)AC-50

BLOWER RESISTORBLOWER RESISTOR REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


2. REMOVE BLOWER RESISTOR(a) Disconnect the connector from the blower resistor.(b) Remove the 2 screws and the blower resistor.

BLOWER RESISTOR INSTALLATION1. 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

BLOWER RESISTOR INSPECTIONINSPECT BLOWER RESISTORContinuity

If continuity is not as specified, replace the blowerresistor.

Condition

Terminal

Constant

-AIR CONDITIONING SYSTEM BLOWER RESISTORAC-51

HEATER MAIN RELAYRELAY REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


2. REMOVE INSTRUMENT LOWER FINISH PANEL(See page BO-46 )3. DISCONNECT HEATER MAIN RELAY FROM A/CRELAY BLOCK

RELAY INSTALLATION1. CONNECT HEATER MAIN RELAY TO A/C RELAYBLOCK2. INSTALL INSTRUMENT LOWER FINISH PANEL3. CONNECT NEGATIVE (-) CABLE TO BATTERY

RELAY INSPECTIONINSPECT HEATER MAIN RELAYContinuity

If continuity is not as specified, replace the relay.

Tester connection toterminal number

Apply B + betweenterminals 1 and 3.

Specified value

1-32-4

Continuity

Continuity

Condition

Constant

4-5

-AIR CONDITIONING SYSTEM HEATER MAIN RELAYAC-52

MAGNETIC CLUTCH RELAYRELAY REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


2. REMOVE INSTRUMENT LOWER FINISH PANEL(See page BO-46 )3. REMOVE MAGNETIC CLUTCH RELAYRemove a screw and disconnect the relay from theconnector.

RELAY INSTALLATION1. INSTALL MAGNETIC CLUTCH RELAYConnect the relay to the connector and install it to thecooling unit with the screw.2. INSTALL INSTRUMENT LOWER FINISH PANEL3. CONNECT NEGATIVE (-) CABLE TO BATTERY

RELAY INSPECTIONINSPECT MAGNETIC CLUTCH RELAYContinuity



Apply B+ betweenterminals 1 and 3.

Specified value

Continuity

Continuity

Condition

Constant 1-3

2-4

-AIR CONDITIONING SYSTEM MAGNETIC CLUTCH RELAYAC-53

CONDENSER FAN RELAY NO.2 ANDNO.3 (USA)

RELAYS REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


2. DISCONNECT CONDENSER FAN RELAY NO. 2 ANDNO. 3 FROM RELAY BLOCK NO. 2

RELAYS INSPECTION1. INSPECT CONDENSER FAN RELAY NO. 2Check the relay the same way as for the heater mainrelay.2. INSPECT CONDENSER FAN RELAY NO. 3Check the relay the same way as for the magneticclutch relay.

RELAYS INSTALLATION1. CONNECT CONDENSER FAN RELAY NO. 2 ANDNO. 3 TO RELAY BLOCK NO. 22. CONNECT NEGATIVE (-) CABLE TO BATTERY

-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N0.3 (USA)AC-54

CONDENSER FAN RELAY NO.2 ANDNO.3 (Canada)

RELAYS REMOVAL1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY


2. DISCONNECT CONDENSER FAN RELAY NO. 2 ANDNO. 3 FROM RELAY BLOCK NO. 5

RELAYS INSPECTION1. INSPECT CONDENSER FAN RELAY NO.2Continuity

If continuity is not as specified, replace the relay.2. INSPECT CONDENSER FAN RELAY NO.3Continuity




Apply B + betweenterminals 1 and 2.

Apply B+ betweenterminals 1 and 2.

Specified value

Specified value

1-23-4

Continuity

Continuity

Continuity

Continuity

Condition

Condition

Constant

Constant

1-2

3-5

3-5

-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY NO.2 AND NO.3 (Canada)AC-55

RELAYS INSTALLATION1. CONNECT CONDENSER FAN RELAY NO. 2 ANDNO. 3 TO RELAY BLOCK NO.52. CONNECT NEGATIVE (-) CABLE TO BATTERY

-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N 0.3(Canada)AC-56

THERMISTOR INSPECTIONINSPECT THERMISTOR RESISTANCE(a) Measure the resistance between terminals at 25�C(77�F).

Resistance:1,500 � at 25°C (77°F)

(b) Place the thermistor in cold water. While varying thetemperature of the water, measure the resistance atthe connector and at the same time, measure thetemperature of the water with a thermometer.(c) Compare the 2 readings on the chart.If the resistance valve is not as specified, replace thethermistor.

THERMISTORTHERMISTOR REMOVAL ANDINSTALLATIONSee item of cooling unit.

-AIR CONDITIONING SYSTEM THERMISTORAC-57

REVOLUTION DETECTING SENSOR(w Power Steering)SENSOR INSPECTIONMEASURE SENSOR RESISTANCEMeasure the resistance between terminals 3 and 4.

Standard resistance:240 ± 80� at 20°C (68°F)

If resistance value is not as specified, replace thesensor.

SENSOR REMOVAL1. REMOVE COMPRESSOR(See page AC-35 )2. REMOVE REVOLUTION DETECTING SENSOR(a) Remove the bolt.(b) Remove the revolution detecting sensor.

SENSOR INSTALLATION1. INSTALL REVOLUTION DETECTING SENSORUsing a torque wrench, tighten the bolt.

Torque: 11 N .m (110 kgf-cm, 8 ft-lbf)

2. INSTALL COMPRESSOR(See page AC-40 )

-AIR CONDITIONING SYSTEM REVOLUTION DETECTING SENSOR (w Power Steering)AC-58

REFRIGERANT TEMPERATURESWITCHSWITCH REMOVAL AND INSTALLATIONSee ”Discharge Valve Removal or Installation” on pageAC-35 or 40.

SWITCH INSPECTIONINSPECT REFRIGERANT TEMPERATURE SWITCHCheck refrigerant temperature switch operation.

If operation is not as specified, replace the switch.HINT: After inspection, throughly clean the switchbefore assembly.

Oil Temperature

120°C (248°F)

180°C (356°F)

Specified Value

No continuity

Continuity

-AIR CONDITIONING SYSTEM REFRIGERANT TEMPERATURE SWITCHAC-59

SWITCHES REMOVAL1. RECOVER REFRIGERANT FROM REFRIGERATIONSYSTEM2. DISCONNECT NEGATIVE (-) CABLE FROM BAT-TERY


3. REMOVE TRIPLE PRESSURE SWITCH FROMLIQUID TUBEDisconnect the connector and remove the triple pres-sure switch.

SWITCHES INSTALLATION1. INSTALL TRIPLE PRESSURE SWITCH TO LIQUIDTUBETighten the triple pressure switch then connect theconnector to it.


2. CONNECT NEGATIVE (-) CABLE TO BATTERY3. EVACUATE AIR FROM REFRIGERATION SYSTEM4. CHARGE SYSTEM WITH REFRIGERANT AND IN-SPECT FOR LEAKAGE OF REFRIGERANT


4. INSPECT TRIPLE PRESSURE SWITCH(Magnetic Clutch Control)(a) Connect the positive (+) lead from the ohmmeter toterminal 1 and negative (-) lead to terminal 2.(b) Check continuity between terminals when refrigerantpressure is changed, as shown.If operation is not as specified, replace the pressureswitch.

TRIPLE PRESSURE SWITCHON-VEHICLE INSPECTION1. DISCONNECT CONNECTOR FROM TRIPLE PRES-SURE SWITCH2. INSTALL MANIFOLD GAUGE SET3. RUN ENGINE AT APPROX. 2,000 RPM

-AIR CONDITIONING SYSTEM TRIPLE PRESSURE SWITCHAC-60

BLOWER SPEED CONTROL SWITCHSWITCH REMOVAL1. DISCONNECT NEGATIVE (-) GABLE FROM BAT-TERY


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 controlassembly.(b) Using a screwdriver, pry loose the clip and push outthe blower speed control switch to rear of the A/Ccontrol assembly.(c) Disconnect the connector from the blower speed con-trol switch.

SWITCH INSPECTIONINSPECT BLOWER SPEED CONTROL SWITCHContinuity

If continuity is not as specified, replace the blowerspeed control switch.

Switch position

IlluminationTerminal

OFF

-AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCHAC-61

SWITCH INSTALLATION1. INSTALL BLOWER SPEED CONTROL SWITCH(a) Connect the connector to the blower speed controlswitch.(b) Install the illumination light to the A/C control assem-bly.(c) Install the blower speed control switch to the A/Ccontrol assembly.2. INSTALL AUDIO AND ASH TRAY3. INSTALL A/C CONTROL PANEL4. CONNECT NEGATIVE (-) CABLE TO BATTERY

-AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCHAC-62

AIR CONDITIONING SWITCHSWITCH REMOVAL1. DISCONNECT NEGATIVE (-) CABLE PROM BAT-TERY


2. REMOVE A/C SWITCHUsing a screwdriver, pry loose the clips and removethe A/C switch.HINT: Tape the screwdriver tip before use.

SWITCH INSTALLATION1. INSTALL A/C SWITCHPush in the A/C switch to the A/C control assembly.2. CONNECT NEGATIVE (-) CABLE TO BATTERY

If continuity is not as specified, check the bulb orreplace the switch.

SWITCH INSPECTIONINSPECT A/C SWITCHContinuity


Illumination circuit

A/C Switch OFF

A/C Switch ON

Specified value

4-54-6

No continuity

Continuity

Continuity

Condition

1-3

-AIR CONDITIONING SYSTEM AIR CONDITIONING SWITCHAC-63

AIR CONDITIONING CONTROLASSEMBLYON-VEHICLE INSPECTIONINSPECT A/C CONTROL LEVERS OPERATIONMove the control levers left and right and check forstiffness and binding through the full range of thelevers.

3. ADJUST AIR MIX DAMPER CONTROL CABLESet the air mix damper on ”COOL” position, install thecontrol cable and lock the clamp.

1. ADJUST AIR INLET DAMPER CONTROL CABLESet the air inlet damper on ”RECIRC” position, installthe control cable and lock clamp.

2. ADJUST MODE DAMPER CONTROL CABLESet the air inlet damper on ”FACE” position, install thecontrol cable and lock the clamp.

A/C CONTROL CABLES ADJUSTMENT

-AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLYAC-64

A/C CONTROL ASSEMBLYINSTALLATION1. 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 andblower unit.HINT: For installing the control cables, refer to ”Ad-justment of A/C Control Cables”.2. INSTALL SAFETY PAD

A/C CONTROL ASSEMBLY REMOVAL1. REMOVE SAFETY PADSee ”Instrument Panel” on BO section.2. REMOVE A/C CONTROL ASSEMBLY(a) Disconnect the control cables from the heater unitand the blower unit.(b) Remove the blower switch and remove the A/C con-trol assembly.

-AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLYAC-65

AMPLIFIER INSPECTIONINSPECT A/C AMPLIFIER CONNECTOR ON WIREHARNESS SIDETest conditions:• Ignition switch ON• Temperature control lever to MAX COOL• Blower switch ONw/o Power Steering

AIR CONDITIONING AMPLIFIERAMPLIFIER REMOVALREMOVE A/C AMPLIFIER(a) Disconnect the connector from the amplifier.(b) Remove the 3 screws and the amplifier.





Approx. 1.5 k� at 25°C (77°F)

w/ Power Steering

Specified value (Resistance)

Specified value (Continuity)

Specified value (Voltage)

Specified value (Voltage)

Battery positive voltage




Approx. 10 to 14 V

Approx. 10 to 14 V

Blower switch OFF

Blower switch OFF

Blower switch ON

Blower switch ON

A/C switch OFF

A/C switch OFF

Stop the engine

Start the engine

Stop the engine

Start the engine

A/C switch ON

A/C switch ON

Approx. 240�

12 - Ground

8 - Ground

8 - Ground

8 - Ground

8 - Ground

1 - Ground

1 - Ground

7 - Ground

7 - Ground

7 - Ground

1 - Ground

1 - Ground

7 - Ground

No voltage

No voltage

No voltage

No voltage

No voltage

No voltage

Continuity

Continuity

Condition

Condition

Condition

Condition

Constant

Constant

Constant

Constant

9-13

2- 13

5 -7

-AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIERAC-66

If continuity is not as specified, replace the A/C ampli-fier.



Specified value (Continuity)

Specified value (Resistance)

12 - Ground Continuity

Continuity

Condition

Condition

Constant

Constant

Constant2 - 12

5-7

Approx. 1.5 k� at 25°C (77°F)

-AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIERAC-67

SERVICE SPECIFICATIONSSERVICE DATA

TORQUE SPECIFICATIONS0.5 ± 0.15 mm (0.02 ± 0.0059 in.)

Compressor x Compressor bracket

Refrigerant charge volume 700 ± 50 g (24.69 ± 1.76 oz.)

Compressor x Discharge hose

Compressor x Suction hose

Cooling unit x Suction tube

Cooling unit x Liquid tube

Magnetic clutch clearance

Condenser x Liquid tube

Receiver x Liquid tube

Drive belt tension

1,450 ± 50 RPMIdle-up speed

Part tightened

160 ± 25 lbf

100 ± 20 lbf

48 in.-lbf

Used belt

48 in.-lbf

New belt

kgf-cm ft-lbf

250

330

140

100

100

N-m

5.5

5.5

-AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONSAC-68

Air conditioning system

Business

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