REFRIGERANT SYSTEM SERVICE PROCEDURES REFRIGERANT SYSTEM SERVI CHARGING PROCEDURE FLOW ICE PROCEDURES Install manifold gauge set 7 Evacuate system and te 3st for aitightnoss ‘Carry out gas ‘Second charge Has second END — i ‘a mie aaa bboen done? ves Teak test Fave all joins been tightened? NO charge ‘que coueten FoR| RSRESSURE Ee Sia eS eee CoWeRESSURE SIDE MANFOLD GAUGE Hanae Hose MANIFOLD GAUGE SET INSTALLATION 1. Fully close the vaives of the manifold gauge, 2. Connect charging hoses to the high- and low-pressure side joints of the manifold gauge. 3. Connect quick couplers to the ends of the charging hoses. 4. Remove the caps from the high- and low-pressure side charging valves. 5. Connect the quick couplers to the charging valves.U REFRIGERANT SYSTEM SERVICE PROCEDURES TAP PINE 1. 10. 1 12. 13. CHARGING Install the manifold gauge set. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge. .. Connect the vacuum pump hose to the center joint of the manifold gauge. . Connect the vacuum pump hose to the vacuum pump. Connect can puncture valves to a 4-way joint. Fully open the can puncture valves and connect service ‘cans to the valves. Regular amount of refrigerant: 600 g { 21.2 oz} . Fully close any can puncture valve that is not connected toa service can. . Connect the 4-way joint to the charging hose that is con- nected to the gauge set air purge valve. ). Open all the valves of the manifold gauge. Start the vacuum pump and let it operate for 15 minutes. After 15 minutes, verify that the high- and low-pressure- side readings of the manifold gauge are at -101 kPa { =760 mmHg , -29.9 inHg } . Close each valve of the manifold gauge. ‘Stop the vacuum pump and wait for about 5 minutes. After 5 minutes, check the low-pressure-side reading of the manifold gauge. If the reading has changed, check for leaks and then repeat from step 9. If reading has not changed, go to step 14. |. Open the service cans by using the can puncture valves. . Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the low-pressure-side reading is at 100 kPa { 1 kg/cm? , 10 psi}.REFRIGERANT SYSTEM SERVICE PROCEDURES U 16. Close the low-pressure side valve of the manifold gauge. 17. Check for leaks by using a gas leak tester. Ifthere are no leaks, go to step 18. If a leak is found at « loose joint, tighten the joint and check for leaks again. I there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. Ifthere are no leaks after tightening the joint, go to step 18, 18. Open the low-pressure side valve of the manifold gauge and charge with half the regular amount of refrigerant. 19. Close the low-pressure side valve of the manifold gauge. Warning Running the engine with the high-pressure side valve open is dangerous. Pressure within the ser- vice cans will increase and the cans could explode, scattering metal fragments and liquid A refrigerant that can seriously injure you. There- fore, do not open the high-pressure side valve while the engine is running. 20. Start the engine and actuate the A/C compressor. 21. Open the low-pressure side valve of the gauge set and charge with the remaining refrigerant. 22. Close the low-pressure side valve of the manifold gauge, 23. Stop the engine and A/C compressor. 24. Check for leaks by using a gas leak tester. Ifthere are no leaks, go to step 25. If a leak is found at a loose joint, tighten the joint and check for leaks again. f there is sti a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. Ifthere are no leaks after tightening the joint, go to step 25. 25. Disconnect the high- and low-pressure-side quick cou- plers from the charging valves. 26. Install the caps to the charging valves. cap v7U REFRIGERANT SYSTEM SERVICE PROCEDURES GAS LEAK TEST Warning + Improperly handling flammable substances is dangerous. It could result in injury or death. Be- fore checking for gas leakage, read the “SERVICE WARNINGS’ (Refer to-page U2) 1. Check for oil stains on the connections shown below. 2. If there is no oil stain, go to step 4. 3. If there is an oil stain, check for a loose connection. If i's loose, tighten the connection to the spacified torque and refill the oil and recharge the refrigerant. If the connection is properly tightened, replace the O-ring and, if necessary, other parts. Refi the oll and recharge the refrigerant. 4. Check for leaks at the connections by using the gas leak tester. 5. If there is leakage, check for a loose connection. If it’s loose, tighten the connection to the specified torque and rfl he ol and recharge te refigerant.[laler te nage UE the connecton is property ightoned replace the O-ring and, if necessary, other parts. Refill the oil and recharge the refrigerant. U-8REFRIGERANT SYSTEM SERVICE PROCEDURES: U Cerone CHARGE CHECK . Install the manifold gauge set. 2 Check the refrigerant pressure reading witn the engine ‘stopped. 3. Verify that the high- and low-pressure-side readings of the manifold gauge are at 493—788 kPa { 5.02—8.04 kgf/cm? , 72—114 psi }. If the pressure readings are lower than specified, recharge the refrigerant. lithe pressure readings are within specifica- tion but there is insufficient cooling, go to the next step. If the pressure readings are within specification and there are no leaks, the refrigerant amount is OK. . Start the engine and run it at a constant 2,000 rpm. Turn the A/C switch on, set the fan switch at MA and set the air intake mode at REC. . Ifthe AIC compressor is short-cycling, note the low-pres- ‘sure-side reading at which the magnetic clutch kicks out. . If the pressure is 170 kPa { 1.7 kgf/cm? , 24 psi } or low- er, evacuate and recharge the refrigerant system with the proper amount of refrigerant. [(Refer to page U-6 It the pressure is 210 kPa { 2.1 kgt/om?, 30 psi } or higher, inspect the thermoswitch. (Hofer 0 page fae REFRIGERANT PRESSURE CHECK 1. Install the manifold gauge set. 2. Close the front doors and the front windows. 3. Warm up the engine and run it at a constart 1,500 rpm. 4. Set the fan switch at the 4th position, 5. Turn the A/G switch on, 6. iZ 8. HI, N @ oe . Set the REC/FRESH lever to RECIRCULATE. (wire g g 2 type) ~. Tum the REC switch on, (logic type) ga Set the mode lever to VENT. (wire type) 9. Turn the VENT switch on. (logic type) fe 10. Set the temperature control lever to MAX COLD. une 11. Measure the ambient temperature and the high- and Soir low-pressure-side readings of manifold gauge. eens 12. If the high- and low-pressure-side readings are in the fee shaded zones shown in the figure, refrigerant system is. rr re) normal. If the readings are abnormal, refer to flowchart (89) (68) (7) (86) (95) (108) No.13 and troubleshoot the system. r AMBIENT TEMPERATURE -C(°F) spat) Ma (kgm? PRESSURE READING OFU REFRIGERANT SYSTEM SERVICE PROCEDURES outlet. let. ‘Turn the A/C switch on. Set the fan switch at the 4th position. WET: AND DRY.BULB, THERMOMETER SxNoer o type) 9. Turn the REC switch on. (logic type) Bae) PERFORMANCE TEST THERMOMETER After servicing the refrigerant system, test its performance. a 1. ntl te manifold gauge set (Refer ta page U=5.) 2. Place a dry-bulb thermometer in the center ventilator . Place a wet- and dry-bulb thermometer at the blower in- . Open the all doors and the all windows. Warm up the engine and run it at constant 1,500 rpm. . Set the REC/FRESH lever to RECIRCULATE. (wire 10. Set the mode lever to VENT. (wire type) 11. Turn the VENT switch on. (logic type) 12. Sot the temperature control lever to MAX COLD. Stabilized condition Blower inlet temperature: 25—35 °C { 77—95 °F} High-pressure-side reading: ioner output temperature stabi- 1.31.6 MPa { 13—17 kgf/cm? , 190—240 psi } 14. After the air conditioning stabilizes, read the wet- and dry-bulb thermometer, and then calculate the relative humidity by using the graph below. HOW TO READ THE GRAPH: ‘AMtermeasuringhetemperaturesof wet-anddy-bulb thonmometerat the blower it, relative arity (%) Jean be obtained, Example: Supposing dry- and wet-bulb temperatures athebiowerinetare25°C(77"F)and19.5°C (67.1 “Fj respectvaly,the pont ofintersecton ofthe doted ines in the graph is 60%, DRY BULBTEMPERATURE °C °F) ventilator outlet and the blower inlet. and the relative humi 60 70 15, Read the dry-bulb thermometer at the air outlet, and cal- culate the temperature difference between the center 16. Verify that the intersection of the temperature difference is in the shaded zone. 17. Ifthe performance is abnormal, troubleshoot the system. (Refer to page U-47.BASIC SYSTEM BASIC SYSTEM STRUCTURAL VIEW 1, Blower unit 4. AIC compressor Removal/ Installation... page U=12 I age U=: Disassembly / Assembly .. page U=13 5. Condenser 2. Heater unit [Removal / Installation 6. Receiver/drier [Removal / installation... 7, Refrigerant lines [Removal / installation - [Removal / installation .BASIC SYSTEM val / Installatic 3 BLOWER UNIT 1. Blower unit connector 3 3 2 3 8 & a oi U-12Disassembly / Assembly BASIC SYSTEM 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. [WIRE TYPE PNOTAENS Air hose Blower hamess Hamess clip ‘Connector bracket Resistor Blower motor Air intake actuator Wire clamp bracket © 10. 1. 12. 13, 14, 15. 16. Wire clamp Air intake link Air guider Air intake crank Air intake door Polyurethane protector Blower case (top) Blower case (bottom)U BASIC SYSTEM HEATER UNIT Removal / installation 4. Drain the engine coolant. 2. Remove the dashboard. 3. Remove the cooling unit 4. Remove in the order shown in the figure. 5. Install in the reverse order of removal. ‘ 1. Quick connector 5. He 2. Hose clamp 3. Heater hose 4, Heater unit connector U-14 ater unit, [Disassembly / Assembly page U=15, Inspection . page U=16.BASIC SYSTEM U Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly, referring to[ Assembly note.|Do not apply extra grease to the links. 1, Duct 18. Airflow mode sub link (VENT) 2. Push nut 19. Polyurethane protector (DEFROSTER) 8. Spring 20. Polyurethane protector (VENT) 4, Air mix crank 21. Polyurethane foam 5. Air mix link 22, Polyurethane foam 6. Air mix rod 23. Seal plate 7. Air mix wire clamp 8. Heater hamess 9. Connector bracket 10. Heater unit bracket 41. Wire clamp bracket 12. Airflow mode wire clamp 26. 27. 28. Side VENT door 13. Airflow mode actuator 29. HEAT door 30. 31 32. 33. ). DEFROSTER door |. Center VENT door . Heater case (1) |. Heater case (2) 14. Airflow mode main link 16. Airflow mode rod 16. Airflow mode sub link (DEFROSTER) 17. Airflow mode sub link (HEAT) U-15U BASIC SYSTEM Assembly note Airflow mode main link 1. Turn the projections of each airflow mode sub lirk out- ward. 2. Set the airflow mode main link to the heater unit as AIRFLOW MODE shown in the figure. PROUECTION See 3. Press the airflow mode main link and rotate it in the direc- tion of the arrow. Set the projections of each airflow mode sub link into the grooves of the airflow mode main link. 4, Rotate the airflow mode main link and verify that each mode is accessed properly. 5. Secure the airflow mode main link, ConntecToR peneieel Heater core ee 1. Disassemble the heater unit 2. Check for cracks, damage, and coolant leakage. Repair or replace the heater core if necessary. 3. Check for bent fins. If they are bent, use a flat-head screwdriver to straighten them, 4. Verify that the heater core inlet and outlet are not dis- torted or damaged. If the quick connector installation rt is damaged, replace the heater core. HEATER CORE [Retro DS OTE U-16BASIC SYSTEM U COOLING UNIT Removal / Installation 1. Discharge the refrigerant from the system. 2. Remove the side panel, glove compartment, and glove compartment cover. [Rafer to section Si.)] 3. If the air bag system is installed, remove the No.1 duct. 4. Ifthe air bag system is installed, disconnect the intake link of the blower unit. (wire type) 5, Remove in the order shown in the figure. Do not allow compressor oil to spill. Immediately Flug all open fittings to keep moisture and dirt out of the system. 6. Install in the reverse order of removal, referring tc 7. Adjust the air intake wire, charge the system and test its performance. [(Refer to pages U-6fand 10, 1. Cooler pipe No.4 3. Cooling unit [Removal / installation. Installation note Below] 2. Cooler pipe No.5 [Disassembly / Assembly... 8) [Inspection page U-19] (Removal /Installation Installation note When installing a new cooling unit (evaporator), add 50 ml {50 ce, 1.7 fl o2 } of compressor oil through the high-pressure side of the A/C compressor. U-17U BASIC SYSTEM Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly, referring td Assembly note.] 119-147 Nm SS (t20—t80kgtem 106-120 nat) Ss e107 Nm (120-180 kgtom , 105190 inter) Nem (eatin, bt) 1. Polyurethane protector (heater side) 9, Rubber protector 2. Polyurethane protector (blower side) 10. Sponge rubber 3, Polyurethane foam 11. Bracket 4. Cooler case (top) 12. Pipe 5. Cooler case (bottom) 13. Expansion valve 6. AC amplifier 7. Thermoswitch 8, Sensor clamp U-18BASIC SYSTEM U HEAT-SENSING TUBE i | expansion a) vaive: Assembly note Expansion valve 1. Replace the O-rings at the expansion valve joints. 2. Apply compressor oil to the O-rings and connect the joints. 3, Tighten the joint to th open-end wrenches. 4, Assemble the heat-sensing tube as shown in the figure. ecified t by using two Thermoswitch ‘Assemble the sensor part of the thermoswitch as shown in the figure. Inspection Evaporator |. Disassemble the cooling unit. (Refer to page U-18.)] 2. Check for cracks, damage and oil leakage. Repair or replace the evaporator if necessary. 3. Check for bent fins. If they are bent, use a flat-head screwdriver to straighten them.U BASIC SYSTEM A/C COMPRESSOR Removal / Installation 4. Discharge the refrigerant from the system. 2. Remove the undercover, splash shield (RH), and A/C drive belt (Refer to section B1 r[B2.) 3. Remove in the order shown in the figure. Do not allow compressor oil to spill. Immediately plug all open fittings to keep moisture out of the system. 4. Install in the reverse order of removal, refering tinstallaion note] 5 Gharge the eystem and testis performance. eter to pages U-sland 10.) 125 (19-26, 16-18) Nem {gt RobE} 1. Flexible hose (Hi 3. ressor Remaval/ te atiation page U=23 Installation note ... 2.7 Installation note Follow the procedure below when replacing the A/C compressor with a new one: 1. Measure the amount of compressor oil remaining in the old A/C compressor. 2. Remove the following amount of compressor oil from the new A/C compressor. Compressor oil to be removed = 120 ml { 120 cc , 4.06 fl oz } - [compressor oil from old A/C compressor + 5—10 ml {5-10 cc , 0.20.3 fl oz }} U-20BASIC SYSTEM U . CONDENSER Removal / Installation 1, Discharge the refrigerant from the s\ 2. Remove the upper seal board. 3. Remove the radiator grille. 4. Remove the undercover. [(Refer to section B1Jor|B2.)] 5. Remove in the order shown in the figure. Do not allow compressor oil to spill. Immediately plug all open fittings to Keep moisture out of the system. 6. Install in the reverse order of removal, referring td Installation note. 7. Charge the system and test its performance. 79-107 (20—T0Kgtem 605-954 inter) 1. Cooler pipe No.1 3. Condenser [Removal installation = page U=23) [installation note ~ below] 2. Flexible hose (HI) [Inspection ... below] ‘Removal / Installation. 7 page U-BS Installation note ‘When installing a new condenser, add 15 ml { 15 ec , 0.5 fl oz } of compressor oll through the high-pres- sure side of the A/C compressor. Inspection 1. Check for cracks, damage, and oil leakage. Repair or replace the condenser if necessary. 2, Check for bent fins. If they are bent, use a flathead screwdriver to straighten them. U-21U BASIC SYSTEM RECEIVER/DRIER Removal / Installation 1. Discharge the refrigerant from the system. 2. Remove the undercover and the splash shield (LH). (Refer to section BTb{B2)] 3, Remove the mud guard (LH). 4, Remove in the order shown in the figure. Do not allow compressor oil to spill. Immediately plug all open fittings to Keep moisture out of the system. 5. Install in the reverse order of removal, referring td 6. Charge the system and test its performance. {bo—tokgtem,60595.4insbt) 1. Cooler pipe No.2 3. Refrigerant pressure switch connector TBemoval/ instalation —————-pagel-2a] 4. Recelerarer Installation note ‘When installing a new receiver/drier, add 10 ml { 10 cc , 0.3 fl oz } of compressor oil through the high- pressure side of the AC compressor. U-22BASIC SYSTEM U REFRIGERANT LINES Removal / Installation 1. Discharge the refrigerant from the system. 2. Remove the following parts, depending on pipe and hose to be removed. Cooler pipalhose to be removed ___ Paris to be removed ___Seetion__| Flexible hose (HI) Undercover, Splash shields, Engine mount momber —TenezT Flexible hose (LO) Undercover, Splash shield (RH) TES] ‘Undereover, Spiash shield (LH) TELIEZT Cooler pipe No.1, No-2 tare = Gharcoal canister TELE eerie: Gnise actuator (Tequipped) fia 3. Remove as shown in the figure. Do not allow compressor oil to spill. Immediately plug all open fittings to keep moisture out of the system. 4, Install in the reverse order of removal, referring to[Installation note] 5. Charge the system and test its performance. Matar ta pages U-Gland 10) se21 (15-22, 11-15) 79-407 {0-10 Kgrom ,603—26.4initt) Tae io igrom,605-264in.8t) N lomo, a) 7107 Km (otto kgtem ,60.595.4 into Nev Chgten bt) 1. Flexible hose (HI) 2. Flexible hose (LO) re 3. Cooler pipe No.1 U-23U BASIC SYSTEM Installation note 1. Replace the O-rings at the pipe and/or hose joints, when installing pipes. 2. Apply compressor oil to the O-rings and connest the joints. 3. When installing a new cooler pipe or flexible hose, add 10 ml { 10.cc , 0.3 fl oz} of compressor oil through the high-pressure side of the AIC compressor. 4, Tighten the joints. (1) Verify that the O-rings are installed. (2) Tighten the nut or bolt of the joint by hand. (8) Fix the bracket and clip installed on the hose or pipe to the vehicle, (4) Tighten the joint to the specified torque. If it is nut joint, tighten in the procedure as the figure. ‘TORQUE WRENCH U-24BASIC SYSTEM REAR HEAT DUCT Removal / installation 4. Remove the front scuff plate and front sic 5. Remove in the order shown in the figure. 6. Install in the reverse order of removal. 1. PCM hamess 3. Rear heat duct 2. FastenerU CONTROL SYSTEM PREPARATION ‘SST CONTROL SYSTEM 49 B061 010 For prevention of A/C. ‘AIC clutch ‘compressor Oil seal and holder paulley rotation | spacer installer gui 49 B061 013. S| For removal of Pressure plate pressure plate remover STRUCTURAL VIEW U-26CONTROL SYSTEM U 1. Magnetic clutch 7. Air intake actuator [Disassembly Assembly ......... below Removal / installation ....... page U-33 inspection page U=29 Inspection. page U=33] 2. Condenser fan 8. Airflow mode actuator al /Installa Removal Installation yage U-33 8. Refrigerant pressure switch 9. Thermoswitch pepo (tpt nage Lael] 4, Relay 10. A/C amplifier [Removal Installation page U-31] Removal /installation ....... page U-34 Inspection... age inspection. page U=34 5. Blower motor, 11. Heater control unit aE ne. page U-39 Uinspection............... page U-41] MAGNETIC CLUTCH Disassembly / Assembly 1. Remove the A/C compressor [{Fefar fo nage U=20)] 2. Disassemble in the order shown in the figure, referring t 3. Assemble in the reverse order of disassembly, referring tol ‘NC COMPRESSOR BODY r9(19, 14) ~ 1. Center nut 5. AIC compressor pulley Nemchgtm abt) | jage U-28. 2. Pressure plate 6. Snap ring [Assembly note. 29) 7. Stator 3. Shim 4. Snap ring U-27CONTROL SYSTEM U-28 Disassembly note Center nut Hold the pressure plate in place by using the SST and remove the center nut. Pressure plate If the pressure plate cannot be removed by hand, use the SST as shown in the figure. AIC compressor pulley 1. Remove the snap ring by using snap-ring pliers. Caution + The edge of the puller can damage the drive belt groove. Avoid contact of the puller to the pulley groove. 2, Set a 25 mm { 1.0 in } socket and a puller on the A/C. ‘compressor as shown in the figure. 3. Turn the shaft of the puller to remove the A/C compres- sor pulley. Assembly note Stator 1. Set the projection of the stator to the A/C compressor body groove as shown in the figure. 2. Connect the connector and install the connector holder.CONTROL SYSTEM U OSE AIC compressor pulley 4, Remove all foreign material from the boss of the A/C ‘compressor and inside the bearing of the A/C compres- sor pulley. 2. Set the SST as shown in the figure. 3. Press the SST to assemble the A/C compressor pulley. Pressure plate 1. Adjust the clearance between the pressure plate and the ‘ANC compressor pulley. (1) Set the A/C compressor on a level block. (2) Rotate the A/C compressor pulley and measure the clearance between the A/C compressor pulley and the pressure plate by using a thickness gauge. Clearance: 0.35—0.65 mm { 0.014—0.025 in } 2. Ifnot as specified, install shims to adjust the clearance. Adjustment shim size: (0.1 mm { 0.004 in }, 0.2 mm { 0.008 in }, 0.4 mm { 0.016 in }, 0.5 mm { 0.02 in } Inspection ‘Stator 1. Disconnect the stator connector. 2. Measure the resistance between the stator connector and the A/C compressor body. Resistance: 3.05—3.35 0 [at 20 °C { 68 °F }] 3. If not as specified, replace the stator. U-29U CONTROL SYSTEM CONDENSER FAN Removal / Installation 1. Remove the upper seal board, radiator grille, and radiator brackets. (Rafer to sections EJS1.)] 2, Remove in the order shown in the figure. 3. Install in the reverse order of removal. 79-107 Non {80-110 Kgtem 685-854 inbt) 1. Condenser fan connector 2. Condenser fan [inspection ....................... below} Inspection 1. Disconnect the condenser fan connector. 2. Connect battery positive voltage to terminal A and ground to terminal B of the condenser fan and check its operation. 3. If condenser fan does not operate, replace the con- denser fan.CONTROL SYSTEM U REFRIGERANT PRESSURE ‘SWITCH 12107 Nem 00 kote, faa—as4inty RECEIVER! DRIER 245 (025,856) 400780 (40-80, 5710) kPa (glo? psi) REFRIGERANT] PRESSURE, SWITCH RELAY CONNECTOR REFRIGERANT PRESSURE SWITCH Removal / Installation . Remove the receiver/drier. (Rafa 2. Remove the Tefigerant presoure swich tom the recel- er/drier. immediately plug the open fiting to keep mois- ture out of the system. 3. Install in the reverse order of removal. Before installing the refrigerant pressure switch, apply compressor oil to the O-ring and connect the joint. 4. Charge the system and tes performance. Inspection Install the manifold gauge set. 2 Make sure that the high-pressure side is inthe ON range ‘shown in the figure. 3. Disconnect the refrigerant pressure switch connector. 4. Verify that there is continuity between terminals A and B of the refrigerant pressure switch. 5. If there is no continuity, replace the refrigerant pressure switch. RELAY Removal / Installation NG relay condenser fen relay |. If the cruise control system is installed, remove the ‘cruise actuator with the actuator cable sill connected and position it away from the suspension tower. 2. Remove the relay bracket. 3. Disconnect the relay connectors. 4, Install in the reverse order of removal. Blower relay 4. Disconnect the relay connector. 2. Remove the blower relay from the relay bracket. 3, Install in the reverse order of removal. U-31U CONTROL SYSTEM Inspection AIC relay, condenser fan rel © ® 4. Remove the relay 2. Connect battery positive voltage and check for centinu- ity between terminals of the relay. OO: Continuity B+: Battery positive voltage A B c D ‘Connection B) B+] GND. x 5 3. If not as specified, replace the relay. BLOWER MOTOR Removal / Installation 1. Remove the blower motor cover. 2. Disconnect the blower motor connector. 3. Remove the blower motor connector from the connector blacket. 4. Remove the air hose. 5. Remove the screws and the blower motor. 6. Install in the reverse order of removal. Inspection 1. Disconnect the blower motor connector. 2. Connect battery positive voltage to terminal B and ground to terminal A of the blower motor. Verify that the blower motor operates. 3. If blower motor does not operate, replace the blower motor. RESISTOR Removal / Installtion 1. Disconnect the resistor connector. 2. Remove the screws and the resistor. 3. Install in the reverse order of removal. Inspection 1. Disconnect the resistor connector. 2. Verify that the resistance between terminals of the resis- tor is as shown below. Terminal Resistance (0) =) 03-06 Ce 1O16 CA 28-60 3. Ifnot as specified, replace the resistor.CONTROL SYSTEM U ‘AIRINTAKE ACTUATOR RECIRCULATE ROTATIONS DIRECTION FRESH AIR INTAKE ACTUATOR Removal / Installation 4. Remove the glove compartment and the glove compart- ment cover ser t-secion ST] 2. If the air bay peer is installed, remove the No.1 duct. 3. Pull out the air intake actuator by removing the screws. 4. Disconnect the air intake actuator connector and re- move the air intake actuator. 5. Install in the reverse order of removal. Inspection 1. Remove the air intake actuator. 2. Connect battery positive voltage to terminal A and ground to terminal G or K of the air intake actuator. 3. Verify that the air intake actuator operates as shown below. Be: Battery postive voltage ‘Connection Movement Be GND. a 6 FRESH to REGIRCULATE K RECIROULATE to FRESH suone_—-—. Sonmier! 4, If not as specified, replace the air intake actuator. AIRFLOW MODE ACTUATOR Removal / Installation 1. Disconnect the airflow mode actuator connector. 2. Remove the screws and the airflow mode actuator. 3. Install in the reverse order of removal. Inspection 1, Remove the airflow mode actuator. 2. Connect battery positive voltage to terminal J or | and ‘ground to terminal | or J of the airflow mode actuator. 3. Verify that the airflow mode actuator operates as shown below. Be: Battery positive voltage Connection = a Movement J v VENT to DEFROSTER T J DEFROSTER to VENT U-33CONTROL SYSTEM ‘SLIDING RANGE ‘SLIDING CONTACT 4. Check for continuity between the terminals of the air- flow mode actuator as shown below. O~0: Continuity elal« Mode BHLEVEL HEAT HEATIDEF DEFROSTER, 5. If not as specified, replace the airflow mode actuator. THERMOSWITCH Removal / Installation 1, Remove the cooling unit 2. Remove the thermoswitch from the cooling unit. 3. Install in the reverse order of removal. Inapection . Remove the thermoswitch. 2 mmorse the sensor part of the thermoswitch in a con- tainer of ice water. 3. Check for continuity between terminals A and B of the thermoswitch. 0: Continuity Terminal re Fj Temperature [3.6 °C (88 °F Jor more ots [08°C (33°F) orless 4. If not as specified, replace the thermoswitch. AIC AMPLIFIER Removal / Installation a Remove the cooling unit. (Refer to page U-17,) wove the AG ampiifer from The eoaing me a. Tpatatlin the reverse order of removal Inspection |. Remove the glove compartment and the glove compart- ment cover. (Refer to section S1 2. Start the engine. 3. Measure the voltage at the terminals of the A/C amplifier inector and refer to the terminal voltage lis J-35.) 4. If not as specified, inspect the appropriate area. 5. If the inspection area is OK, replace the A/C amplifier.CONTROL SYSTEM U Bs: Battery positive voltage Terminal! Signal name Connection Test condition \Voltage (V) | Inspection area a fice (NC 10 Afuse |g switch at ON B+ |» Continuity [Fuse—A/C ampir fier AC 10 Ignition switch at LOCK, 7 eee 0 | AGIOA fuse 3B [AC signal Refigerant pres- | Magnetic clutch on > Contnaly [POM —Refriger: | femeenen ant pressure switch: 1K-8, | | Max.1 | Rotigerant pressure switch—A'G amplifier: AB} }* Terminal yee te 1 ampier (3 Magnetic clutch off | |+ Retric ment ressure switch | ee | detetoaoe test | + PM | _[AtCawich signal [+ AIC ewich (wire [AIG owich of Tp [Terminal votage of AC ampl- ee fier (A) nit (logic ype). [A/C switch on and fan (Wire type) Switch at it postion Contin (AC ampier— Meehan + Fan switch 0 |(Lesie'ype) | Continuity [A/C amplifier Heater contol unit’ C—B, Heater contol unit—Fan m ! ' ! 1 1 U-35U CONTROL SYSTEM HEATER CONTROL UNIT Removal / Installation Wire type 1. Remove the meter hood, side panel, glove compartment, and glove compartment cover. [Refer to section $7.) : the order shown in the figure. 3. Install in the reverse order of removal. Screw Fan switch connector Heater control unit connector Heater control unit Noose [Wire adjustment... 3. Airintake wire U-36CONTROL SYSTEM U Logic type 1, Remove the meter hood. 2. Remove in the order shown in the figure. 3, Install in the reverse order of removal. 1. Air mix wire 4. Heater control unit connector 5. Heater control ut 2. Screw 3. Fan switch connector U-37U CONTROL SYSTEM Wire Adjustment Airflow mode wire 4. Set the MODE lever at DEFROSTER. 2. Connect the airflow mode wire to the airflow mode main link. 3. Set the airflow mode main link to DEFROSTER and insert a screwdriver ($5) into the set hole. Clamp the alr- flow mode wire. 4. Verify that the MODE lever moves in its full stroke. SETHOLE SAG Air mix wire eek a 1. Set the temperature control lever at MAX COLD. 2. Connect the air mix wire to the air mix link. 3. Set the air mix link to MAX COLD and insert a screw- driver ($5) into the set hole. Clamp the air mix wire. 4. Verify that the temperature control lever moves in its full stroke. Air intake wire 1. Set the REC/FRESH lever at FRESH. 2. Connect the air intake wire to the air intake link. 3. Set the air intake link to FRESH and insert a screwdriver (5) into the set hole. Clamp the air intake wire. 4. Verify that the REC/FRESH lever moves in its full stroke. U-38CONTROL SYSTEM Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of removal. WIRE TYPE Switch panel Cover Clip Air mix wire Airflow mode wire NOgSeN . Air intake wire ‘Temperature control lever ). MODE lever |. REC/FRESH lever Bulb Switch body U-39CONTROL SYSTEM U-40CONTROL SYSTEM U Inspection Fan switch Wire type 4. Check for continuity between the terminals of the fan switch, 2. Ifnot as specified, replace the fan switch. HEATER CONTROL [AIC SWITCH CONNECTOR UNIT CONNECTOR 0: Continuity Fan switch Heater control unit DIE a 5 Logic type 1. Check for continuity between the termianls of the fan switch. 0: Continuity Terminal Switch posi OFF elu 1 2 3 4 2. Hfnot as specified, replace the fan switch. uU-41U CONTROL SYSTEM AIC switch (wire type) 1. Check for continuity between the termianls of the A/C ‘switch. 0: Continuity ‘RC switch E OFF ON, 2. Turn the A/C switch on. 3. Connect battery positive voltage and ground to the ter- minals of the A/C switch. Bs: Battery positive voltage Br ‘GND 5 AK F E 4. Verify that the light-emitting diode illuminates. 5. If not as specified, replace the A/C switch. ‘Switch body (logic type) Preparation Connect battery positive voltage to terminal F and ‘ground to terminal J. REC switch 1. Connect a 1 ko resistor between terminals C and F. 2. Turn the REC switch on, and measure the voltage between terminals C and J. B+: Battery positive voltage REC switch Voltage I ‘ON TV orless FF ~_ : r 3. If not as specified, replace the heater control unit 4. Connect a 1 k@ resistor between terminals A and F. 5. Turn the REC switch off, and measure, the voltage between terminals A and J. B+: Battory positive voltage REC switch Vortage OFF TWortess OW Be : 7 6. If not as specified, replace the heater control unit @. MODE switch . 1. Connect a 1 KO resistor between terminals J and L. : 2. Connect a jumper wire between terminals J (or negative battery terminal) and R. 3. Measure the voltage between terminals J and L. Bi: Battery positive votage Terminal Vottege Jat Be R = ©. 4. If not as specified, replace the heater control unit. U-42CONTROL SYSTEM U 5. Connect a 1 k® resistor between terminals J and N. 6. Connect a jumper wire between terminals J (or negative battery terminal) and P. 7. Measure the voltage between terminals J and N. Be: Battery positive voltage Terminal Voltage I at JEN Be p 8. If not as specified, replace the heater control unit. " ®@ 9. Connect a 1 kQ resistor between terminals J and L. 10. Connect a jumper wire between terminals J (or negative battery terminal) and P. 11. Measure the voltage between terminals J and L. Terminal Voltage J TV or less 12. If not as specified, replace the heater control unit. 13, Connect a 1 k@ resistor between terminals J and N. 14, Connect a jumper wire between terminals J (or negative battery terminal) and R. 15. Measure the voltage between terminals J and N. [solos fetal GLalers Ts Pale[ of 3] Terminal Voitage JEN TVorless 16. If not as specified, replace the heater control unit. 17. Check for continuity between the following terminals while pressing the MODE switches. 0: Continuity T alol|m Terminal Switch VENT BHLEVEL HEAT HEATIDEF, DEFROSTER, 18. If not as specified, replace the heater control unit. AIC switch (if equipped) 1. Check for continuity between terminals B and D while pressing the A/C switch, 0 Continuity Terminal AIC switch W OFF ‘ON. 2. Ifnot as specified, replace the heater control unit. U-43U TROUBLESHOOTING TROUBLESHOOTING TROUBLESHOOTING NOTES ‘* Precise understanding of customer complaints is the key to diagnosing problems. ‘* Diagnosis of air conditioning system problems can be difficult because of the surrounding temperatures. ‘Therefore, checking the system operation is important. Further checking the system operation in a log- ical order is necessary for the accurate understanding of problems. USING THIS SECTION When troubleshooting, follow the procedure shown below. ‘START Determine symptoms from customer. Is |_NO there really a problem? ves ‘Check system operation according to [+] checklist procedure. | —YES__,| Have components been Does system work properly? reps i YES No Refer to appropriate flowchart based on symptoms, ‘Work through each flowchart step. ‘Repair or replace components as nec- Explain system operation to customer. essary. re [ee eeeeeeeeaeeaee END usTROUBLESHOOTING U *_ Note the following points when using the flowcharts. Flowchart Mo.__| A/C sienal eyst 3 Taspection Belated parte=A/C empl heater control unit.ecu wiring harness. Te TeapectTon proceaire — mC C—m@ Wa SSN Tiearnect Taper Fite between tarainal Bor C of AIC amplifier comector fa feaals) snd ground. torminal 8 DNorify that omperature around and ground | NO. | eniteh=A/C amplifier:A~8) 3 | evaporator temperature sensor Is 3.5 (G8. oF more, Taper wird Tonove Jumper ite and go to Steed Start engine. between | YES Ado megratic clutch and condensor fan | terminal C | epnrate? sre ground | NO | Check A/C amplifier (ofer to page U-38)] | easure voltage at torninal of heater Be_| Go to steps | 4 | control unit comoctorfomale:6-pin), Pe rd ae 6 @** control unit:¢— 20) Turn the Tani tion enitch to OF IP) Replace heater control unit YES | Qatar to page U-30 5 | Ble thace continuity betwoon sermineis ‘of heater control unit conmsetor ai Topalr wiring barvess|leater sontrol walt NO | ~mideay connector Sonmestor onal? 1, Only those parts, connectors, and hamesses that are directly related to the item being checked are indi- cated in the wiring diagram. 2. Follow the steps in order when troubleshooting the system. 3. Before inspection, turn all switches to OFF. When moving from step to step, Keep the switches, connec- tors, and jumper wire in their former position unless otherwise instructed Before connecting or disconnecting a jumper wire, tum the ignition switch to LOCK to prevent burning the electrical parts. After the jumper wire is connected or disconnected, the ignition switch can be turned to ON again. 4, When checking for continuity of the wiring hamess, the terminal names are shown under “Terminal” and their corresponding connector names are shown under “Inspection procedure.” When repairing the wir- ing harness, the terminal names and the corresponding part names to which they are connected are shown under “Action.” U-45U TROUBLESHOOTING MALE CONNECTOR ©, 0 a c MALEPIN. SB FEMALE PIN POM CONNECTOR @2-PIN) POM CONNEGTOR (20-FIN) THERMOSWITCH eel x25 (CONNECTOR No. U-46 5. Inspect connectors from either the male or female side stated after the connector name. 6. When more than one connector is attached to the same part, the pin number enclosed in(_) after the connector name distinguishes the connectors. The wiring diagram connector number shown before alphabet letter distinguishes the terminals. 7. When more than one hamess connects two different parts, the wiring diagram connector number enclosed in (_ )after the connector name distinguishes the connec- tors.TROUBLESHOOTING U ‘TROUBLESHOOTING Checklists Determine symptoms of the problem based on the customer's complaints. Refer to the fuse checklist and match the symptoms obtained from the customer with those listed in the table. Check the appropri- ate fuse. If the fuse is OK, operate the system. Determine the general area of the problem; for example, airflow, idle-up, or temperature. Look at the main checklist and locate the general problem area (first column). Follow each step of the instructions for the specific system (second column). if the system does not operate properly (third col- umn), determine the symptoms and corresponding flowchart number (fourth and fifth columns). Refer to the appropriate flowchart and troubleshoot the system. Fuse checklist ‘Symptom Related fuse Entire control system does not operate ‘AIG 10 A (fuse block) Blower motor does not operate HEATER 40 A ‘Condenser fan does not operate ‘AD FAN 30 A "AIG compressor idle-up operates, but magnetic clutch and condenser fan do not operate TURN 108 ‘Magnetic clutch does net operate ‘AIC 10 A (main fuse block) Main checklist Start and warm up the engine so that the engine coolant temperature reaches 40—100 °C { 104—212 °F }. Keep the engine running while doing the procedures. WIRE TYPE ‘TEMPERATURE CONTROL LEVER INDICATOR LIGHT. REGIFRESH LEVER, 2—-s i @ wer 2s ale | | wove LEVER FAN SWITCH AIG SWITCH. LOGIC TYPE INDICATOR LIGHT RECSWITCH ACSWITCH eToleoleo © BISA se | 7 | @ | ee jac Saoe sr ne wasceS OFT TEMPERATURE CONTROL LEVER FAN SWITOH U-47(Electrical load should be blower motor only) ‘Sed, and 4th at 2nd, 3rd, andlor th TROUBLESHOOTING 5 Flowchart No. eee Procedure Proper operation Symptom ay Entre control | (Wire ype) Flowing corre system | Gono sytem doos not 1 EE Spera tan ewtch and Ac | parts operate whion porate se Huminate switch. Switches are operated: * indicator ight of AC switch + Blower motor Magnetic etch {Condenser fan ‘Logie ype) Folowing contro system | Control system does not i Operate fan switch, REC | parts operate when operate and iluminate gage U=50 Sulich, MODE owitch, and | wiches are operated: pope 7 . + indeator ight of each a coin pisos ‘ot operate and indicator | [[page U=E0)] light of each switch does feet ete not iluminate 2 Airifake actuator {Allow mode actuator [Each actuator does not Sees porate and incator ight 2 Condenser fan Gheach sviteh does not tluminate ‘ir outet volume | Setfan switch in order at | Blower motor operates ac- | Blower motor does not 5 system 1S. 2nd, Sr, and th. | eording tofen switch op- | operate [feage U5] a Blower motor does not 2 ‘operate properly with fan Swrch af tet, 2nd, 30, or an ‘rintake mode | (Wire ype) “intake wire (ar take | Arinlake modo dows not | Wire adustment system 4. Setfan ewitch at &th. | mode) operates (changes) | change 2. Set REC/FRESH lever | according to REC/FRESH inorder at each air | ever operation intake mode ‘Logi ype) Trintake actuator (air | Aritako actuator doos not 3 1. Set fan switch at 4th. intake mode) operates | operate 2. Set REC switch in order | (changes) according to ateach arintke mode. |REC switch operation Tidiow mode | (Wire type) Aiflow mode wire (aiffow | Affow mode does not | Wire adjustment ystem {i'Set an snitch at ath. | mode) operates (changes) | change 2. Set MODE lever inorder | according to MODE lever, at each alow mode. | operation (Logic type) ‘iriow mode actuator (air | Aifiow mode actuator does a SSet tan antch at ath. | low made) operatos | not operate propery 2. Set MODE switch in (changes) according to order at each aiffow | MODE switch operation mode. Electrical load | Set an switch in order at | Electrical oad ile-up oper- | Eectcal oad idl-up does z idl-up ysiem | Yet 2nd, Srd and 4th. | ates wh fan switch at dnd, |not operate wit fan sich U-48TROUBLESHOOTING U General Fiowshar No. cw Procedure Proper opeeson Symptom ae Tir oulet temper | | Satan avch tam, [Arma wie (ar oat” [Ar oat tperaturo dos | Wir adjutant hire aysiom’ |2. Change temperature | poraurs) operation fachange, page 0-231 control lever from MAX COLD to MAX HOT. (changes) acoording to temperature control lever 3. Tun AIG switch on. Magnetic clutch, condenser fan, and AIC compressor ‘dle-up operate ‘Magnetic clutch, condenser fan, and AIC compressor idle-up do not operate 10 ‘AIC compressor idlo-up operates, but magnetic ‘clutch and condenser fan do not operate Hl ‘Only magnetic clutch does ot operate it Only condenser fan does ot operate Magnetic cuich, condenser fan, and AIC compressor ‘idle-up operate, but cool air does not discharged or ait cooling ability is iow He U-49U TROUBLESHOOTING Flowcharts Flowchart No. Me caamene Crit eystom doesnot operate and Mum 1 system inspection [Related paris... Wiring hamess Remedy (Wire type) Repair the wiring harness [Fuse—A/C ampli (Logic type) _ Repair the wiring harness [Fuse—Heater control unit: A/C 10 A—F]. AC 10 A—A). Heater control unit | Symptom . ‘Rilo mode actuator does not operate and Flowchart No. power source system dicator light of each switch does not ilu- inspection tnlnate 2 (ogictype onty) [Related parts... Heater control uni, wiring harness Remedy Check for continuity between the A/C 10 A fuse and terminal F of the heater control unit. If there is continuity, replace the heater control unit. Heater contorlunit | Symptom ana Each actuator does not operate and indica - ground system inspection tor light of each switch does not illuminate 3 (logictype oniy) [Related paris... Heater control unit, wiring hamess Remedy ‘Check for continuity between terminal J of the heater control unit and ground. If there is continuity, replace the heater control unit. ‘Palarin page USP fom ...+--» Electrical load Idlewup does not operate with Flowchart No. | Electial lad ictoap [YPN fan switch at 2nd, org andlor ath 4 ne " Related parts .... Fan switch, PCM, wiring harness Remedy ‘Check the following parts. Repair or replace any abnormal parts. 1. Wiring hamess [PCM—Fan switch: 1P—H] 2. Fan switch| 3. Terminal 1P of PCM EZ) ‘Symptom ........ AIG compressor idle-up operates, but mag- Flowchart No. | AVC power source system netic clutch and condenser fan do not oper- inspection ate 5 Related parts .... PCM (BP MTX, 25 MTX), wiring harness Remedy (BP MTX, Z5 MTX) i ‘epair or replace any abnormal parts. If the parts are normal, check the PCM, rt 1. Wiring hamess [Fuse—A/C relay: TURN 10 A—A] 2. Wiring harness [A/C relay—PCM: B—1G] (BP ATX, Z5 ATX) Repair the wiring hamess [Fuse—A/C relay: TURN 10 A—Al. U-50TROUBLESHOOTING U Flowchart No. Symptom... Blower motor does nol operate : Taspection" %'" — |Related parts ... Blower motor blower relay fan switch, wiring harness oe Bs RESISTOR Ne bs WW 0a won af Je : 3 ‘ siowe ren : BLowen : ROTOR a} fo 5 Bs: Battery positive voltage ‘ground? Tnopection procedure Terminal | Result ‘Action 7) Tum ignition switch to ON. B+ | GotoStep4 2) Measure volage at terminal of resistor D connector (female). ‘Other | Goto Step? Measure voliage at terminals of blower B+ ___| Check terminal 8 ‘motor connector (female). A cares Gs eonss Be | Repair wiring harness [Blower motor — : Resistor: BD} oa ace blower motor rong ‘Measure voltage at terminals of blower relay ‘Br | Bepair wiring hamess [Blower relay — connector (female). D> Blower motor: O—A] ‘ther _[ Check terminal C Be | Check terminal A c Repair wiring hamess [Fuse—Blower relay. Other | HEATER 40A—C} + | Gheck terminal 8 A Repair wiring hamess [Fuse—Blower relay. Other [AC 10A—A) Br | Repair wiring hamess 8 [Blower relay (8)—GND} ‘ther | Replace blower relay 1) Tum ignition switch to LOOK. Fleplace fan switch 2) Disconnect fan switch connector. YES _|[(Reter to page U-39 brlU=40)] 8) ls there continuity between terminal of | | B—Ground fan switch connector (female) and No | RoPair wiring hamess [Fan switch (6)—GND) U-51U TROUBLESHOOTING lowoha it ‘Symptom «...... Blower motor does not operate properly with Gs sien! i Lino ‘system fan switch at 1st, 2nd, 3rd, or 4th 7 sontinal Related parts ... Resistor, fan switch, wiring hamess ESISTOR Loaig TYPE HEATER ‘AC SWITCH FAN SWITCH B+: Battery positive voltage ‘Step Inspection procedure Terminal [Result ‘ation 1] p Fumigation echo ON. Br | Checkterminals A, Band 2) Measure voltage at terminals of resistor |p — ‘connector (ertale) | Repair wiring harness [Blower motor— octr female) Otner | Renal wc ha Beal) [Goto Step2 ABC ‘Other | Replace resistorl(Bafar to page I-32) orion) 2 | Measure voltage at terminals of fan switch Be | Check terminal E connector (female) 6 ther | Repair wiring hamoss [Resistor—Fan switch: DG Br E Other _ | Repair wing hamess [Resistor—Fan sch: BE] Br | Check terminal D F Other | Repair wiring hamess [Rosistor—Fan switch: C—F] Replace fan switchl(Refer i page U=aalor e+ | Renae D> | Repair wiring hamess [Resistor—Fan Other | switch: AD] U-52TROUBLESHOOTING U Flowchart No. airintake actuator aye- [Symptom .....-. Airintake actuator does not operate ‘tem inspection Related parts ... Blower unit, air intake actuator, heater contro! 8 (logie type only) pene” unt, wiring harness 162 AIRINTAKE ACTUATOR we toa 3 ‘5 lo | HEATER CONTROL UNIT Br: Battery postive votage Step inspection procedure Terminal [Result ‘Ration 1 | 1) Remove air intake actuator. Goto Step 2 ves 2) Tum tontion switch to ON. 43) Set tan switch at ath 7 4) Operate aiintake crank by hand. Check blower unit 5) Does air intake mode change smoothly NO. from RECIRCULATE to FRESH? 2] Tum an switch of Be [Goto Steps 2} Measure volage at terminal of aicintake | = a | Repair wiring hamoss (Fuse —Ai intake actuator connector (female). Other 7 "NC 10 q 3 | 1) Turn ignition switch to LOCK. Goto Step 4 2) Turn REC switch on. YES: 3) Is there continuity between terminal of air | K-—ground intake actuator connector (female) and no |SetSteps ground? @ [5 Tum REC owiten off = 2) Is there continuity between terminal of air intake actuator connector (female) and | G—9round ground? NO 3 [1 Disconnect heater control uni connector. YES 2) is there continuity between terminals of (all) airiniake acuatr connector female) | GA and heater contol unt connector NO. | Repair wiring harness thai has no continually tomate)? (pariaty | (ritake acuator—Heater control unt) U-53TROUBLESHOOTING Symptom .....-» Allow mode actuator does nat operate Flowchart No. | artow made actuator crt {ogi type ont Related parts .. Heater unit, airflow mode actuator, heater uv Resto tpe cay) control unit, wiring harness n Z HEATER CONTROL UNIT Step Inspection procedure: Terminal | Result ‘ation 1 | 1) Remove airflow mode actuator (Rafer) Go to Step 2 2) Tum ignition switch to ON. YES 3) Set fan switch at 4th. 4) Operate airflow mode main link by - hand ‘Check heater unit '5) Does allow mode change smoothy to io VENT, BL-LEVEL, HEAT, HEAT/DER, and DEFROSTER? 2 | 1) Check airflow mode actuator. YES Go to Step 3 fer to page U-33. 2) Does airflow mode actuator operate a no | Ronee ai actuator properly? 3/1) Tum ignition switch to LOCK. YES Replace heater control unit 2) Disconnect heater control unit conneo- {all tor 8) Is there continuity between terminals of Repair wiring hamess that has no continu- allow mode actuator connector, NO (female) and heater contol unt connec- (partan | (Aitiow mode actuator—Heater contor tor female)? unit) U-54TROUBLESHOOTING U Symptom -.----» Magnetic clutch, condenser fen, and AIG rower te NC signal 6 compressor idie-up do not operat [Ate sina ersten sagas Be reigerant pressure ATCamplTr, 10 IMC switen (wire type), fn switch (wie type) heater contort unt (gic type, wiring hermes RERRGERANT BreSsune SiTcH tee NCANPLIFER 8 RESISTOR | nc swrrcu anne Tye) AEATERCONTHOL UNTT Losi TvPE) _FANSWITCH ©: pomne n) Boater) @®: E (WIRE TYPE) Biloaic tet Sep Thepetion procedure Terminal [Recut ation 7 [1) Disconnect refigeant pressure ewich yes | Remove jumper wire and go 1 Stop connedior 2) Connect jumper wre betwoen erinal 8 tfretigorent pressure swith connector | ‘heck or conity betwoon ving harness (female) and ground. ‘of PCM and refrigerant pressure switch: 2) Startengine. No | [KB and check POM 4) Domagnotic clutch, condenser fan, and Ez [NG compressor kde-up operate? 2 |) Tum ignition switch to LOCK Yes | Connect eigoran pressure sch com 2) Isthere conta between terminals of redtor and goto Step reget eenre sun commer | OA gan pss Sch 3] 1) Connon jumper wo botwoon tinal Yes | Disconnect jumper wire rom terminal B and FGM ante coonosar amas) | Jamoe wre connect to terminal © ‘and ground. ir wiring harne 2) Verify that temperature around sensor terminal B Repair wiring 18S it SUSOEEESS SS eres | NO [Egret crn 9) Start engine. arper we Remove jumper wie and goto Step 4 4) Do magnetic clutch, condenser | and | between Yes (wire type) or Step 6 (logic type) ‘NC compressor io-op operate’ terminal © : ° serinaucd | NO | Check AC amplier/Rafer ia naga ead] U-55U TROUBLESHOOTING Bt: Batery postive votage Sep Tnepertion procedure Temminal_[ —Resut Action | Measure votage at terinal of AC avich Be [Gow Seps }eornector (female). D ‘oer | Repair wiring hamess [AIC ampifier—A'C Swe OB) 5.) Tam anion svich 9 LOOK. Replace fan vier Eero pane =O] 2) Disconnect A/C switch connector. = 3) Turn ANG wich on De 4) Is there continuity betwoon terminals of No | RePlace A/G ewitchl(Refr to page U-39) AIC switch connector (male)? & | Measure vohage at einal of heater com Be [Goto Step? for unt connector Gomale- : a Reina Fane (NE anplior Heater contol unit CB) 7 |i) Tum inion sich io LOGK Ropar wig hamess 2) Disconnect heater contor! unit connector. ves [Heater control unit—Fan switch: B—D] 3) Turn AIC switch on. BD 4) others conthuty between terminals of to ea ‘heater control unt connector (male)? U-56TROUBLESHOOTING U Flowchart No, Symptom -.-1-7s Only magnetic clutch does not operate ne Magni ch yom Tired pars" Aly, mapelo ch, POM (OP ATE an o oat “" ADO, wiring hamess: : ° ‘at B sua we joa toa WeRELAY te rom A l MAGNETIC 3}|| eter Bt: Bator postive votlage Sep Thepection procedure Terminal Resuit ‘ation | 1) Connect jumper wire between teinalB ‘heck for contnay between wiring hares GIA relay connector and ground yes | SIAC relay and PeM [B—1Gl, and check 2) Stan engine. = SLR A za 3} Does magnetic och operate? NO | Goto Sipe 2 | Measure votage at teminale of NC relay jz Be [Goto Steps ‘connecter (female). Other ‘Check terminal C B+ | Check teminal A © Other | Repair wiring hamess ruse NG ely: AC 10 A—C] Be Replace A/C relay] a ‘ther _ | Repair wing hamess [Fuse—A/C relay: TURN 10 A—A]_ 3 | Measure voltage at teminal of magneto By /oheckmagnetic cist lutch connector (femal). A (Geter io page U=29) ‘Repair wiring hamess [A/C relay — Other | Magnetic clutch: O—A } U-57U TROUBLESHOOTING Flowchart No. Tras Only condenser fan does not jowchar a Symptom iy condenser fan operate 2 Mepection "Related parts ... Condenser fan relay, condenser fan, PCM (BP ATX, 25 ATX), wiring hamess & TAN AD FAN 10a 2A c ‘CONDENSER FAN RELAY ° @ Pom A © :16 9° wrx, z5Mr) 18.8 A) ‘CONDENSER FAN sates ATX) 8 Be: Battery postive voltage Step Inspection procedure Terminal | —_Aetion 1 | 1) Connect jumper wire between terminal B ‘heck for continuity betwen wing hamess of condense fan relay connector of condense fan relay and POM (B—1 {fomate) and ground. ves [BP MTX, 25 MIX1B—1B: BP ATXIB—1A: 2) Stat engine. - 5 ATX|, and check PCM (BP ATX, 5 ATX) 3) Does condenser fan operate? ear samion Pt NO [GotoStep2 2 | Measure vohage a terminals of condenser | Br [Goto Steps fan relay connector (female). Other | Cheatcteminal B+ | Check tenninal A . ‘Other | Repair wiring hamess [Fuse—Condenser fan relay: AD FAN 30 A—C)_ Be A Other | Ropai wiring Ramoss [Fuse—Condensor fan relay: TURN 10 AA] 3 | Measure voltage at terminals of condenser Be | Chock terminal 8 ae = Repair wiring hamess [Condenser fen relay —Condenser fan: DA] Be _| Repair wing Ramess [Condenser fan (@) . Gn} ter _| lace sander an U-58TROUBLESHOOTING U ‘Symptom . « Magnetic clutch, condenser fan, and A/C Flowchart No. — compressor lale-up operate, but coo lr does Reiger compressor pope bc @ Related paris... Refrigerant system 20 (20,20) 3 3202-201 agupnessuR sve 3 trur2e) 8 tats. 20 & 15(48,210}} q rat 20 2 rota. 0 $ 1.2412, 170} a> 1.111, 160} LOW-PRESSURE SIDE a 10(10, 0) a: exoit9.27 us aar(az.2a) ge taney gs o13(13, 18) ES 1 sw cs) 68) 7) 86) 85) (108) AMBIENT TEMPERATURE “O1°F) Sep Tapesion procedure Result ation 7 | Conds retigerantprssure check, Tigh and ow-prosourer | Goto Step? (Roterto page U-3) Side readings are higher than nonnal High and low-pressure | Goto Step do adinge are lower than normal Fihrpressuo-ide rad [Goto Sep 4 ing sa itl ower than normal: ow-prossure-side reading fate higher than normal | ighpressuro-ae read [Goto Sip 6 ing ios fo normal pos fue range and then drops Below ange: lwpres- sures args moe we No difference between Improper compression of A/C compressor Tigh andiowpressure- | Heplace WC compressor side readings {(tetecto nage Laan) 2 | fre condenser fine dogged or damaged? Insficient refigeaton in condenser yes ean tna eon ra No Too moch efigrant ‘Aust etigorant amount U-59TROUBLESHOOTING Step Inspection procedure fetion 3 | 1) Ganduct gas leak test. "ako a necessary measur, depending on ves tho ros faa ak Tost 2) Are there any oll stains or gas leaks? Tnsucont reigoran de o secular leak age No Ibufcent charging | Regulate reiigerant amount [[fetertopage U-5) 7] lsat censing bein is propo poston TExpancion valve opening oo wie because and securely comected fo evaporate out — of expansion valve mafuncion pipe? (asta page 195) Ragce pansion abo Expanelon vaveopering too wide because No cfimproper heet-sensing tube metalation Flonetal nea-sensng be [tietrtonage 19 3 |) Tum of fan owich and wal for about 10 Tpansion valve dogged due to fozen Tuts. ves mowture 3} ave rescue ronan (diterinragull2) 3} Are pressure readings nomal immed ately after A/C compressor is tumed on’ NO Goto Step 6 © [is heat sorang tube ns proper postion? Exganen ave cegpewi ogy a | Eroasion ave cltng oo wo bocause YES cot expansion valve malfunction or heat- Sonohg tbe leakage Fonlacs expansion ave [(Reter to page U=18) | Expansion valve closing oo wide because No Otmproper heat seneng tube instalation etl heatammang weCCL ge ea) Tce Patel Ed