Académique Documents
Professionnel Documents
Culture Documents
GROUP 55
HEATER, AIR
CONDITIONER AND
VENTILATION
CONTENTS
SERVICE SPECIFICATIONS. . . . . . .
55-3
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . .
55-72
LUBRICANTS . . . . . . . . . . . . . . . . . .
55-3
55-74
SPECIAL TOOLS. . . . . . . . . . . . . . . .
55-4
DISCHARGING SYSTEM . . . . . . . . . . . . . .
55-74
55-75
PERFORMANCE TEST . . . . . . . . . . . . . . .
55-75
55-76
55-76
55-77
TROUBLESHOOTING . . . . . . . . . . . .
ON-VEHICLE SERVICE. . . . . . . . . . .
55-4
55-71
55-71
55-71
55-78
55-71
55-78
55-71
WARNING
Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal
injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the
SRS inoperative).
Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized
MITSUBISHI dealer.
MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B - Supplemental
Restraint System (SRS) before beginning any service or maintenace of any component of the SRS or any
SRS-related component.
NOTE
The SRS includes the following components: front impact sensors, SRS-ECU, SRS warning lamp, airbag module, clock
spring and interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection
with SRS service or maintenace) are indicated in the table of contents by an asterisk (*).
55-2
HEATER CONTROL ASSEMBLY
AND A/C SWITCH . . . . . . . . . . . . . . .
EVAPORATOR ASSEMBLY . . . . . . .
55-88
55-79
55-88
55-79
55-89
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .
55-80
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-90
55-80
55-91
55-91
55-82
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-93
55-82
55-93
HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . .
55-83
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-95
55-84
BLOWER ASSEMBLY . . . . . . . . . . . . . . . . .
55-85
55-85
CONDENSER AND
CONDENSER FAN MOTOR . . . . . . .
55-96
55-96
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .
55-97
REFRIGERANT LINE. . . . . . . . . . . . .
55-98
55-86
55-98
55-86
55-99
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . .
55-87
DUCTS . . . . . . . . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
VENTILATORS. . . . . . . . . . . . . . . . . .
REMOVAL AND INSTALLATION . . . . . . . .
55-100
55-100
55-102
55-102
55-3
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1552000300292
Item
Standard value
750 100
850 100
LO
2.54
ML
1.24
MH
0.6
0.3 0.5
LUBRICANTS
M1552000400299
Item
Specified lubricant
Quantity
1300, 1600
140 mL
2000
120 mL
SUN PAG 56
As required
Refrigerant
R134a (HFC-134a)
480 520 g
55-4
SPECIAL TOOLS
SPECIAL TOOLS
M1552000600312
Tool
Tool number
Name
Application
MB991367
Special spanner
MB991386
Pin
MB991223
A:MB991219
B:MB991220
C:MB991221
D:MB991222
Harness set
A: Test harness
B: LED harness
C: LED harness adapter
D: Probe
B991367
D
MB991223 AC
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
SYMPTOM CHART
M1552009600364
M1552009900440
Symptom
Inspection
Procedure
Reference
Page
When the ignition switch is "ON" the A/C does not operate.
P.55-5
P.55-6
P.55-11
P.55-20
P.55-29
P.55-39
P.55-43
55-5
TROUBLESHOOTING
Symptom
Inspection
Procedure
Reference
Page
P.55-54
P.55-55
10
P.55-58
11
P.55-61
12
Refer to
GROUP 14
P.14-4
SYMPTOM PROCEDURES
INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C does not Operate.
COMMENTS ON TROUBLE SYMPTOM
The blower system or the compressor system may
be defective if there is no cool air coming from the
spit hole.
TROUBLESHOOTING HINTS
Malfunction of blower motor
Malfunction of A/C compressor
DIAGNOSIS
Check that the blower motor operation when the
blower switch is moved to the "HI" position.
(1) Turn the ignition switch to the "ON" position.
(2) Turn the blower switch to the "HI" position.
55-6
OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL MOTOR
<LHD>
<RHD>
<RHD>
<LHD>
<RHD>
<LHD>
A/C-ECU
<LHD>
<RHD>
SB : Sky blue
DIAGNOSIS
STEP 1. Check the defogger and A/C operations.
Q: Do the defogger and A/C work normally?
YES : Go to Step 2.
NO <L.H.D.> : Refer to Inspection procedure 9
55-7
TROUBLESHOOTING
3 2
1
7 6 5 4
Harness side
AC303804 AD
AC301541 EF
Connector: C-107
<R.H.D.>
Harness side
AC303816 AI
Harness side
AC303804 AD
Connector: C-107
<R.H.D.>
Harness side
AC303804 AD
Harness side
Connector: C-107
<R.H.D.>
AC303816 AI
Harness side
AC303816 AI
55-8
TROUBLESHOOTING
Connector: C-35
<L.H.D.>
C-209
C-35 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC303798 AJ
C-209
Harness side
Connector: C-35
<R.H.D.>
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-210
Harness side
2
1
6 5 4 3
C-35(L)
AC303809 AF
AC303814AI
Connector: C-106
<L.H.D.>
C-106
C-209
Harness side
AC303804 AC
Connector: C-106
<R.H.D.>
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-210
Harness side
2
1
6 5 4 3
AC303823 AE
55-9
TROUBLESHOOTING
Harness side
C-139 (B)
C-107
C-106
C-106
AC303802 AE
Harness side
C-107
Connector: C-139
<R.H.D.>
AC303804 AK
Connector: C-139
<L.H.D.>
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
Harness side
C-139 (B)
AC303818 AJ
AC303802 AE
55-10
Harness side
C-107
panel (A/C-ECU).
AC303816 AO
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-11
TROUBLESHOOTING
INSPECTION PROCEDURE 3: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted). <L.H.D.>
A/C-ECU System Circuit
ENGINE-ECU
ENGINE-A/T-ECU
DUAL
PRESSURE
SWITCH
A/C-ECU
HEATER CONTROL PANEL
RESISTOR
AIR THERMO
SENSOR
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
SB : Sky blue
NOTE
M/T
A/T
55-12
DIAGNOSIS
STEP 1. Check the defogger and outside/inside
air selection damper control motor operation.
Q: Do the defogger and outside/inside air selection
damper control motor work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 9
Harness side
B-114 (B)
AC303782 AC
Connector: B-114
<4G6-L.H.D.>
Harness side
B-114 (B)
AC303790 AC
expansion valve.
C-122 (GR)
C-123 (Y)
Harness side
C-122
C-123
AC303805 AE
55-13
TROUBLESHOOTING
Connector: B-114
<4G1-L.H.D.>
Harness side
B-114 (B)
AC303782 AC
C-122 (GR)
C-123 (Y)
Harness side
C-122
Connector: B-114
<4G6-L.H.D.>
Harness side
C-123
AC303805 AE
B-114 (B)
AC303790 AC
Connector C-123
(Harness side)
AC305159 AB
AC305161AB
55-14
TROUBLESHOOTING
Connector C-139
(Harness side)
1
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
AC301541EW
AC301541EX
Harness side
C-139 (B)
Harness side
AC303802 AE
AC303804 AE
Harness side
C-139 (B)
AC303802 AE
55-15
TROUBLESHOOTING
Connector: C-109
<L.H.D.>
Connector: C-106
<L.H.D.>
C-106
AC303804 AE
Connector: C-139
<L.H.D.>
Harness side
C-139 (B)
AC303804 AC
AC303802 AE
Connector: A-31
<L.H.D.>
A-31 (BR)
Harness side
AC303804 AC
Connector: C-139
<L.H.D.>
AC303839 AH
Harness side
C-139 (B)
AC303802 AE
55-16
TROUBLESHOOTING
Connector: A-31
<L.H.D.>
A-31 (BR)
C-125 (Y)
Harness side
C-126 (GR)
AC303839 AH
Harness side
Connector: C-139
<L.H.D.>
C-126
C-125
38 37363534 33 3231
4645 44 4342 41 4039
77 76 75
7473 7271
89 88 87 86 85 84 83 82 81 80 79 78
98 97
96 95 9493 92 91 90
Harness side
C-139 (B)
AC303805 AG
AC303802 AE
NOTE:
Connector: C-114
<LHD>
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25
AC303804 AN
55-17
TROUBLESHOOTING
NOTE:
Connector: C-15
<L.H.D.>
Connector: A-31
<L.H.D.>
A-31 (BR)
C-15 (L)
AC303800 AE
Harness side
Connector: C-104
<L.H.D.>
C-104 (GR)
AC303839 AH
AC303804 AB
C-125 (Y)
C-126 (GR)
Harness side
C-125
38 37363534 33 3231
4645 44 4342 41 4039
C-126
77 76 75
7473 7271
89 88 87 86 85 84 83 82 81 80 79 78
98 97
96 95 9493 92 91 90
AC303805 AG
55-18
TROUBLESHOOTING
C-123 (Y)
C-123 (Y)
C-124 (GR)
C-124 (GR)
Harness side
C-123
C-124
Harness side
4645 44
43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160
59 58
C-123
4645 44
43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160
59 58
AC303805 AF
C-124
AC303805 AF
Connector: C-139
<L.H.D.>
Harness side
C-139 (B)
AC303802 AE
NOTE:
Connector: C-15
<L.H.D.>
C-15 (L)
AC303800 AE
55-19
engine-A/T-ECU <A/T>.
55-20
TROUBLESHOOTING
INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted). <R.H.D.>
DUAL
PRESSURE
SWITCH
A/C-ECU
HEATER CONTROL PANEL
RESISTOR
AIR THERMO
SENSOR
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow
BR : Brown O : Orange GR : Gray R : Red P : Pink V : Violet
SB : Sky blue
NOTE
M/T
A/T
55-21
TROUBLESHOOTING
DIAGNOSIS
STEP 1. Check the defogger and outside/inside
air selection damper control motor operation.
Q: Do the defogger and outside/inside air selection
damper control motor work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 10
Harness side
B-114 (B)
AC303786 AB
Connector: B-114
<4G6-R.H.D.>
Harness side
B-114 (B)
AC303794 AB
expansion valve.
Harness side
C-122
C-123
AC303817AF
55-22
TROUBLESHOOTING
Connector: B-114
<4G1-R.H.D.>
Harness side
C-122 (GR)
C-123 (Y)
B-114 (B)
AC303786 AB
Harness side
C-122
Connector: B-114
<4G6-R.H.D.>
Harness side
C-123
AC303817AF
B-114 (B)
AC303794 AB
Connector C-123
(Harness side)
AC305159 AB
AC305161AB
55-23
TROUBLESHOOTING
Connector C-139
(Harness side)
6 5 4 3 2 1
12 11 10 9 8 7
AC301541EW
AC301541EY
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
Harness side
AC303818 AJ
AC303816 AJ
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-24
TROUBLESHOOTING
Connector: C-109
<R.H.D.>
Connector: C-106
<R.H.D.>
Harness side
AC303816 AJ
Connector: C-139
<R.H.D.>
AC303816 AH
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
AC303816 AH
Connector: C-139
<R.H.D.>
Harness side
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303825 AH
AC303818 AJ
55-25
TROUBLESHOOTING
Harness side
C-125 (Y)
AC303825 AH
C-126 (GR)
Connector: C-139
<R.H.D.>
Harness side
Harness side
C-126
C-125
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
38 37363534 33 3231
4645 44 4342 41 4039
77 76 75
7473 7271
89 88 87 86 85 84 83 82 81 80 79 78
98 97
96 95 9493 92 91 90
AC303818 AJ
NOTE:
AC303817AH
Connector: C-28
<RHD>
AC303814 AJ
55-26
TROUBLESHOOTING
NOTE:
Connector: C-28
<RHD>
Connector: A-31
<R.H.D.>
A-31 (BR)
AC303814 AJ
Harness side
Connector: C-135
<RHD>
AC303825 AH
AC303818 AH
C-125 (Y)
C-126 (GR)
Harness side
C-125
38 37363534 33 3231
4645 44 4342 41 4039
C-126
77 76 75
7473 7271
89 88 87 86 85 84 83 82 81 80 79 78
98 97
96 95 9493 92 91 90
AC303817AH
55-27
TROUBLESHOOTING
C-124 (GR)
C-124 (GR)
C-123 (Y)
C-123 (Y)
Harness side
C-123
C-124
4645 44
43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160
59 58
Harness side
C-123
4645 44
43 42 41
57565554 5352 5150 49 48 47
666564 63 62 6160
59 58
AC303817AG
C-124
AC303817AG
Connector: C-139
<R.H.D.>
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-28
engine-A/T-ECU <A/T>.
55-29
TROUBLESHOOTING
IGNITION
SWITCH (IG2)
<LHD>
BLOWER
RELAY
BLOWER
SWITCH
<LHD>
<RHD>
<LHD>
<RHD>
BLOWER
MOTOR
SB : Sky blue
TROUBLESHOOTING HINTS
Malfunction of the blower relay
Malfunction of the blower switch
Damaged the wiring harness or connectors
Malfunction of the blower motor
55-30
DIAGNOSIS
Connector: C-110
<L.H.D.>
Harness side
AC303804 AF
Connector: C-110
<R.H.D.>
Connector: C-110
<L.H.D.>
Harness side
AC303816 AK
Harness side
Connector C-110
(Harness side)
Connector: C-110
<R.H.D.>
1
2
Harness side
AC301541EG
AC303816 AK
55-31
TROUBLESHOOTING
Harness side
Harness side
AC303804 AF
AC303804 AF
Connector: C-110
<R.H.D.>
Connector: C-110
<R.H.D.>
Harness side
Harness side
AC303816 AK
AC303816 AK
Connector C-110
(Harness side)
1
2
AC301541 CA
55-32
TROUBLESHOOTING
AC303808AL
Connector: C-214
<R.H.D.>
Junction block (front view)
AC303808AL
Connector: C-214
<R.H.D.>
Junction block (front view)
AC303822AM
AC303822AM
Connector C-214
(Junction block side)
55-33
TROUBLESHOOTING
C-210
Connector: C-214
<L.H.D.>
Junction block (front view)
C-214
Junction block side
Harness side
C-214
C-210
Connector: C-214
<R.H.D.>
Junction block (front view)
AC303809 AL
C-210
Connector C-214
(Junction block side)
C-214
Harness side
C-210
3 2 1
4
5
AC301541EJ
55-34
TROUBLESHOOTING
C-212
C-214
C-212
C-214
Harness side
C-212
Harness side
C-212
AC303809 AP
AC303823 AO
NOTE:
Connector: C-07
<R.H.D.>
AC303814 AR
55-35
TROUBLESHOOTING
C-211
AC303808AL
C-214
Connector: C-214
<R.H.D.>
Junction block (front view)
Harness side
C-211
AC303822AM
AC303809 AN
NOTE:
Connector: C-21
<L.H.D.>
Connector C-214
(Junction block side)
3 2 1
4
5
AC301541EK
AC303798 AK
55-36
TROUBLESHOOTING
C-211
Connector: C-140
<L.H.D.>
C-214
Harness side
Harness side
C-211
Connector: C-140
<R.H.D.>
AC303823 AL
NOTE:
Harness side
Connector: C-121
<RHD>
AC303818 AK
Connector: C-138
<R.H.D.>
AC303818 AI
55-37
TROUBLESHOOTING
Harness side
C-214
AC303802 AF
Harness side
C-210
Connector: C-140
<R.H.D.>
Harness side
AC303823 AK
AC303818 AK
C-210
C-214
Harness side
C-210
AC303809 AL
55-38
TROUBLESHOOTING
Connector: C-110
<L.H.D.>
AC303804 AF
Connector: C-110
<R.H.D.>
Harness side
AC303816 AK
Connector: C-140
<L.H.D.>
Harness side
AC303802 AF
Connector: C-140
<R.H.D.>
Harness side
AC303818 AK
55-39
BLOWER
SWITCH
RESISTOR
<LHD>
<RHD>
BLOWER
MOTOR
DIAGNOSIS
STEP 1. Check that the blower motor operates
when the blower switch is moved to the "4 (HI)"
position.
(1) Turn the ignition switch to the "ON" position.
(2) Turn the blower switch to the "4 (HI) " position.
Q: Does the blower motor operate when the blower
switch is moved to the "4 (HI)" position?
YES : Go to STEP 2.
NO : Refer to Inspection procedure 5 "Blower fan
55-40
TROUBLESHOOTING
Connector: C-109
<L.H.D.>
AC303804 AE
Connector: C-109
<R.H.D.>
Harness side
AC303816 AJ
Connector: C-140
<L.H.D.>
Harness side
AC303802 AF
Connector: C-140
<R.H.D.>
Harness side
AC303818 AK
55-41
TROUBLESHOOTING
Connector: C-109
<L.H.D.>
Harness side
Harness side
AC303804 AF
AC303804 AE
Connector: C-110
<R.H.D.>
Connector: C-109
<R.H.D.>
Harness side
Harness side
AC303816 AK
AC303816 AJ
Connector: C-140
<L.H.D.>
Harness side
AC303802 AF
Connector: C-140
<R.H.D.>
Harness side
AC303818 AK
55-42
TROUBLESHOOTING
C-109
Harness side
C-109 C-110
C-110
AC303804 AL
Harness side
C-109
C-109 C-110
C-110
AC303816 AP
55-43
TROUBLESHOOTING
FUSIBLE LINK
<RHD>
<LHD>
REAR WINDOW
DEFOGGER
RELAY
<LHD>
<RHD>
<RHD>
<LHD>
A/C-ECU OR
HEATER
CONTROL UNIT
<LHD>
REAR WINDOW
DEFOGGER
NOTE
: SEDAN <LHD>
: WAGON <LHD>
: SEDAN <RHD>
: WAGON <RHD>
<RHD>
REAR WINDOW
DEFOGGER
SB : Sky blue
TROUBLESHOOTING HINTS
Malfunction of the rear window defogger relay
Malfunction of the rear window defogger
Damaged the wiring harness or connectors
Malfunction of the manual air conditioner control
panel (A/C-ECU) or the heater control unit
55-44
DIAGNOSIS
STEP 1. Check the A/C and outside/inside air
selection damper control motor operation.
Q: Do the A/C and outside/inside air selection damper
control motor work normally?
YES : Go to Step 2.
NO <L.H.D.> : Refer to Inspection procedure 9
AC303954 AI
Connector: F-22
<SEDAN - L.H.D.>
Harness side
AC303943 AD
Connector: F-22
<WAGON - R.H.D.>
Harness side
AC303956 AH
Connector: F-22
<SEDAN - R.H.D.>
Harness side
AC303945 AE
55-45
TROUBLESHOOTING
Harness side
1
AC303954 AI
AC301541EL
Connector: F-22
<SEDAN - L.H.D.>
Harness side
AC303943 AD
AC301541EM
AC301541
Connector: F-22
<WAGON - R.H.D.>
Harness side
AC303956 AH
Connector: F-22
<SEDAN - R.H.D.>
Harness side
AC303945 AE
55-46
TROUBLESHOOTING
AC303808AK
Connector: C-213
<R.H.D.>
Junction block (front view)
AC303808AK
Connector: C-213
<R.H.D.>
Junction block (front view)
AC303822AL
AC303822AL
C-211
C-213
Harness side
C-211
AC303809 AM
NOTE:
Connector: C-21
<L.H.D.>
AC303798 AK
55-47
55-48
TROUBLESHOOTING
C-211
Connector: C-213
<L.H.D.>
Junction block (front view)
C-213
Junction block side
Harness side
C-211
C-213
Connector: C-213
<R.H.D.>
Junction block (front view)
AC303823 AM
NOTE:
Connector: C-121
<R.H.D.>
AC303822AL
AC303816 AB
Connector C-213
(Junction block side)
Connector: C-138
<R.H.D.>
3 2 1
4
5
AC301541EO
AC303818 AI
C-213
Harness side
C-210
AC303809 AK
C-213
Harness side
C-210
AC303823 AI
55-49
55-50
TROUBLESHOOTING
F-02
F-22
F-02
AC303954 AJ
Connector: F-22
<SEDAN - L.H.D.>
C-213
Harness side
C-215
Harness side
C-215
7 6 5
15 14 13
4 3 2 1
11 10 9 8
12
Connector: F-22
<WAGON - R.H.D.>
Harness side
AC303809 AR
AC303956 AH
Connector: F-22
<SEDAN - R.H.D.>
C-213
Harness side
C-216
Harness side
C-216
7 6 5
15 14 13
12
4 3 2 1
11 10 9 8
AC303823 AS
AC303945 AE
Harness side
C-139 (B)
AC303802 AE
Connector: C-139
<R.H.D.>
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-51
55-52
TROUBLESHOOTING
Connector: C-139
<L.H.D.>
C-212
C-213
Harness side
C-139 (B)
AC303802 AE
Harness side
C-212
Connector: C-139
<R.H.D.>
AC303823 AN
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
C-213
C-212
Harness side
C-212
AC303809 AO
55-53
TROUBLESHOOTING
Connector: F-06
<WAGON - L.H.D.>
Harness side
Harness side
AC303954 AH
Connector: F-06
<SEDAN - L.H.D.>
AC303943 AE
Connector: F-06
<SEDAN - R.H.D.>
Harness side
Harness side
AC303943 AE
AC303945 AF
Connector: F-06
<WAGON - R.H.D.>
Harness side
Connector F-06
(Harness side)
AC303956 AG
Connector: F-06
<SEDAN - R.H.D.>
AC301541EP
Harness side
55-54
Connector: F-06
<SEDAN - R.H.D.>
Harness side
AC303945 AF
INSPECTION PROCEDURE 8: Rear Window Defogger Timer Function does not Operate.
COMMENTS ON TROUBLE SYMPTOM
Turn ON the rear window defogger switch. If the rear
window defogger does not shut off after roughly 11
minutes then the rear window defogger timer is
malfunctioning.
TROUBLESHOOTING HINTS
Malfunction of the manual air conditioner control
panel (A/C-ECU) or the heater control unit
55-55
TROUBLESHOOTING
A/C-ECU
HEATER CONTROL PANEL
DIAGNOSIS
STEP 1. Connector check: C-139 A/C-ECU
connector
Connector: C-139
<L.H.D.>
Harness side
C-139 (B)
AC303802 AE
55-56
TROUBLESHOOTING
Harness side
C-139 (B)
Harness side
C-139 (B)
AC303802 AE
AC303802 AE
NOTE:
Connectors: C-210, C-212
<L.H.D.>
Junction block (front view)
C-210
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
C-210
Harness side
C-212
AC301541EQ
C-212
Harness side
AC303809 AJ
55-57
TROUBLESHOOTING
Harness side
Harness side
C-139 (B)
C-139 (B)
AC303802 AE
AC303802 AE
NOTE:
Connector: C-104
<L.H.D.>
C-104 (GR)
Connector C-139
(Harness side)
8 7 6 5 4 3 2 1
16 15 14 13 121110 9
AC303804 AJ
AC301541ER
panel (A/C-ECU).
Go to Step 5.
panel (A/C-ECU).
NO : Repair the wiring harness.
55-58
INSPECTION PROCEDURE 10: Malfunction of the A/C-ECU Power Supply System. <R.H.D.>
A/C-ECU Power Supply Circuit
IGNITION
SWITCH (IG2)
A/C-ECU
HEATER CONTROL PANEL
DIAGNOSIS
STEP 1. Connector check: C-139 A/C-ECU
connector
Connector: C-139
<R.H.D.>
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-59
TROUBLESHOOTING
Connector: C-35
<R.H.D.>
Connector: C-139
<R.H.D.>
C-35(L)
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303814 AS
AC303818 AJ
Connector C-139
(Harness side)
6 5 4 3 2 1
12 11 10 9 8 7
Harness side
C-210
C-212
AC301541ES
Harness side
C-212
AC303823 AJ
Connector: C-139
<R.H.D.>
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
55-60
TROUBLESHOOTING
Harness side
Harness side
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
C-139 (B)
6 5 4 3 2 1
12 11 10 9 8 7
AC303818 AJ
panel (A/C-ECU).
AC301541ET
panel (A/C-ECU).
Go to Step 5.
6 5 4 3 2 1
12 11 10 9 8 7
NO :
AC303818 AJ
55-61
TROUBLESHOOTING
BATTERY
RELAY
BOX
<RHD>
<LHD>
<RHD>
<LHD>
A/C
COMPRESSOR
RELAY
A/C
REFRIGERANT
TEMPERATURE
SWITCH
ENGINE-ECU
ENGINE-A/T-ECU
MAGNETIC
CLUTCH
A/C
COMPRESSOR
NOTE
: M/T
: A/T
TROUBLESHOOTING HINTS
Malfunction of the A/C compressor relay
Damaged the wiring harness or connectors
55-62
DIAGNOSIS
Connector: B-17X
Connector: B-17X
Relay box side
Relay box side
2
Front of
vehicle
AC304988 AB
Front of
vehicle
AC304988 AB
Connector B-17X
(Relay box side)
Front of
vehicle
3
AC301541EU
55-63
TROUBLESHOOTING
Connector: B-17X
C-210
C-209
Front of
vehicle
AC304988 AB
C-209
Harness side
NOTE:
Connector: C-15
<L.H.D.>
6 5 4
3 2 1
14 13 12 11 10 9 8 7
C-210
Harness side
2
1
6 5 4 3
AC303809 AF
C-15 (L)
AC303800 AE
Connector: C-35
<L.H.D.>
C-35 (L)
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
AC303798 AJ
55-64
TROUBLESHOOTING
Connector: B-17X
C-210
C-209
Relay box side
2
Front of
vehicle
C-209
Harness side
AC304988 AB
6 5 4
3 2 1
14 13 12 11 10 9 8 7
NOTE:
Connector: C-35
<R.H.D.>
C-210
Harness side
2
1
6 5 4 3
C-35(L)
AC303823 AE
AC303814AI
Connector: C-135
<RHD>
C-135 (L)
AC303818 AH
55-65
TROUBLESHOOTING
Front of
vehicle
Front of
vehicle
AC304988 AB
AC304988 AB
NOTE:
Connector: A-13
<LHD>
Connector B-17X
(Relay box side)
Front of
vehicle
A-13 (B)
AC303857AB
AC301541EV
Connector: C-111
<RHD>
1 2 3
4 5
6 7 8 9 10 11 12
AC303816 AF
55-66
TROUBLESHOOTING
Harness side
Relay box side
B-114 (B)
AC303782 AC
Front of
vehicle
Connector: B-114
<4G6-L.H.D.>
AC304988 AB
Connector: B-114
<4G1-L.H.D.>
Harness side
Harness side
B-114 (B)
AC303790 AC
B-114 (B)
Connector: B-114
<4G1-R.H.D.>
AC303782 AC
Connector: B-114
<4G6-L.H.D.>
Harness side
Harness side
B-114 (B)
AC303786 AB
B-114 (B)
Connector: B-114
<4G6-R.H.D.>
AC303790 AC
Connector: B-114
<4G1-R.H.D.>
Harness side
Harness side
B-114 (B)
AC303794 AB
B-114 (B)
AC303786 AB
55-67
TROUBLESHOOTING
Connector: B-114
<4G6-R.H.D.>
Harness side
B-114 (B)
AC303794 AB
C-122 (GR)
C-123 (Y)
Harness side
C-122
C-123
AC303805 AE
C-122 (GR)
C-123 (Y)
Harness side
C-122
C-123
AC303817AF
55-68
TROUBLESHOOTING
Front of
vehicle
Front of
vehicle
AC304988 AB
AC304988 AB
Connector: C-123
<LHD - M/T>
Connector: C-122
<LHD - A/T>
C-123 (Y)
C-122 (GR)
Harness side
Harness side
AC303804 AH
Connector: C-123
<RHD - M/T>
AC303804 AG
Connector: C-122
<RHD - A/T>
Harness side
Harness side
C-123 (Y)
AC303816 AM
C-122 (GR)
AC303816 AL
55-69
TROUBLESHOOTING
<C-139>
1
9 10 11 12 13 14 15 16
AC300861AC
Checking requirement
Normal condition
Defogger switch: ON
0V
System voltage
0V
System voltage
System voltage
0V
A/C stopped
0V
A/C switch: ON
Blower switch: ON
System voltage
0V
Lighting switch: ON
System voltage
blower switch: lo
System voltage
10
Ignition switch: ON
System voltage
11
Always
0V
12
Earth
Always
0V
13
14, 15
16
Always
0V
55-70
TROUBLESHOOTING
<C-139>
1 2 3 4 5 6
7 8 9 10 11 12
AC304990 AB
Checking requirement
Normal condition
A/C stopped
0V
A/C switch: ON
Blower switch: ON
System voltage
0V
Earth
Always
0V
Always
0V
Lighting switch: ON
System voltage
Ignition switch: ON
System voltage
blower switch: lo
System voltage
Defogger switch: ON
0V
System voltage
0V
System voltage
System voltage
0V
Always
0V
10
11
12
55-71
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
SIGHT GLASS REFRIGERANT LEVEL
TEST
M1552008400378
<1300, 1600>
Refer to GROUP 11A, On-vehicle Service Drive
Belt Tension Check P.11A-8.
<2000>
Refer to GROUP 11C, On-vehicle Service Drive
Belt Tension Check P.11C-8.
AC005963 AC
High/Low
Pressure Side
CAUTION
State
Insufficient
Sufficient or excess
refrigerant
AC005671AC
Low-pressure side
High-pressure side
210 25
2060 200
230 20
2650 200
ON
ON
OFF
OFF
(kPa)
AC001368 AD
55-72
ON-VEHICLE SERVICE
CHARGING
M1552001200362
High-pressure
valve
Low-pressure
valve
Gauge manifold
Charging hose
Adapter
(yellow)
valve
Charging hose
(blue)
Switch
R-134a
R-12
connection
connection
port
port
Vacuum
Quick
pump
joint
adaptor Vacuum
(for low
pump
pressure)
Power supply
plug
CAUTION
CAUTION
Switch
Low-pressure
service valve
A
Sleeve
AC212526AB
CAUTION
Vacuum pump
adaptor switch
Low-pressure
service valve
Vacuum
pump
AC212535 AB
55-73
ON-VEHICLE SERVICE
!
CAUTION
CAUTION
Valve open
Valve close
Charging valve
Adaptor valve
Service can
(Refrigerant container)
Service can
AC212536 AB
Low-pressure
service valve
AC212537AB
CAUTION
55-74
!
CAUTION
Valve open
Charge valve
Valve close
Adaptor valve
Quick joint
(for low-pressure)
Low-pressure
service valve
AC300373 AB
DISCHARGING SYSTEM
M1552013000105
55-75
ON-VEHICLE SERVICE
PERFORMANCE TEST
M1552001400355
Low-pressure
valve
High-pressure
valve
Gauge manifold
Charging
hose (red)
CAUTION
Charging
hose (blue)
A
Adaptor valve
(for lowpressure)
Lowpressure
service
valve
Sleeve
Highpressure
service
valve
Adaptor valve
(for highpressure)
AC304576 AB
AC001388 AB
55-76
20
25
30
35
8.0 11.0
12.0 16.0
17.0 21.0
22.5 27.5
740 840
950 1,050
1,160 1,300
1,360 1,550
150 190
190 240
240 300
300 375
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to P.55-74).
2. Charge the system with approximately 480 520
g of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
!
CAUTION
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
55-77
ON-VEHICLE SERVICE
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesnt exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to P.55-71).
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.
Battery
voltage
Tester
connection
Specified
condition
Not applied
45
Open circuit
Connect
45
terminal 3 to
the positive
battery
terminal
Connect
terminal 1 to
the negative
battery
terminal
Less than 2
ohms
1
4
2
Front of
vehicle
Blower relay
AC305307AB
1 2 3
4
5
Battery
voltage
Tester
connection
Specified
condition
Not applied
14
Open circuit
Connect
14
terminal 2 to
the positive
battery
terminal
Connect
terminal 3 to
the negative
battery
terminal
Less than 2
ohms
AC305308 AB
55-78
ON-VEHICLE SERVICE
2
1
2
1
AC305307 AC
Battery
voltage
Tester
connection
Specified
condition
Not applied
24
Open circuit
Connect
24
terminal 1 to
the positive
battery
terminal
Connect
terminal 3 to
the negative
battery
terminal
Less than 2
ohms
Air filter
Instrument panel
AC305114 AB
55-79
3
4
AC304650 AB
>>B<< 1.
>>A<< 2.
3.
4.
5.
Removal steps
Air mixing door control cable
connection
Mode selection damper cable
connection
Knob
Centre panel
Manual air conditioner control panel
assembly
Mode selection
damper link
FACE
position
DEF position
AC304856 AB
<L.H.D.>
Mode
selection
damper link
Mode locator
FACE position
DEF position
AC304854 AB
55-80
INSPECTION
M1552014300927
Mode locator
2
5
3
6
AC304857AB
<L.H.D.>
Air mix damper lever
Mode locator
MAX. COOL
position
Tester connection
Specified
condition
0 (OFF)
1 2, 2 4, 2 5, 2 6 Open circuit
1 (LO)
12
Less than 2
ohms
2 (ML)
24
Less than 2
ohms
3 (MH)
25
Less than 2
ohms
4 (HI)
26
Less than 2
ohms
AC304855AB
Switch
position
4
8
1
7
6
5
AC100614 AB
55-81
1.
2.
3.
4.
<<A>> 5.
<<A>> 6.
7.
8.
Disassembly steps
Switch panel
Rear window defogger switch
Air conditioner switch
Inside/outside air selection switch
Mode selection damper control
cable
Air mixing damper control cable
Blower switch assembly
Manual air conditioner control panel
(A/C-ECU)
(-) flat-tipped
screwdriver
Clip
claw
AC100619AB
55-82
-Pipe coupling
12 2 Nm
5
7
9
6, 7
O ring
6
1
8N
44 10 Nm
44 10 Nm
AC304861AB
1.
2.
3.
Removal steps
Front deck crossmember
Centre duct
Intake duct
Foot duct (RH), Rear heater duct A
(RH) upper side (Refer to
P.55-100.)
<<A>>
<<A>>
4.
5.
6.
7.
8.
9.
55-83
CAUTION
HEATER UNIT
DISASSEMBLY AND REASSEMBLY
<L.H.D.>
M1551005400224
2
3
8
-Pipe coupling
4
6
10
5N
7
4, 7
O ring
1.
2.
3.
4.
5.
Disassembly steps
Foot duct (LH)
Heater core
Expansion valve
Joint
O ring
6.
7.
8.
9.
10.
55-84
9
-Pipe coupling
3
7
4N
8
6
1.
2.
3.
4.
5.
O ring
Disassembly steps
Foot duct (RH)
Heater core
Expansion valve
O ring
Evaporator cover
AC304863AB
6.
7.
8.
9.
55-85
BLOWER ASSEMBLY
DISASSEMBLY AND REASSEMBLY
M1551005500179
2
1
6
4
5
AC3054131AB
1.
2.
3.
4.
Disassembly steps
Joint duct
Resister
Outside/inside air selection damper
control motor
Hose
5.
6.
7.
55-86
1
2
AC304885 AB
<<A>>
1.
2.
3.
AC304916
55-87
INSPECTION
M1551006300275
RESISTER CHECK
1
3
CAUTION
2
4
Inside air
AC304843
Standard value ()
2.54
1.24
0.6
Outside air
Lever
operation
At the inside
position
Connect
terminal 7 to
the positive
battery
terminal
Connect
terminal 4 to
the negative
battery
terminal
The lever
moves from the
inside position
to the outside
position
At the outside
position
Connect
terminal 7 to
the positive
battery
terminal
Connect
terminal 6 to
the negative
battery
terminal
The lever
moves from the
outside position
to the inside
position
AC100626 AB
AC100625 AE
55-88
EVAPORATOR ASSEMBLY
EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION <L.H.D.>
M1552003600214
-Pipe coupling
1, 2, 4, 7
2
12 2 Nm
10
O ring
3 8
7
6
5
Y2346AU
<<A>>
<<A>>
1.
2.
3.
4.
5.
6.
7.
Removal steps
Flexible suction hose connection
Liquid pipe B connection
Expansion valve
Joint
Glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (Refer to
GROUP 13A, Engine-ECU and
Engine-A/T-ECU P.13A-401).
Joint duct
Foot duct (LH), Rear heater duct
(L.)H, Rear heater duct L.H (Refer
to P.55-100).
Evaporator cover
Evaporator
CAUTION
55-89
-Pipe coupling
1, 2, 6
O ring
2
12 2 Nm
3
7
1
7
9
8
6
5
4
<<A>>
<<A>>
1.
2.
3.
4.
<<B>>
5.
6.
7.
Removal steps
Flexible suction hose connection
Liquid pipe B connection
Expansion valve
Glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
Engine-ECU <M/T> or
Engine-A/T-ECU <A/T> (Refer to
GROUP 13A, Engine-ECU and
Engine-A/T-ECU P.13A-401).
Joint duct
Foot duct (LH), Rear heater duct
(LH) (Refer to P.55-100).
Evaporator cover
Evaporator
O ring
AC304886AB
8.
9.
CAUTION
55-90
EVAPORATOR ASSEMBLY
INSPECTION
M1552014300938
Blower unit
AC305312 AB
CAUTION
Resistance
25
(k)
20
15
10
5
0
-10 0 10 20 30 40
Temperature (C)
AC103376 AB
55-91
Pre-removal Operation
Refrigerant Discharging (Refer to P.55-72).
Post-installation Operation
Drive Belt Tension Adjustment (1300, 1600: Refer to
GROUP 11A, On-vehicles Service Drive Belt Tension
Check P.11A-8, 2000: Refer to GROUP 11C, On-vehicles
Service Drive Belt Tension Check P.11C-8).
Refrigerant Charging (Refer to P.55-72).
<2000>
-Pipe coupling
7
1, 2
<1300, 1600>
O ring
3
<1300, 1600>
<2000>
1
4
<<A>>
<<A>>
1.
2.
3.
<<B>>
4.
<<C>>
5.
<<D>> >>A<< 6.
7.
Removal steps
Flexible suction hose connection
Flexible discharge hose connection
O ring
Drive belt <1300, 1600>
Drive belt <2000>
A/C compressor
A/C compressor bracket
12 2 Nm
AC304850AB
CAUTION
55-92
CAUTION
A
B
Hole B
Hole A
AC107640 AD
AC203472 AC
L-shaped
hexagon
wrench
AC107641AC
CAUTION
55-93
INSPECTION
M1552014300949
AC005671AC
3N
8
7
6
11
5
10
N
4
16 1 Nm
AC100630 AB
1.
2.
3.
>>D<<
<<A>> >>C<< 4.
5.
>>B<< 6.
7.
8.
>>A<< 9.
10.
11.
55-94
Using snap ring pliers, fit the snap ring so that the
snap rings tapered part is on the outside.
>>C<< SELF-LOCKING NUT INSTALLATION
MB991386
MB991386
MB991367
MB991367
AC100633 AB
AC100633 AB
Compressor
unit pin hole
AC100634 AB
Rotor
Clutch coil
Tapered part
AC001412 AB
AC100637AB
55-95
INSPECTION
M1552014300950
150C
120C
CAUTION
Contiunity
No continuity
Oil temprature
AC100810 AD
Thermometer
Engine oil
AC100787 AB
Temperature
Less than 2
ohms
No continuity
150C or more
55-96
1
2
4.9 0.9 Nm
10
N 10
-Pipe coupling
5, 6
O ring
9
8
N
1.
2.
3.
4.
10
AC304889 AB
<<A>>
<<A>>
5.
6.
>>A<< 7.
8.
9.
10.
55-97
INSPECTION
M1552014300961
CAUTION
A304852
55-98
REFRIGERANT LINE
REFRIGERANT LINE
REMOVAL AND INSTALLATION <L.H.D.>
M1552006400402
8N
8 N
1
2
Low-pressure side
service valve
4.9 0.9 Nm
8 N
5
4.9 0.9 Nm
8N
8N
12 2 Nm
-Pipe coupling
1, 2, 3,
5, 6
O-ring
O-ring
AC304553 AB
<<A>>
<<A>>
<<A>>
1.
2.
3.
4.
<<A>> >>A<< 5.
<<A>> >>A<< 6.
7.
8.
Removal steps
Dual pressure switch
Liquid pipe A
Flexible discharge hose
Expansion valve cover
Flexible suction hose
Liquid pipe B
Expansion valve cover
O ring
CAUTION
55-99
REFRIGERANT LINE
8N
13 1 Nm
Low-pressure side
service valve
Hign-Pressure
Side Service Valve
1
8N
4.90.9 Nm
2
5
7
8N
8N
12 2 Nm
8N
4.9 0.9 Nm
-Pipe coupling
1, 2, 3,
5, 6
O-ring
O-ring
AC304554 AB
<<A>>
<<A>>
<<A>>
1.
2.
3.
4.
<<A>> >>A<< 5.
<<A>> >>A<< 6.
7.
8.
Removal steps
Dual pressure switch
Liquid pipe A
Flexible discharge hose
Expansion valve cover
Flexible suction hose
Liquid pipe B
Expansion valve cover
O ring
CAUTION
55-100
DUCTS
DUCTS
REMOVAL AND INSTALLATION
M1553001000101
Cross-section A-A
Clip
Instrument panel
2
6
A
3
9
10
7
8
11
13
12
AC304890 AB
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
55-101
55-102
VENTILATORS
VENTILATORS
REMOVAL AND INSTALLATION
M1553001600318
Cross-Section A-A
Claw
Cross-Section B-B
Claw
B
AC304949AB
1.
B
AC304951