T1 AIR BAG SYSTEM INSPECTION OF SST (DEPLOYMENT TOOL) © Use the SST to deploy a lve air bag module before disposing of it. * Before connecting the SST to the clock spring connector or airbag module connector, inspect the opera- tion of the SST. CONNECTOR A a ACTIVATION SWITCH RED LIGHT Inspection Procedure 1. Follow the steps below to it pect the operation of the SST. rnapoation prosadre Tight condition Step Inspection proced acne ‘Connect red clip to positive battery 1 | terminal and black clip to negative | ON | OFF battery terminal 2__| Connect connectors A and B ofSST._| OFF | ON ‘3 [Press activation switch. ‘ON | OFF, 2. If not as specified, do not use the SST because it may cause the air bag to unexpectedly deploy upon connec- [ACTIVATION tion to the hamesses. SWITCH ACTIVATION ‘SWITCH RED LIGHT T1-112U g system service warnings. @ beginning any service procedure, refer to section T1 of this manual for | HEATER AND AIR CONDITIONER SYSTEMS (B-134a SYSTEM INTRODUCTION |... U- 2] FQUTLINE siceteccrsesersessrscrss U= 2] [SERVICE WARNINGS U3) REFRIGERANT SYSTEM SERVICE HARGII EDURE FLOW .. U- 5 MANIFOLD GAUGE SET ICHARGING. REFRIGERANT PRESSURE SWITCH. BLOWER MOTOR REFRIGERANT PRESSURE RFORMANCE TEST RESISTOR:U R-134a SYSTEM INTRODUCTION R-134a SYSTEM INTRODUCTION OUTLINE R-12 and other fluorocarbons now used in air conditioners can destroy the ozone layer in the strato- sphere. The result is an increase in hazardous ultraviolet rays which over time can adversely affect both human health and the biosphere. Because of this concer, Mazda has chosen to use R-134a (HFC-134a), a hydrofluorocarbon-based refrigerant that does not deplete the ozone layer, in this vehicle. + R-12 and R-134a are not interchangeable; system parts and system service tools also differ. The table below compares the two systems. (Maintenance-related items only) Refrigerant Systems Pat Roi sysiom | A-134a system Remarks Rotiigerant Ghlorofuore- | Hydrofluoro- ie refrigerants are mixed or one refigerantisusedinasystem| ‘carbon-12 carbon-134a _| that requires the other, the compressor ol wll separate fom the (CFC-12) (HFC-134a) refrigerant andnot circulate within the system. This can damage (Co1F) (CHoFCF) the A/G compressor. In adalton, mixing R—194a with R12 or using F-134a instead of R~12 in an R12 system can lower the ‘durability ofthe NBR O-ring and dissolve the fluorine rusber O- Fings. Ite fluorine rubber O-rings are dissolved, refrigerant may leak. [Compressor oi | Mineral ol Polalkyiene glycol | Special compressor ols for R-194a airconditioning systems are cil (PAG oil) [SP10} | developed by each airconditioning vendor. Theretore, use only ‘the specified ol for each model vehicle. If @ PAG ol other than ‘the spectied type is used, the AIC compressor and refigerant system can be damaged. ithe compressor ols are mixed or one compressor olis used ystem that requires the other, the refrigerant will separate fromthe compressor oll andnot circulate within the system. This can damage the AIG compressor. Mixing PAG ollwith mineral ol ‘sing PAG ol instoad of mineral olin an P12 systom can lower the durabilty of the NBR and fluorine rubber O-rings. O-ing Nitile butadiene | High-ciculated __| fan NBA O-ringis usedin an R-134a PAG ol and rubber (NBR) nitrile butadiene _| R-134awilliower the durability of the O-ing fa fuorine rubber Fluorine rubber [rubber (HNBR) | O-ring is used in an R~134a ayetom, the F-134a wil issolve the O-ring and cause the reftigerant to leak. Joint nats Tnch threads | ‘Meticthreads | Thread standards for joint nuts connecting cooler pires and hoses have been changed to avoid connecting R-12 sysiem parts with R134a system parts Joint blocks ‘The bolt sizes and part measurements for joint blocks connect- = = ing cooler pipes and cooler hoses have been changedio avoid connecting R-12 system parts with R-134a system parts, [Charging valve | Screw-on ‘Quickcconnect | The shape ofthe charging valve difers for each system o avoid HE38—24 UNF _ | type confusion. The quick-connect type charging valve prevents LO: 7/16—20 UNF | Hi: 16 mm {0.6 in} | retigeran rom leaking when the charging hase is connected to da. the valve. LO: 19mm (0.5in} dia.R-134a SYSTEM INTRODUCTION U Service Tools Part Roizeystem | A-194a system Remarks Tool joints Tnch threads | Metric threads | Thread standards for tool joints have been changed to avoid connecting R12 system tools with R—134a system tools. harging valve | Serew-on type ick-connect type | The shape ofthe charging valve joints difer for each system to ‘Charging Quick “The shape of the charging valve joins differ for each Joints HI:@/8—24 UNF | HI: 16mm (0.6 in} | avoid confusion. The quick-connect type charging valve joint LO: 7/1620 UNF | dia. prevents refrigerant from leaking when the charging hoseiscon- LO: 13 mm (0.5 in }| nected tothe valve. da. (Manifold gauge | High-pressure-side | High-pressure-side | R-134a requires a higher pressure to condense than R12. maximum reading: | maximum reading: 29MPa(30 kal |3.5MPa (35 kal! com?, 430 psi) | om, 600 psi) Gasloaktester | Gas ype Electic ype | Agas eaktestoreacts wih chlorine iniZtoindcatetheloca- let ype tion ofa leak. This kind of tester does nat work wth an P-134a systom, however, because R~134a has no chloe. Two kinds of elect testers ae avaliable: those that work excusively wth one systom ortho other, and those that work witboth, A testor builtenly or 12 ayetomscannotbo useduwith an R-134a sys tom ‘SERVICE WARNINGS Using/Handling Unapproved Refrigerant * Using a flammable refrigerant, such as OZ--12, in this vehicle is dangerous. In an accident, the re- frigerant may catch fire, resulting in serious injury or death. When servicing this vehicle, use only R-134a, * Checking for system leaks on a vehicle that has been serviced with flammable refrigerant, such as OZ-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite the refrigerant, causing serous injury or death. Ifa flammable refrigerant may have been used to service the system, or if you suspect a flammable refrigerant has been used, contact the local fire marshall or EPA office for information on handling the refrigerant. U-3R-134a SYSTEM INTRODUCTION MOISTURE ABSORPTION PAG OIL Servicing Refrigerant System ‘* Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause re- frigerant inguish or remove the above- mentioned heat ‘sources and maintain adequate ventilation. Storing Refrigerant The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seri- ‘ously injure you. Store the refrigerant at tempera- tures below 40 °C { 104 °F}. Handling Refrigerant ‘Handling liquid refrigerant is dangerous. A drop of it on the skin can resutt in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and con- sult a doctor. SERVICE CAUTIONS ‘Compressor Oil (SP10) + Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately. ‘* PAG oil has a higher moisture absorption efficiency the previously used mineral oil. If moisture ces with the compressor oil, the refrigerant sys- tem could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent mois- ture absorption.REFRIGERANT SYSTEM SERVICE PROCEDURES REFRIGERANT SYSTEM SERVICE PROCEDURES CHARGING PROCEDURE FLOW ‘START Install manifold gauge set fo 1 Evacuate system and test for aitightness Do pressure teadings change? Repair leakage }——— First charge Tighten joints Repairjoints Carry out gas leak test T No ‘Second charge NO been done? ‘Are there any leaks? ‘Has second charge Yes MANFOLD GAUGE riz Hose ‘quic coupten FoR| ASH SRESSURE one gucxco gees PRESSURE founcns counang ee ae oe Feoae EGWISRESSURE SIDE MANIFOLD GAUGE SET INSTALLATION 1. Fully close the valves of the manifold gauge. 2. Connect charging hoses to the high- and iow-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 PINS JOAN PUNCTURE VALVE ~“SERVICE CAN CHARGING eae @ No 1. 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's con- nected to the gauge set air purge valve. Open alll the valves of the manifold gauge. . Start the vacuum pump and letit 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 intig } . 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 kgf/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 a loose joint, tighten the joint and check for leaks again. If there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there 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 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 vaive of the manifold gauge. 23. Stop the engine and A/C compressor. 24. Check for leaks by using a gas leak tester. If there are no leaks, go to step 25. If a leak is found at a loose joint, tighten the joint and check for leaks again. if there is still a leak at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 9. If there 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. U7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” 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 it'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 i's loose, tighten the connection to the specified torque and refil the oil and recharge the rofigorant (Hater te oae U-eat the connection is properly tightened, replace the O-ring and, if necessary, other parts. Refill the oll and recharge the refrigerant. U-8REFRIGERANT SYSTEM SERVICE PROCEDURES U REFRIGERANT CHARGE CHECK 4. Install the manifold gauge set. (Refer to pans U-5.] 2. Check the refrigerant pressure reading with 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. (Retr tal Ifthe pressure readings are within specifica- tion but there sufficient cooling, go to the next step. If the pressure readings are within specification and there are no leaks, the refrigerant amount is OK. 4. Start the engine and run it at a constant 2,000 rpm. 5. Turn the A/C switch on, set the fan switch at MAX-HI, and set the air intake mode at Ri 6. Ifthe A/C compressors short-cyciing, note the low-pres- ‘sure-side reading at which the magnetic clutch kicks out. 7. Ifthe 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/cm?, 30 psi } or higher, inspect the thermoswitch, inate fopage. tei d 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 constant 1,500 rpm. 4. Set the fan switch at the 4th position. 5. Tum the A/C switch on. 6. Set the REC/FRESH lever to RECIRCULATE. (wire type) 7. Turn the REC switch on. (logic type) gl 8, Set the mode lever to VENT. (wire type) 9. Turn the VENT switch on. (logic type) 10. Set the temperature control lever to MAX COLD. 11. Measure the ambient temperature and the high- and low-pressure-side readings of manifold gauge. 12. If the high- and low-pressure-side readings are in the shaded zones shown in the figure, refrigerant system is rr er) normal. If the readings are abnormal, refer to flowchart {88} (68) (77) {86} (95) (104) No.13 and troubleshoot the system. AMBIENT TEMPERATURE °C(°F) FOLD GAUGE 5 2 2 ; uU-9REFRIGERANT SYSTEM SERVICE PROCEDURES DAY.BULB THERMOMETER WET: AND DAY-BULB, THERMOMETER. PERFORMANCE TEST After servicing the refrigerant system, test its performance. 1. ital the manifold gauge set (Refer ta page U5.) 2. Place a dry-bulb thermometer in the center ventilator outlet. 3. Place a wet- and dry-bulb thermometer at the blower in- let. 4. Open the all doors and the all windows. 5. Warm up the engine and run it at constant 1,500 rpm. 6. Turn the A/C switch on. 7. Set the fan switch at the 4th position. 8. Set the REC/FRESH lever to RECIRCULATE. (wire type) 9. Tum the REC switch on. (logic type) 10. Set the mode lever to VENT. (wire type) 41. Tum the VENT switch on. (logic type) 12. Set the temperature control lever to MAX COLD. 13. Wait until the air conditioner output temperature stabi- lizes. Stabilized condition Blower inlet temperature: 25—35 °C { 77—95 °F} High-pressure-side reading: 1.3—1.6 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. [HOWTO READ THE GRAPH: Altermoasuringthetamperaturesofwet-anddry-bulb {termometer at the blower it, relative mit (%) [canbe obtained, Example; Supposing dry-and wet bub temperatures Jattioblowerbnetare25°C(77"F }and19.5°C(67.1 *F respectively, the pointotintersectonofthedoted lines inthe graph is 60%. a 1B) (3) 3) SOUcF) Ee i DRY BULB TEMPERATURE 25(77) 20(68) 15(59) 3 6070 RELATIVE HUMIDITY (%) ‘ ; 15, Read the dry-bulb thermometer at the air outlet, and cal- culate the temperature difference between the center ventilator outlet and the blower inlet. 16. Verity that the intersection of the temperature difference and the relative humidity is in the shaded zone. 17. Ifthe performance is abnormal, troubleshoot the system. (Refer to page U-47. U-10BASIC SYSTEM ‘STRUCTURAL VIEW BASIC SYSTEM 1. Blower unit 4. AIC compressor Removal Installation page U-12 [Removal /Installation ...._ page U=20) Disassembly / Assert page U=13 5. Condenser 2. Heater unit [Removal installation... page U-21 = 1 Assembly page U=15] 6. Receiver/drier [Inspection ..... ++. page U-16] [Removal / installation... page U-22] 3. Cooling unit 7. Refrigerant ines [Removal installation... page U-23 Removal / installation... U=25 U-11BASIC SYSTEM 3. Blower unit 1. Blower unit connector inector 2. Blower motor cont U-12BASIC SYSTEM Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of disassembly. WIRE TYPE vy [WIRE TYPE o 1. Air hose 9. Wire clamp 2. Blower harness 10. Air intake link 3. Hamess clip 11. Air guider 4. Connector bracket 12. Air intake crank 5. Resistor 13. Airintake door 6. Blower motor 14, Polyurethane protector 7. Air intake actuator 15, Blower case (top) 8. Wire clamp bracket 16. Blower case (bottom) U-13U BASIC SYSTEM HEATER UNIT Removal / Installation 1. 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. (Loaic TYPE) 1. Quick connector 5. Heater unit 2. Hose clamp Disassembly / Assembly page U-15 3. Heater hose inspection page U-16 4. Heater unit connector U-14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) 3. 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 24, Heater core 8. Heater hamess 9. Connector bracket 10. Heater unit bracket 11. Wire clamp bracket : 12. Airflow mode wire clamp . Side VENT door 18. Airflow mode actuator 29. HEAT door 14. Airflow mode main link 30. DEFROSTER door = 31. Center VENT door 15. Airflow mode rod 32. Heater case (1) 16. Airflow mode sub link (DEFROSTER) 33. Heater case (2) 17. Airflow mode sub link (HEAT) U-15U BASIC SYSTEM AIRFLOW MODE SUB NK AIRFLOW MODE HEATER UNIT MAIN LINK. PROJECTION ‘auIGK CONNECTOR INSTALLATION 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 ‘shown in the figure, 8. Press the airflow mode main link and rotate itin 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. Inspection Heater core 1. Disassemble the heater unit. (Refer to page U-15.)| 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 is damaged, replace the heater core. (ffotarte page UTE) 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. (Refer to saction S1.)] 83. If the air bag system is installed, remove the No.1 duct. o section St.) 4. If the air bag system is installed, disconnect the air intake wire from the air 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 glug all open fittings to keep moisture and dirt out of the system. 6. Install in the reverse order of removal, referring tol Installation note. 7, Adjust the air intake wire, charge the system and test its performance. [(Refer to pages U-6and 10) 1. Cooler pipe No.4. 3. Cooling unit [Removal Installation. Uz [installation note = below 2. Cooler pipe No.5 [Disassembly / Assembly... page U-18] (Removal /Installation = page U=23] [Inspection . =. page U=19] Installation note When installing a new cooling unit (evaporator), add 50 ml { 50 ce , 1.7 fl oz } 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 e147 Nm (120-180 gem , 105130 nibt) Neon (gt bt) Polyurethane protector (heater side) 9. Rubber protector Polyurethane protector (blower side) 10. Sponge rubber Polyurethane foam 11. Bracket \ Cooler case (top) Cooler case (bottom) AIC amplifier Thermoswitch 2 NoOgaeNs ‘Sensor clamp U-18BASIC SYSTEM U HEATSENSWG TUBE ‘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 t ‘open-end wrenches. 4. Assemble the heat-sensing tube as shownin the figure. ecified torque by using two EXPANSION VALVE ‘THAYER Thermoswitch ‘Assemble the sensor part of the thermoswitch as shown in the figure. = l gS I Wan } UN tt Stim) Inspection Evaporator 1. Disassemble the cooling unit. 2! Check for cracks, damage and oil leakag replace the evaporator if necessary. 3. Check for bent fins. If they are bent, use a flat-head screwdriver to straighten them. Repair or U-19U BASIC SYSTEM A/C COMPRESSOR Removal / Installation . Discharge the refrigerant from the system. 9. Remove the undercover, splash shield (RH), and A/C drive belt [(Refer to section BY pr[B2.) |. 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. . Install in the reverse order of removal, referring tolInstallation note.) Charge the system and tests performance. (Retr fo pages U-eland TO) 9a eps te5(19e26, 16-18) Nim (gt, BE) 1. Flexible hose Hh 3. pressor Installation note . . 2. Flexible hose LO} 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 , 0.2—0.3 floz }] U-20BASIC SYSTEM U _ CONDENSER Removal / Installation 1. Discharge the refrigerant from the s\ 2. Remove the upper seal board. (Refer to section E)] 3. Remove the radiator grille. 4. Remove the undercover [(Refer to section Btlor|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 (ao—HoNgtem 60595. tnibt) 1. Cooler pipe No.1 3. Condenser [Removal Installation = page U-23] [Installation note. = below] 2. Flexible hose (HI) [Inspection ... = below | smoval / Installation. age U~Z Installation note ‘When installing a new condenser, add 15 ml { 15 ec , 0.5 fl oz } of compressor oll through the high-pres- 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 flat-head screwdriver to straighten them. U-21U BASIC SYSTEM RECEIVER/DRIER: Removal / Installation 4. Discharge the refrigerant from the system. 2. Remove the undercover and the splash shield (LH). (Refer to section BT b{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, referr 6. Charge the system and test its performance. {so okgtem 605-95.4insbt) 1. Cooler pipe No.2 3. Refrigerant pressure switch connector TBemaval/Instalation——————-pagel-23) 4. Recelvercrier . Unstallation note below] Installation note ‘When installing a new receiver/drier, add 10 ml { 10 ce , 0.3 fl oz } of compressor oil through the high- pressure side of the A/C 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 pipemhose to be removed Paris to be removed Flexible hose (HI) Undercover, Splash shields, Engine mount member Flexible hose (LO) Undercover, Splash shield (RH) ‘Undercover, Splash shield (LH) ‘Cooler pipe No.1, No.2 Tiger = ‘Charcoal canister erences ‘Cruise actuator (equipped) 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, referrin 5. Charge the system and test its performance. (Matar ta pages Uesland 70) 21 (15-22, 11-15) 73-107 {80-110 egtem ,6035—95.4 instr) ret07im ~ {80110 kgom , 68.5954 inte) \ 099 (S040, 2-28) 79107 Km {010 kgtem ,60.5-95.4 nib} Nev (hgten fbr) 1. Flexible hose (Hl) Installation notes pane U=2a a page U-24] 2. Flexible hose (LO) 6. Cooler pipe No.4 Linstallation note 02.2.2. page U-24 | [installation note . page U-24] 3. Cooler pipe No.1 7. Cooler pipe No.5. Installation note 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 connect 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 AC 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 U REAR HEAT DUCT Removal / Installation 1. Remove the front se: 2. Remove the center console and side wal 3. Remove the PCM. | 4. Remove the front scuff plate and front side trim, and tum over the floor covering. 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 498061 010 ‘AIC clutch holder For prevention of AC ‘compressor pulley rotation 49 Gos2.311 il seal and ‘Spacer installer guide For installation of AIC ‘compressor pulley 49 BO61 013. For removal of Pressure plate pressure plato remover [LOGIC TYPE WIRE TYPECONTROL SYSTEM U 1. Magnetic clutch 7. Air intake actuator [Disassembly / Assembly ... .. below Removal / Installation ....... page U-33 inspection .. page U-29 Unspection page U=aa] 2. Condenser fan 8. Airflow mode actuator a Removal / Installation je U-33. 3. Refrigerant pressure switch 9. Thermoswitch {Removal /installation page U-31] (Removal / installation .. ._page U-34 | nee ye U- is 10. amplifier Removal J Installation ....... page U-34 I 11. Heater control unit [inspection ................. page U-34] Dissssenly Assert 22. page U=39 inspection page U-41] MAGNETIC CLUTCH Disassembly / Assembly 1. Remove the A/C compressor. 2. Disassemble in the order shown in the figure, referring tol Disassembly note] 3. Assemble in the reverse order of disassembly, referring to Assembly note.| ‘NC COMPRESSOR BODY ata | igen 8 1. Center nut 5. AIC compressor pulley eeeeeeeee age jisassembly note. 2. Pressure plate Disassembly note _pageU-28] 6. Snap ring [Assembly note... page U-29} 7. Stator 3. Shim 4. Snap ringCONTROL SYSTEM = con CONNECTOR HOLDER 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 ‘AIC compressor pulley 1, 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 ‘AC 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. (Refer to sections EJS1.)] 2. Remove in the order shown in the figure. 3. Install in the reverse order of removal. 79-107 Nim {80-110 gtem ,68.5—85.4 nsbt) 1. Condenser fan connector Inspection 4. 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. hd 3. If condenser fan does not operate, replace the con- denser fan. U-30CONTROL SYSTEM U REFRIGERANT PRESSURE ‘SWITCH 29-107%m {90—0kgrem, jaa—ssainbry RECEIVER! DRIER 70-220 (17-22, 25-22) (90-34 ,490—400) 245 (025,856) 400—780 ORLESS (40-80, 5710) ka (gto? psi) REFRIGERANT] eS PRESSURE ‘SWITCH RELY BRACKET OL & RELAY CONNECTOR RELAY CONNECTOR REFRIGERANT PRESSURE SWITCH Removal / Installation 1. Remove the receiver/drier. [Rafer to page U-22.)] 2. Remove the refrigerant pressure switch from the recei er/drier. Immediately plug the open fitting to keep mois- ture out of the system. 3. Install in the reverse order of removal. Be‘ore installing the refrigerant pressure switch, apply compressor oil to the O-ring and connect the joint. 4. Charge the system and test is performance. Inspection 1. Install the manifold gauge set. 2. Make sure that the high-pressure side is in the 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 ‘AIC relay, condenser fan relay 1. 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 1. 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 relay, blower reray R 1 Remove the relay. (Ralar to raga U-31) 2. Connect battery positive voltage and check for continu- ity between terminals of the relay. 0: Continuity B+: Battory positive voltage 2O ‘Connection B+ | GND x 5 A B c D 3. If not as specified, replace the relay. BLOWER MOTOR Removal / Installation . Remove the blower motor cover. Disconnect the blower motor connector. Remove the blower motor connector from the connector blacket. Remove the air hose. Remove the screws and the blower motor. Install in the reverse order of removal. BLOWER UNIT BLOWER MOTOR AIR HOSE eae ep Inspection 1. Disconnect the blower motor connector. 2. Connect battery positive voltage to terminal Band 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 (a) =) 03-06 Ce 10-16 cA 28-60 3. If not as specified, replace the resistor.CONTROL SYSTEM U ‘AIRINTAKE ACTUATOR RECIRCULATE ROTATIONSs DIRECTION AIR INTAKE ACTUATOR Removal / Install 4. Remove the glove compartment and the glove compart- ment cover ster to-secion ST] 2. Ifthe air pap 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. B+: Battery positive voltage ‘Connection Movement Be GND. a 6 FRESH to RECIRCULATE K RECIROULATE to FRESH contac! SERING "x ROTATION = | | DIRECTION 4. Ifnot 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 Movement Be ‘GND J T T J VENT to DEFROSTER: DEFROSTER to VENT U-33CONTROL SYSTEM ‘SLIDING RANGE SLIDING CONTACT woonr 4. Check for continuity between the terminals of the air- flow mode actuator as shown below. O—0: Continuity minal Mode VENT BILEVEL HEAT HEATIOEF DEFROSTER, a ela] « 5. If not as specified, replace the airflow mode actuator. THERMOSWITCH Removal / Installation 1, Remove the cooling unit. (Refer to page U-17,)] 2. Remove the thermoswitch from the cooling urit. 3. Install in the reverse order of removal. Inspection |. Remove the thermoswitch. 2 Immorce te 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 Temperature Q 2 36°C (38°F) ormore of (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,) ve the A/G ampli rom The cooing me } 3. Install in the reverse order of removal. Inspection 1. Remove the glove compartment and the glove compart- ment cover. (Refer to section St 2. Start the engine. 3. Measure the voltage at the terminals of the A/C amplifier ector and refer fo the terminal voltage list. 4, Ifnot as specified, inspect the appropriate area. 5. If the inspection area is OK, replace the A/C amplifier.CONTROL SYSTEM U Terminal voltage (Reference) Be: Battery postive vottage [Terminal] _ Signal name Connection TTest condition [Voltage (V) Inspection area A lige [AIC 10 Afuse [ignition switch at ON Bs [+ Continuity (Fuse—A/C ampi- fier AC 10 AA) Ignition switch at LOOK, 7 a 0 | ACIOA fuse 8 [AC signal efigerant pres- [Magnetic catch on + Contnaty PCM —Retriger sure switch antpressure switch: 1KB, max.1 | Retigerant pressure ‘witch--A/C amplifier: AB] + Terminal vtage of AC Magnetic chich of ample (©) + Rago pressure switch e+ |" WBetertonage Lean) . Fae [Refer to section Fi brfF2)) © [a evan cgnal >A och (te |NC wich of Terminal votage of AC amp type) oa fier (A) Heater onto |e ich on andfan Wire wpe) wich at st poaton P Contalty (AC amon Ream C0, an aie SND + Fan switch 0 |(Legietype) + Continuity (VC ampiiier Heater control unt C~B, Heater control uni—Fan m ! | | | 1 U-35U CONTROL SYSTEM HEATER CONTROL UNIT Removal / Installation Wire tyr 1. Remove the meter hood, side panel, glove compartment, and glove compartment cover. 2, Remove in the order shown in the figure. 3. Install in the reverse order of removal. 4. Screw 5. Fan switch connector ix wil 6. Heater control unit connector [Wire adjustment... 7. Heater control unit 8. Airintake wire = [Disassembly / Assembly... page U-a0] [Wire adjustment... page U-38) 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 assen 3. Fan switch connector U-37U CONTROL SYSTEM Wire Adjustment Airflow mode wire 1. 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 air- flow mode wire. 4. Verify that the MODE lever moves in its full stroke. Air mix wire 1. Set the temperature control lever at MAX COLD. 2. Connect the air mix wire to the air mix link. 8. 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 4. (95) into the set hole. Clamp the air intake wire. Verify that the REC/FRESH lever moves in its full stroke. U-38CONTROL SYSTEM U Disassembly / Assembly 1. Disassemble in the order shown in the figure. 2. Assemble in the reverse order of removal. WIRE TYPE Air intake wire spe page U-42) ‘Temperature control lever Knobs 10. MODE lever it 11. REC/FRESH lever 12. Fan swit 13. Bulb Airflow mode wire 14. Switch body NogaenCONTROL SYSTEM u4oCONTROL SYSTEM U Inspection switch Wire type 1. Check for continuity between the terminals of the fan switch. 2. If not as specified, replace the fan switch. HEATER CONTROL AIC SWITCH CONNECTOR UNIT CONNECTOR 0: Continuity Heater control unit a 5 Logic type 4. Check for continuity between the termianis of the fan switch. —0: Continuity Terminal ‘Switch posi OFF Flealu 1 2 3 4 2. If not as specified, replace the fan switch. uU-41CONTROL SYSTEM AIC switch (wire type) 4 1. Check for continuity between the termianis of the A/C pe owTenl | switch. 0: Continuity ‘RIC owt E OFF « OW 2. Tum the A/C switch on. 3. Connect battery positive voltage and ground to the ter- minals of the A/C switch. Bt: Battery postive voltage Be “GND. B A 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 i 1. Connect a 1 k@ resistor between terminals C and F. 2. Tum the REC switch on, and measure the voltage between terminals C and J. Be: Batory postive voltage REC switch Voltage ON TV or less OFF Be . 3. If not as specified, replace the heater control unit 4, Connect a 1 k9 resistor between terminals A anc F. ‘ 5. Turn the REC switch off, and measure, the voltage between terminals A and J. B+: Battery postive voltage REC switch Voltage OFF TWerless ON Be 6. Ifnot 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. B+: Battery positive voltage Terminal Voltage Jat Br R t o 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 2] oF battery terminal) and P. 7. Measure the voltage between terminals J and N. Br: Battery positive voltage J Terminal Wotage J J=N 8 8. If not as specified, replace the heater control unit. © 9. Connect a 1 k® 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 Vortage = TVorless 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. 1. Measure the voltage between terminals J and N. [s[oloMS connector female). Other _ [Goto Step2 2 | Measure voltage at terminal of Blower A Be | Check terminal B motor connector (female). Ghar [Gots Sep’ Be | Repair wiring hamess [Blower motor — . Resistor: BD} ace blower motor Omer | petteriopans Ue] 3 | Measure voltage a torminals of Blower relay Be | Repair wing hamess [Blower relay — connector female). > Blower motor: D—A] ‘ther | Check terminal G B+ | Check terminal A c Ri harm | Repair wiring hamoss [Fuse—Blower relay. Other | HEATER 40 A—C] Be | Check terminal B A Other | Repair wiring hamess [Fuse—Blower relay: NIC 10 A—Al Br | Repair wing hamess 5 [Blower relay (6)--GNO] ‘Oher | Replace blower relay @_[1) Tumigniion switch to LOCK Replace fan switch 2) Disconnect fan switch connector. YES _|[(Reter to page U-3o prU—40] 3) Is there continuity between terminal of | Ground fan switch connector (female) and No | RePairwinng hamess ‘round? [Fan switch (6}—GND} U-51U TROUBLESHOOTING mn ‘Symptom ....... Blower motor does not operate properly with eee Raninatch eystaen fan switch at 1st, 2nd, 3rd, or 4th 7 pecton. Related parts ... Resistor, fan switch, wiring hamess RESISTOR mse 3} wc swircn B+: Battery positive voltage ‘Step Inspection procedure Terminal | Result ‘ation + [2 Fanon ech w ON Br __ | Check terminals A, Band C leasure voltage at terminals of resistor > if ee rea 1 _ | Repair wiring hamess [Blower motor— jctor Gemnaleh. Other | Resistor: B—D) Beal) [Goto Stop? A.8.C | other | Replace resistorlGaiarinpagalLa2] orton) 2 | Measure voltage at terminals of fan switch B+ Check terminal E connactor (female). a ther _ | Repair wing hamess (Resistor—Fan Br | Check terminal F iC cotner | Repair wiring hamess [Resistor—Fan Br | Check terminal F Reps ‘har (Fe air wiring hamess Resistor—Fan Other | switch: C—FI Replace fan switchl(Refario page U=Galor eB > esa ‘er | Repair wiring hamess [Resistor-—Fan Other | switch: A—D] U-52TROUBLESHOOTING U Flowchart No. ‘Ar intake actuator sys~ «Air intake actuator does not operate tem inepection Related parte .-- Blower unt ar intake acustor, eater contol 8 (logic type only) unit, wiring harness re [ARINTAKE ACTUATOR ne wa ia ‘- A HEATER CONTROL UNIT Be: Batery postive votage Step Trapection prosedre Result ation 1 | 1) Remove air intake actuator. Go to Step 2 ves 2) furnipitenortch 1 ON, 3 sariahowtan ta 4) Oporate aia cranky hand. heck Bower ant 5) Does air intake mode change smoothly NO ftom RECIRGULATE to FRESH 2 [1p Taman wich ot Be [Gore Siops 2} Mensur vhage trina of ai ktako 3 tttuntor connector ral) ner _ | Rep wing hares FeAl 3 | 1) Turn ignition switch to LOCK. Goto Step 4 2) Turn REC switch on. Yes: 5} etree contnaty baton erin of i intake actuator connector (female) and no |StSteps gone? 7 [iy Tum REC awh of e|Repiane ace ear 2) Is there continuity between terminal of air 2 (Refer to page U-33)] Irak actuator connector tema) and | —__|ieeceree eS gourd? NO [GotoSteps © [7 Disconnect hoalr conv ul conten Yes | Resto healer cont unt 2} Is there contnty between terminals of ‘an air intake actuator connector (female) — lndeaterconvl unt connector NO | Ropar wing haress tat hoa no conaly female)? (partial) | (Airintake actuator—Heater control unit) U-53TROUBLESHOOTING Flowchart No. | airtow mode actuator [S¥™PtOm ....... Allow mode actuator does not operate system inspection Properly 9 (logic type only) elated parts... Heater unit airiow mode actuator, heater control uni, wiring harness [AIRFLOW MODE ACTUATOR '5) Does airflow made change smoothly to VENT, BI-LEVEL, HEAT, HEAT/DEF, and DEFROSTER? F fl =i e =F EATER CONTROL UNIT Trapection procedure Terminal [Result ation 7) famove allow mode actuator EASE Govw Sep? iomgetael 2) Tur lgntion switch to ON. Yes 4} Operate aiow mode main ok ito ro al - y hand. a Check heater unit No 1) Check airflow mode actuator. 2) Does airflow mode actuator operate property? Yes [Goto Steps vo | Seta emer (female) and heater control unit connec- {or female)? 7) Tum ignition switch to LOCK. JAN YES: jace heater control unit 2) Disconnect heater control unit connec- | K—P, HM, (all) tor FO, D-a, 3) Is there continuity between terminals of | C—S, B—T, Repair wiring hamess that has no continu- airflow mode actuator connector ACR No ity (partan | (Aitiow mode actuator—Heater conto, unit) U-54TROUBLESHOOTING U ‘Symptom . Magnetic clutch, condenser fan, arena fC signal eyoten compressor idle-up do not operat A signal oye elated pars ~~~ PCM, refigrantpressureswitch, Campi, 10 AIC switch (wire type), fan switch (wire type), heater contorl unit (logic type), wiring harness REFRIGERANT PRESSURE SWITCH ice ‘AIC AMPLIFIER ‘AIC SWITCH (WIRE TYPE) RESISTOR HEATER CONTROL UNIT (LOGIC TYPE) FAN SWITCH @: D «wire TYPE) SESE, @: E(wiRE TYPE) san, Sap | pesto sce teri [reat ro fe | eae chest Faroe reine seer connector. ‘YES 2) Connect jumper wire between terminal B rmeimpe nboween toring ® | Chakra ban tr eso eine Oe eat et oa ose ron eee 44) Do magnetic clutch, condenser fan, and Ea) erry = [amar ar oOo = Bg er Seectwaes fence + Wares rae caramels oe ‘or C of A/C amplifier connector (female) | Jumper wire connect to terminal C eric, erat Tope wing hamoos 2 BE npemare wondonun wnt Joma®, |g | Sarena aac Feces igo a oon Faae npn eae oeF 4) Do magnetic clutch, condenser fan, and | between ves (wire type) or Step 6 (logic type) anata encore ant fete ‘and ground NO _| Check A/C ampliferl{Refer to page U=34)] U-55heater control unt connector (male)? TROUBLESHOOTING Be: Battery pettve vottage Step) Inspection procedure ‘Terminal [Result ‘etion | Measure votage at terminal of AIG ewlich Br [Got Steps connector (female). D ‘oner | Repair wiring hamess [AIC ampiie—AG sith: CD} 3 |) Tum gation switch to LOGK Replace fan ewich| [eter to page 0-39] 2) Disconnect A/C switch connector. he 3) Tum AC switch on De 4) Is there continulty between terminals of No | RoPlace AIC swich[Refer to page U-38)] AC switch connector (male)? | Measure voltage at terminal of heater con- Bs [Goto Step7 tort unit connector (female). 8 ne Repat wing hase [TAC amplier-—Heater control unt: C—B) 7 |) Tum ignition switch to LOOK. Repair wiring harness 2} Disconnect heater contor unit connector. YES | [Heater contol unit—Fan switch: 8—D] 3) Tum AIC switch on. Bo 4) [s there continuity between terminals of xo eae U-56TROUBLESHOOTING U Flowchart No. 1" Inspection Magnetic clutch system ‘Symptom ....... Only magnetic clutch does not operate Related parts ... AIC relay, magnetic clutch, PCM (BP ATX, 25 ATX), wiring harness: 16 POM ct TuAN 10a eB AIC RELAY MAGNETIC CLUTCH B+: Battery postive voltage Step Inspection procedure Terminal_[ Result ‘ation 1 |) Connect jumper wire between term (Check or continuity between wiring hamess Qf AIC relay Connector and ground. yes | AC relay and PCM (B—1G}, and check 2) Start engine, = Eran Ar 25 ‘aol io secion 7] 8) Does magnetic clutch operate? NO__ [Goto Step2 2 | Measure voltage at terminals of AIC relay D Be [Goto steps connecter ems}. Other | Check terminal C Be ___| Check terminal A e Other _ | Repair wiing hamess [Fuse—AC relay: AIC 10 A—C] Be __[ Replace AC relay eferto page U=ai)] a ‘tner | Repair wiring hamess [Fuse—A/C relay: TURN 104A] 3 | Measure voltage a terminal of magnetic Br [Check maanetic clutch ‘clutch connector (female). a ‘Other | Repair wiring hamess [A/C relay — Magnetic clutch: DA ] U-57U TROUBLESHOOTING Fowahar We mp Only candenear Tan doe nt oper Condenser an eyo 2 Senders Telaled paris Condeneer an relay, condenser fn, POM GP ATX, 25 ATX), wiring harness Be 1 ‘CONDENSER FAN RELAY TURN AD FAN 108 20A A ce iF B % ® Pox A © 1e.gp ure 1mm sean CONDENSER FAN tageATS 3 Be: Battery postive votage Sep Tpapedton procedure Terminal” [Rest ‘ation 7 [1 Connect umpor wre betwoon trina B Check for coninaly botwoon wing arose {corset an toay comer Stcondense fan lay and PCM [6 16s ffemat and gourd ves | Bene 26 wniBo4e: be ATE TA 2) Sarengin, = 25 ATK) and shock POM (BP ATX. 25 ATX) 3} Doos cendanser fan operate? aa NO | Got Sep? 7 [oasis votage atten ofconarsor | Br [ote Siep3 (envely connector ome) ee ce Br GhecktominalA c ‘other | Repair wiring hamess[Fuse—Gondenser fan rlay: AS FANT 90 AC] Foplace condenser Tan lay A es ner | FeparwingRamessFuso—Condoear fan rel 'URN 10 A—A] 3 | Woasure vatago al torinal of condenser Be | Chock iominal fan connector {tera}. a ‘Other | Repair wiring hamess (Condenser fen relay —Condenser tan: D—A] Go] Rel wing arose [Condoncar Tan) 5 Peto! ner [gare srr uU-58TROUBLESHOOTING U Flowchart No. inspection 13 Refrigerant system ‘Symptom ....... Magnetic clutch, condenser fan, and AIC compressor idle-up operate, but cool air does not discharged or air cooling ability is low Rolated parts ... Refrigerant system PRESSURE READING OF MANIFOLD GAUGE Ma (kgtem?, ps!) HIGH-PRESSURE SIDE LOW-PRESSURE SIDE ss ae (59) (68) (77) (86) {95} (104) AVBIENTTEMPERATURE “CLF Tip Tnapeaton prosedre esa Teton 7 | Sond eigerant presoure chock | igh and towprsauro [Goto Sep? thoterts pases} Te roeangs So higher ihantormal High and owrprosoue [Goto Sip 3 {ide rdinge are ower than ormal Tigh pressures ead [GoTo Sip Ing io lower nan norma: ow pressure side reading is a little higher tran romal High-pressure-side read- | Go to Step 5 ing rises to normal pres- SSotange ond then crops Below ange; ow pres cele easy sop ie No difference between Improper compression of A/C compressor Newrandion pressure | eplees A'S conprscor Tio readings [ities npaget2a 2 | Are condenser fins clogged or dam: 1? Insufficient refrigeration in condenser se YES: Clean or | oak oe fins NO. ‘Too much refrigerant juatretigorant amount U-59TROUBLESHOOTING Sep Thapedion procedure Resa Talon 3 |) Conduct gas ek ost Tae arecessay measure depending on ves 2) Ate there any ol stains or gas leaks? Tro rout of ogag oak tea No Insufficient refrigerant due to secular leak- age Insufficient charging Feegulate refigerant amount fer to Ts heat-sensing tube in its proper position ‘and securely connected to evaporator outlet Pipe? Yes ‘Expansion valve opening too wide because cof expansion valve malfunction hepa espendon No ‘Expansion valve opening too wide because ‘of improper heat-sensing tube installation Feinstall heat-sensing tube [(eter to page U=T9)-1 1) Tum off fan switch and wait for about 10 minutes. 2) Set fan switch at 4h. 8) Are pressure readings normal immedi- ately after AIC compressor is tumed on? Yes Expansion valve clogged due to frozen moisture [tring NO Goto Stop 6 Ts heat-sensing tube in its proper position? Yes Expansion valve clogged with foreign mato- rial Expansion valve closing too wide because of expansion valve malfunction or heat- ‘sensing tube leakage iserteesoe 10” “Expansion valve closing too wide because ‘of improper heat-sensing tube installation Fast bantam teCL get relay aC Oe, Sel) Dee