AC-1

A I R C O N D I T I O N I N G SYSTEM

•
PRECAUTION AC- 2

D E S C R I P T I O N · · · .. · · · · · • · · · · · AC- 5

PREPARATION AC- 7

USE OF M A N I F O L D G A U G E SET AC- 8

EVACUATING A I R IN R E F R I G E R A T I O N SYSTEM

ANO C H A R G I N G WITH R E F R I G E R A N T ··· AC- 9

TROUBLESHOOTING ··••···•····· AC- 12

REFRIGERANT VOLUME AC- 19

ORIVE BELT T E N S I O N .. · · · · · · · · · · · · · • · · · · · · · · · · · · · · AC- 20

I D L E - U P SPEED · · · · · · · · · · · · · · · · · · · · "' · "' · · · · · · · · · · · AC- 20

R EF R I GE R A N T UNES .•..•..•.•...•..•....••..•.... AC- 21

COOLING U N I T · · · · · · · · · · · · · · · · · · · · • · · · · · · · · · · · · AC- 23

HEATER U N I T ··········· AC- 24

BLOWER U N I T ··· AC- 26

COMPRESSOR •.........•...•.........•...••.......•. AC- 27

RECEIVER ·•··•·················•··•··· AC- 33

CONDENSER ·· ·· · · · · · · · · · · · ·· · · .. · .. · · · AC- 34

EVAPORATOR ·••·······• AC- 35

HEATER RADIATOR AC- 35

• WATER VALVE · · · · · · · •

EXPANSION V A L V E · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·

V A C U U M SWITCHING VALVE (VSV) · · · · · · · · ·

AC-

AC-

AC-
35

36

36

BLOWER M O T O R · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · AC- 38

BLOWER RESISTOR .. · · • · · · · • • · · • · · · · · · · · · AC- 38

PRESSURE S W I T C H · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · AC- 39

THERMISTOR · • · · • · · · · AC- 39

RELAY · · · · • · • · · · • · · · · · • · · · • · · · • · · · • · · · · · · · · · · · • · · • • · · · · • · AC- 40
!
A I R C O N D ITI O N I N G CONTROL
q

ASSEMBL Y ····•··•·••·······················•······· AC- 40

A I R C O N D ITI O N I N G A M P LI F I E R ··············· AC- 44

S E R V I C E SPECIFICATIONS .. · · · · · · · · · · · · • · • · • · · · · · AC- 46

•
AC-2
AIR C O N D I T I O N I N G SYSTEM - PRECAUTION

PRECAUTION
AC1Tt-0I

H A N D L I N G P R E C A U T I O N S FOR
�

� REFRIGERANT

1. DO NOT HANDLE REFRIGERANT IN AN E N C L O S E D

•
AREA O R N E A R A N OPEN FLAME

2. ALWA YS WEAR EYE PROTECTION

AC2810

3. BE CAREFUL THAT LI Q U I D REFRIGERANT DOES

NOT GET IN YOUR EYES OR ON YOUR SKIN

lf liquid refrigerant gets in your ayes or on your skin:

(a) Wash the area with lots of cool water.

CAUTION: Do not rub your ayes or skin.

(b) Apply clean petroleum jelly to the skin.

(c) Go immediately to a physician or hospital for profes­

sional treatment.

At1n-01

H A N D L I N G PRECAUTIONS FOR

REFRIGERANT CONTAINER

1. NEVER HEAT CONTAINER OR EXPOSE IT TO

2.
NAKED FLAME

BE CAREFUL NOT TO DROP C O N T A I N E R A N D NOT

TO APPLY PHYSICAL SHOCKS TO IT

•
ACITl-02

PRECAUTIONS WHEN CHARGING

Wrong Okay

REFRIGERANT

1. DO NOT OPERATE COMPRESSOR WITHOUT

� �
ENOUGH REFRIGERANT IN REFRIGERANT

SYSTEM

lf there is not enough r e fr i g e r a n t in the r e fr i g e r a n t

system oil lubrication will be i n s u f fi c i e n t a n d compres­

Nll084 sor burnout may occur, so take care to avoid this.

2. DO NOT OPEN H I G H P R E S S U R E M A N I F O L D VALVE

W H I L E COMPRESSOR IS OPERATING

lf the high pressure valva is opened, refrigerant flows

in the reverse direction and could cause the charging

cylinder to ruptura, so open and close the only low

pressure valva.

•
 AC-3
AIR C O N D I T I O N I N G SYSTEM - PRECAUTION

3. BE CAREFUL NOT TO OVERCHARGE SYSTEM

WITH R E F R I G E R A N T

lf r e fr i g e r a n t is overcharged, it causes problems such

• as i n s u f fi c i e n t

overheating etc.
cooling, poor fu e l economy, angina

ACHL-01

G A S LEAK TEST D E S C R I P T I O N

1. PERFORM IN THESE C O N D I T I O N S :

• Stop angina.

• Secura good ventilation (lf not, the gas leak de­

tector may react to volatile gases which are not

r e fr i g e r a n t , such as evaporated gasolina and ex­

haust gas.)

• Repeat the test 2 or 3 times.

• Make sure there is s o rn e refrigerant remaining in

the r e fr i g e r a t i o n system.

When compressor is OFF: approximately 392 - 588

2,
KPa (4 - 6 kgf /cm 57 - 35 psi)

2. GAS LEAK TEST IN A/C UNIT

• (a) Bring

before

HINT:
the gas

p e r fo r m i n g
leak detector

the test.
close to the drain hose

I Nt45l9
•

•
After

unit

Expose
for
the

more

the
blower

than

gas
motor

leak
1 5
is stopped,

minutes.

detector sensor
leave

the
the A/C

under

the drain hose.

• When bring the gas leak detector close to the

drain hose, make sure that the gas leak detector

do e s not react to the volatile gases.

lf such reaction is unavoidable, th e ve h i c l e must be

lift e d up,

(b) lf gas leak is not d e t e ct a d on the drain h o s e, r e mo ve

the blower r e sistor from the A/C u n i t. T h e n i n s ert the

N14518 gas l e a k d e t e ctor s e n s o r into th e unit and p e r fo r m the

test.

3 GAS LEAK TEST AT PRESSURE SWITCH

Dis c o n n e c t the conn e ctor and l e av e the p r essure

s witch for a pp r o x i m a t e l y 20 m i n u t e s . T he n b r i n g the

gas leak d e t e ctor close to th e pressure switch and

p e rform the test .

• 4 GAS LEAK TEST AT REFRIGERANT LINES

Bring

lines
th e

and
gas

p e r fo r m
le ak

the
detector

t e st .
c l os e to t he refrigerant

HINT: Make sur e th e r e is no d i rt on joints.

AC-4
AIR C O N D I T I O N I N G SYSTEM - PRECAUTION

AC1TA-OI

S U P P L E M E N T A L R E S T R A I N T SYSTEM

(SRS)

The TOYOT A T A C O M A is equipped with an SRS (Spp­

lemental Restraint System) such as the driver airbag.

•
Failure to carry out service operations the correct

sequence c o u l d cause the SRS to unexpectedly deplo­

yed during servicing, possibly leading to a serious

accident. Further, if a mistake is made in servicing the

SRS, it is possible the SRS may fail to operate when

required. Before servicing ( i n c l u d i n g removal or instal­

lation of parts, inspection or replacement), be sure to

read the fllowing item carefully, t h e n follow the cor­

rect procedure described in the repair m a n u a l.

•
 AC-5
AIR C O N D IT I O N I N G SYSTEM - DESCRIPTION

DESCRIPTION

PARTS L O C A T I O N

•
Water Valve

Engine Room

-----T Junction Block No. 1

....---,-- • Heater M a i n Relay

•
Heater Control Assembly

• A/C Switch

• Blower Speed Control Switch

Cooling Unit

• Blower Resistor

• Evaporator

• Expansion Valva

• A/C A m p li fi e r

• Thermistor

Blower Unit

• Blower Motor

Heater U n i t

•
• Heater Radiator

N14285
AC-6
AIR C O N D I T I O N I N G SYSTEM - DESCRIPTION

ACOII-OC

DAMPERS POSITION

Mode Damper

Outside Air

Air Mix Damper

Air lnlet 1 • 1
Damper J L

-
-ro
C: F A C E

Heater Core

Blower Motor
To Foot

•
Max Cool Damper Mode Damper

Air Flow Vent

Air Flow Mode
Mode
Damper Posions
Center Side Foot Def.

...
Face
� CD ® ® o o
Bi-Level .-;; ® ® @) o o o
Foot ,,J @ ® @ o o o

Foot/Def.
•11
@ (J) @ o o o
Def.
� CD ® @ o o

�Jmt The size of c i r c u l e (0) indicates the proportion of the air flow volume.

•
Z15456
1 '

' 1
 AC-7
AIR C O N D I T I O N I N G SYSTEM - PREPARATION

PREPARATION
ACOIT-OA

S S T ( S P E C I A L S E R V I C E TOOLS)

• 07110-58060 Air Conditioner Service Tool Set

(07117-58060) Refrigerant Orain Service Valve

(07117-58070) T-Joint

(07117-58090) Ouick Disconnect Adapter Suction (diam. 1 3 mm)

--·-····•···•-·•····••·········-·····-·····-····-················--···-······-·•··---··---····-····-···· --···--·•··•··•·--·-······················································-··········--····-··

(07117-88070) Refrigerant Charging Hose Suction (Blue)

o
(07117-88080) Refrigerant Charging Hose Utility (Green)

o
07112-66040 Magnetic Clutch Remover

07112-76060 Magnetic Clutch Stopper

0 71 1 4 - 8 4 0 1 0 Snap Ring Pliers

07114-84020 Snap Ring Pliers

•
 AIR C O N D I T I O N I N G SYSTEM - PREPARATION.
AC-8
U S E OF M A N I F O L D G A U G E SET

0 71 1 6 - 3 8 3 6 0 Gas Leak Detector Assembly

R E C O M M E N D E D TOOLS
•
09082-00050 TOYOTA Electrical Tester Set.

ACtKZ-1111

LUBRICANT

ltem Capacity Classification

Compressor oil - N D - O I L 8 or equivalent

When replacing receiver 1 O ce (0.34 fl.oz.)

When replacing condensar 40 ce ( 1 . 4 fl.oz.)

When replacing evaporator 40 ce ( 1 .4 fl.oz.)

When replacing compressor 140 ce (4.8 fl.oz.)

U S E OF M A N I F O L D G A U G E SET
ACOKl-07

M A N I F O L D G A U G E SET I N S T A L L A T I O N

1. CONNECT CHARGING HOSES TO MANIFOLD

•
GAUGE SET

Tighten the nuts by hand.

C A U T I O N : Do not connect the wrong hoses.

2. CONNECT QUICK DISCONNECT ADAPTERS TO

C H A R G I N G HOSES
Lo

Ch Tighten the nuts by hand.

Ho
3. CLOSE 80TH HAND VALVES OF MANIFOLD

GAUGE SET

4. REMOVE CAPS FROM SERVICE VALVES ON RE­

FRIGERANT LI N E

Nlll004

5. CONNECT OUICK DISCONNECT ADAPTERS TO

SERVICE VALVES

HINT: Push the quick disconnect adapters onto the

service valva, then s l i d e the sleeve of the q u i c k dis­

connect adapters downward to lock it.

•
J\04392
 AIR C O N D I T I O N I N G - EVACUATING A I R IN R E F R I G E R A T I O N
AC-9
SYSTEM SYSJEM ANO C H A R G I N G WIIH BEEBIGERANT
ACOKC-ot

M A N I F O L D G A U G E SET R E M O V AL

1. CLOSE BOTH HAND VALVES OF MANIFOLD

• 2.
GAUGE SET

DISCONNECT OUICK DISCONNECT

FROM SERVICE VALVES ON REFRIGERANT LI N E

ADAPTERS

t H I N T : Slide the sleeve of the q u i c k d i s c o n n e c t adapt­

Jl ers upward to

from the service valva.

unlock the connector and remove it

t-0;553

3. INSTALL CAPS TO SERVICE VALVES ON REFRIG­

ERANT LI N E

EVACUATING AIR IN
Quick DisconnectÓ"'
Adapter R E F R I G E R A T I O N SYSTEM A N D

:d •• Charging Hose CHARGING WITH R E F R I G E R A N T

AC1GA-0A

•
1. CONNECT OUICK DISCONNECT ADAPTERS TO

C H A R G I N G HOSES

2. REMOVE CAPS FROM SERVICE VALVES ON RE­

�Service Velve
FRIGERANT LI N E S

N13795
3. INSTALL MANIFOLD GAUGE SET ON SERVICE

VALVES

(a) Close both h a n d valvas of m a n i fo l d g a u g e set.

(b) Connect the q u i c k d i s c o n n e c t adapters to the service

valvas.

4. EVACUATE AIR FROM REFRIGERATION SYSTEM

(a) Connect the vacuum pump adaptar to the vacuum

Vacuum

Pump pump.

Vacuum Pump Adaptar

N13794
 AIR C O N D I T I O N I N G - EVACUATING AIR IN R E F R I G E R A T I O N
AC-10
SYSTEM SYSTEM ANO C H A R G I N G WIIH BEEBIGERANT

(b) Connect the center hose of the m a n i fo l d g a u g e set to

the vacuum p u m p adaptar.

(c) Open both the h i g h and low hand valvas and run the

(d)
vacuum p u rn p ,

After 1 O m i n u t e s or more, check that the low pressure

gauge indicates 750 m m H g (30 i n . H g ) or more.

•
HINT: lf the reading is not 750 mmHg (30 in.Hg) or

more, close both hand valvas of manifold g a u g e set

and stop the vacuum p u m p .

Check the system for leaks and repair as necessary.

(e) Close both the high and low hand valvas and stop the

vacuum pump.

(f) Leave the system in this condition for 5 m i n u t e s or

longar and c h e c k that there is no gauge indicator.

Vacuum Pump Adaptar

N13791

5. INST ALL C H A R G I N G CYLINDER

HINT: When handling the charging cylinder, always

follow the direction given in the instruction m a n u a l.

(a) Charge the proper a m o u n t of refrigerant in charging •

p
cylinder.
Air '/ �
,,
(b) Connect the center hose to the charging cylinder.

CAUTION: Do not open both high and low hand valves of

manifold gauge set.

(c) Open the valve of charging cylinder.

(d) Press the valve core on the sida of manifold gauge a n d

expel the air inside of the cantar hose.

H i g h Prassura

Service Valva

j Refrlge,atlon System 1

Charging Cylinder

Nl3793

•
 A I R C O N D IT I O N I N G - EVACUATING AIR IN R E F R I G E R A T I O N
AC-11
SVSTEM SVSTEM ANP C H A R G I N G WIIH BEEBIGERANT

6. INSPECT REFRIGERATION SYSTEM FOR LEAKS

(a) Open the h i g h pressure h a n d valva a n d c h a r g e refrig­

erant .

• (b) When the low pressure g a u g e

(1

valva.
kgf/cm
2,
14 psi), close
indicates 98 kPa

the high pressure hand

(c) Using leak detector, check the system for leakage.

(d) lf leak is fo u n d , repair the faulty component or con­

nection. Add evacuate air from refrigeration system

(Refer to 4).

Gas Leak

Detector

N13792

7. CHARGE REFRIGERANT INTO REFRIGERANT

SYSTEM

lf there is no l e a k after refrigrerant leak check charge,

the proper a m o u n t of refrigerant into refrigerant into

•
refrigeration system.

1
CAUTION:
:1

• Nevar run the engine when charging the system

through the h i g h pressure sida.

• Do not open the low pressure hand valva when

the system is being c h a r g e d with li q u i d refriger-

ant.

(a) Open the h i g h pressure h a n d valva fully.

(b) Charge specified a m o u n t of refrigerant, t h e n close the

h i g h pressure hand valva.

H I N T : A fully charged system is i n d i c a t e d by the s i g h t

glass being free of any b u b b l e s .

1 Refrlgeratlon Systern 1
8. REMOVE MANIFOLD GAUGE SET FROM SERVICE

VALVES

Nl3700 (a) Close both h a n d valvas of m a n i fo l d g a u g e set.

(b) Disconnect the quick disconnect adapters from the

s e rvic e valv a s.

9. INSTALL CAPS TO SERVICE VALVES ON REFRIG-

ERANT LINES

•
AC-12
AIR C O N D IT I O N I N G SYSTEM - TROUBLESHOOTING

TROUBLESHOOTING
ACOLH-OA

Use the table below to h e l p you find the cause of the problem.The numbers indicate the priority •

of the l i k e l y cause of the problem.Check each part in order. lf necessary, replace these parts.

O)
o M o o (X) (X) ,-.... ,-....
.... N M M N N
1
1
1
1
1 1 1 1 1

u u
""" """ """ (.) (.)

\\
See page u u u u u
<( <( <( <( <( <( <( <( <(

... e
e
cu .s=
...
«I
.s:.

E
... u
Q)

.21
...
u

... cu
111
-�

� ...... '3

111
Part Name
e: E
.2.

"O
111 ...
CI)

n,
...
:,
«I ... .s=
cu e o ... e
... ...
o
�
Q,

E
.21
...
o >

...
Q)

> e
... > § E 'i $
111
Q)
.... 'iii

e e ..9:! e
«I
o ... Q) 111 ... .s=
cu n, Q)
i
... cu
... o ... o ... tií e �
.... ...
o o
... u
� o
... >
f n, ... ... :,

o
o
u
... ... e:
·¡; Q)
.i
o
111
:,
o e
o ü
e ·¡; 111 111 l'O
Q) ] o
Q,
e, 111 o ... 111
u
E
Q)

e· u ... E 111

...
�
...
E
... .!:
Q)
...
u cu 111
11) ·¡:¡

::,
G) G)
... Q,
Q)
C)
... cu
·s, � CI) Q) Q) ·e:
> s¿ ...
Q)
g e 0. e
Trouble
o
>
·e

"O
e:
cu <
:,
o «I
�
.S!
� �
u
.e
C>·
·5,

e
-...
Q)
E
o
C)

«I
... ... ... ... ...
Q)

:r: IX)
.S!
IXI
.S!
IXI
... :f LIJ
... u �
u u u u u u
� Q) Q) Q) Q)

0.
111
¡ Q,
111
Q,

111
Q,

111 i
Q,
111

.5 .5
-= -= -= -= -=

No blower operation 1 4 3 2

No air temperatura control 1 2

No compressor operation

Compressor operates immediately

1

1
6 8 4 3

•
2

No cool air comes out 1 2 4 3

Cool air comes out immediately 1 2

Cool air comes out only at high

1 2 3

engine rpm

lnsufficient cooling 1 2 3 5

No engine idle up when A/C

switch on

No warm air comes out 1 2

',1)1961

•
1 '
 AC-13
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

a, a, <0 LO
-.:1" (Y) LO <0 N ('I')
('I') ('I') ('I') ('I') -.:1" ('I') ('I') � ('I')

1 1

(..)
'
'
(..) (..)
'
u (..)
' (..)
' (..)
' (..)
' u (..)
'

<( <( <(

<( <( <( <( <( <( <(

11)

e:
>
en
o
o
... ·.:;
�
... (.)
CI)
e CI)

o e: >
CI) (.) e ¡;;
.s::.
> o >
e
¡;;
o -
�
... CJ
0)
CI)
> e,,
... ... ·.:;
.s::. � ... e
(1) � e
CI) o
... e ... CJ
11)
o
... ·;:: :.2 . ...
(/) ... o CI)
CI)
-a
e CI) (1)
... ·¡¡¡ 0)
11)
-
�

�
Q)
... 11)

E
·¡ ...
CJ o
...
::, ::,
Q)
> o e ·;:: ·¡
<O

-
.Q) (/) -� <O

-...
11)
"O
e
Q. <O
Q) 11)
"O 11) :e
CJ 10 Q.
!¿ (..) CI) e: (1)
o
CI)
... !¿ ...
u
CI)

a: w
>
w
X
...
(.)
<( --
<( a.
.s::.
1- <(
<O
E ...
e,, ::,
o
Q)

Q.
e:
·;::
::,
(.)
...
(1)
11)
(1) (1)

.E � :e
>

2 7 5 10 9 1 1

3 5 4 6

5 4 6 3 7

6 4

2 3 1

l/01%2

•
AC-14
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

ACONQ-OM

R E F R I G E R A N T SYSTEM I N S P E C T I O N W I T H M A N I F O L D G A U G E SET

T h i s is a method in w h i c h the trouble is located by u s i n g a manifold gauge set.

(See " U S E OF M A N I F O L D G A U G E SET" on paga A C - 8 )

R e a d the m a n i fo l d g a u g e pressure when the following conditions are established:

(a) Temperatura at the a i r inlet with the switch set at RECIRC is 30 - 35 º C (86 - 95 º F )
•
(b) E n g i n e r u n n i n g at 1 , 5 0 0 rpm

(c) Blower speed control switch set at h i g h

(d) Temperatura control set at max. cool

H I N T : lt s h o u l d be notad that the g a u g e indications may vary slightly d u e t o ambient temperatura

conditions.
ACONll-00

1. N O R M A L L Y F U N C T I O N I N G REFRIGERATION SYSTEM

Gauge reading:

Low pressure side:

2)
0 . 1 5 - 0.25 MPa ( 1 . 5 - 2.5 kgf/cm

High pressure side:

2)
1.37 - 1 . 5 7 MPa ( 1 4 - 1 6 kgf/cm

134

"°4147

•
 AC-15
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

2. M O I S T U R E PRESENT IN REFRIGERATION SYSTEM

•
Condition: Periodically cools and then falls to cool

N04148

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• During operation, pres­ • Molsture enterad in • Drier in oversaturated (1) Replace receiver/drier

sure on low pressure refrlgeration system state (2) Remove moisture in

side sometimes freezes at expansion cycle through repeat­

becomes a vacuum and valve orifica and • Moisture in refrigeration edly evacuating air

sometimes normal temporarily stops cycle, system freezes at (3) Charge proper amount

but normal state Is expanslon valve orifica of new refrigerant

restored after a time and blocks circulation of

when the Ice melts refrigerant

\/01034

• 3. I N S U F F I C I E N T REFRIGERANT

Condition: lnsufficient cooling

N04149

Symptom seen in refrlgeration

Probable cause Diagnosis Remedy
system

Pressure low on both low and
high pressure sides
• Bubbles seen in sight glass
continuously
• lnsufficlent cooling
performance
• Gas leakage at sorne place In • lnsufficlent refrlgerant In ( 1) Check for gas leakage with
refrigeration system system leak detector and repair if
J. necessary
Refrigerant leaking (2) Charge proper amount of
refrigerant
(3) lf lndlcated pressure value is

near O when connected to

• gauge, create the vacuum

after inspecting and repalring

the locatlon of the leak

\/01035
AC-16
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

4. P O O R CIRCULATION OF REFRIGERANT

•
Condition: lnsufficient cooling

N04160

Symptom seen in
Probable cause Diagnosis Remedy
refrigeratíon system

• Pressure low on both • Refrigerant flow ob­ • Receiver clogged • Replace receiver

low and high pressure structed by dírt in re­

sidas ceiver

• Frost on tubas from re­

ceiver to unit
V01030

5. REFRIGERANT DOES NOT CIRCULATE

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

N04160

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• Vacuum indicated on • Refrigerant flow ob­ • Refrigerant does not cir­ 11) Check heat sensing

low pressure side, very structed by moisture or culate tube, expansion valva

low pressure indicated dirt in refrigeration sys­ and EPA

on high pressure side tem (21 Clean out dirt in expan­

• Frost or dew seen on • Refrigerant flow ob­ sion vstvs'bv blowing

piping before and after structed by gas leakage with air

receiver/drier or expan­ from expansion valve lf not able to remove

sion valva heat sensing tube dirt, replace expansion

valva

(3) Replace receiver

(4) Evacuate air and

charge new refrigerant

to proper amount.

For gas leakage from

heat sensing tube, re­

place expansion valve.

•
V01041
 AC-17
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

6. R E F R I G E R A N T OVERCHARGE OR I.NSUFFICIENT C O O LI N G OF C O N D E N S E R

•
Condition: lnsufficient Cooling

N041S1

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• Pressure too high on both • U n a b l e to develop • Excessive refrigerant in ( 1 ) Clean condensar

low and high pressure sufficient performance cycle ➔ refrigerant (2) Check fan motor

sides due to excessive overcharged operation

• No air bubbles seen refrigerant in system • Condensar cooling (3) lf ( 1 ) and (2) are in

through the sight glass • lnsufficient cooling of insufficient ➔ condensar normal state, check

even when the engine condensar fins clogged or fan motor amount of refrigerant

rprn is lowered. faulty Charge proper amount

of refrigerant

V01032

• 7. AIR PRESENT IN REFRIGERATION SYSTEM

Condition: lnsufficient cooling

NOTE: These gauge indications are shown when the refrigeration

system has been opened and the refrigerant charged

without vacuum purging.

N04153

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• Pressure too h i g h on • Air enterad in • Air present in (1) Check compressor oii
both iow and high refrigeration system refrigeration system to see if it is dlrty or
pressure sides J, insufficient
• The low pressure piping • lnsufficient vacuum (2) Evacuate air and

•
is hot to the touch purglng charge new refrigerant
• Bubbles seen in sight

glass

V01033
AC-18
AIR C O N D I T I O N I N G SYSTEM - TROUBLESHOOTING

8. EXPANSION VALVE IMPROPERLY

MOUNTED/HEAT S E N S I N G T U B E DEFECTIVE

(OPENS TOO WIDE)

•
Condition: lnsufficient cooling

N04152

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• Pressure too high on • Trouble in expansion • Excessive refrigerant in (1) Check heat sensing

both low and high valva or heat sensing low pressure piping tube installed condition

pressure sides tube not installed cor­ J. (2) lf ( 1 ) is normal, check

• Frost or large amount rectly • Expansion valve opened expansion valva

of dew on piping on low too wide Replace if defectiva

pressure side

V01031

9. DEFECTIVE COMPRESSION COMPRESSOR

•

Condition: Does not cool

N04146

Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system

• Pressure too high on low • Interna! leak in • Compression defectiva • Repair or replace
pressure side compressor J, compressor
• Pressure too low on h i g h • Valva leaking or broken
pressure slde sliding parts

•
VOI029
 AC-19
AIR C O N D I T I O N I N G SYSTEM - REFRIGERANT VOLUME

REFRIGERANT VOLUME
ACOOG-11

REFRIGERANT V O L U M E INSPECTION

• 1.

2.

3.
SET TEMPERATURE CONTROL AT MAX. C O O L

SET BLOWER SWITCH AT '"HI'"

SET AIR INLET CONTROL AT '"RECIRC'"

4. A/C SWITCH ON

6. FULL Y OPEN DOORS

Nt4185
6. RUN E N G I N E AT APPROX. 1 , 6 0 0 RPM

7. I N S P E C T A M O U N T OF REFRIGERANT

Observe the sight glass on the liquid tube.

ltem Symptom Amount of refrigerant Remedy

(1) Check for gas leakage with gas

leak tester and repair if necessary

1 Bubbles present in sight glass lnsufficient•

(2) Add refrigerant until bubbles disap-

pear

2 No bubbles present in sight glass Nona, sufficient or too much Refer to items 3 and 4

(1) Check for gas leakage with gas

No· temperatura difference between leak testar and repair if necessary

3 Empty or nearly empty

compressor inlet and outlet (2) Add refrigerant until bubbles disap-

• 4
Temperatura

inlet and outlet

between

is
compressor

noticeably different
Correct or too much
pear

Refer to items 5 and 6

lmmediately after air conditioning is (1) Discharge refrigerant

5 turnad off, refrigerant in sight glass Too much (2) Evacuate air and charge proper

stays clear amount of purified refrigerant

When air conditioning is turnad off, re-

6 Correct -
frigerant foams and then stays clear

• Bubbles in the sight glass with ambient tempera­

tures h i g h e r than usual can be considered normal if

cooling is sufficient.

--ow

REFRIGERANT CHARGE VOLUME

Specified amount:

600 ± 50 g ( 2 1 . 1 6 ± 1 . 7 6 oz.)

•
AC-20
AIR C O N D IT I O N I N G SYSTEM - ORIVE BEL T T E N S I O N

ORIVE BELT TENSION

CORRECT WRONG ACIIIF-02

ORIVE BELT T E N S I O N INSPECTION

.1 . INSPECT ORIVE BELT INSTALLATION C O N O I T I O N

Visually check drive belt for cracks, o i l i n e s s or wear.

Check that the belt does not touch the bottom of the
•
pulley groove.

lf necessary, replace the drive belt.

MA0036

5VZ-FE
2. INSPECT ORIVE BEL T OEFLECTION
2RZ-FE

3RZ-FE · U s i n g a belt tension g a u g e , check the drive belt ten­

Compressor Crankshaft Crankshaft Pulley sion.

Belt tension gauge:

Nippondenso B T G - 2 0 (95506-00020) or

-:
ldle Pulley
Borroughs No. B T - 3 3 - 7 3 F

Orive belt tension:

New belt 1 6 0 ± 25 lbf

Compressor l d l e Pulley

N15986
U sed belt 1 0 0 ± 20 lbf

HINT:

• '"New belt" refers to a belt which has been used

Nippondenso Borroughs

less than 5 minutes on a ru n n i n g e n g i n e .

• "Used belt" refers to a belt which h a s been used

on a r u n n i n g e n g i n e for 5 m i n u t e s or more.

• After installing the drive belt. check that it fits •

properly in the ribbed grooves.

EC0003 EC0001 !'01881

ACHM-Ot

ORIVE BELT REMOVAL

1. REMOVE PS ORIVE BEL T

(See SR section)

2. REMOVE E N G I N E U N O E R COVER

3. LOOSEN IOLE PULLEY LOCK NUT

Torque: 39 N•m (400 kgf-cm, 29 ft•lbf)

4. LOOSEN ANO REMOVE COMPRESSOR ORIVE BEL T

!'06121

ACHN-01

ORIVE BEL T INSTALLATION

lnstallation is in the reverse order of removal •

•
 AC-21
AIR C O N D I T I O N I N G SYSTEM - REFRIGERANT UNES

IDLE-UP SPEED AC1L0-OI

IDLE UP SPEED ·1NSPECTION

1. WARM UP E N G I N E

2. SET V E H I C L E IN THESE C O N O I T I O N S :

• Blower switch high position

• A/C switch on

• M a g n e t i c c l u t c h on

3. INSPECT I O L E - U P SPEEO

Standard idle up speed:

2 R Z - F E , 3 R Z - F E Engine:

900 ± 50 rpm

5 V Z - F E Engine:

850 ± 50 rpm

REFRIGERANT LINES
ACOOL-OU

T I G H T E N I N G T O R Q U E OF R E F R I G E R A T I O N LINES

Suction Hose

Discharge�-::r, \lil:�==-

• Hose
·<·-__

Liquid Tube �
L1qu1

--,1;
::=::=f
� ------�
u

-�--
e

m--
-t-
_,
'---�

Evaporator
1

¡' j Compressor

Liquid ____..;¿�rt1
Condenser \
Tube
Suction
I

Hose
___ '-- ______ _ _ G;:��
Discharge

Hose

.>
� ' -:-:.-----...__

--s:::,--=,=i Q ·,
Liquid _

Tube
-=-•"------- Suction
Discharge Hose
. , Hose
�

5VZ-FE 2RZ-FE • 3RZ-FE

Nl4191

ACOOM-OZ

O N - V E H I C L E INSPECTION

1. INSPECTION H O S E ANO TUBE C O N N E C T I O N S FOR

LOOSENESS

2. INSPECT HOSES ANO TUBES FOR LEAKAGE

U s i n g a gas leak detector, c h e c k for leakage of refrig­

• erant.
AC-22
AIR C O N D I T I O N I N G SYSTEM - REFRIGERANT UNES

AC111G-OI

REFRIGERANT LINES REPLACEMENT

1. DISCHARGE REFRIGERANT FROM REFRIGERA­

2.
TION SYSTEM

REPLACE FAUL TY TUBE OR HOSE

NOTICE: Cap the open fittings lmmediately to keep mois­

•
ture or dirt out of the system.

3. TORQUE C O N N E C T I O N S TO SPECIFIED T O R Q U E

NOTICE: Connections should not be torqued tighter than

the specifled torqued.

Receiver x Liquid tube

Torque: 6.0 N • m (61 kgf,cm, 53 ft,lbf)

Condensar x Discharge tube

Torque: 1 0 N•m ( 1 0 0 kgf-cm. 7 ft-lbf)

Condensar x Li q u i d tube

Torque: 1 4 N•m ( 1 4 0 kgf-cm, 1 0 ft-lbf)

Compressor x Discharge tube

Torque: 1 0 N-m ( 1 0 0 kgf•cm, 7 ft-lbf)

Compressor x Suction tube

Torque: 1 0 N - m ( 1 0 0 kgf-cm, 7 ft-lbf)

Cooling unit x Li q u i d tube

Torque: 1 4 N•m ( 1 4 0 kgf-cm, 1 0 ft-lbf)

Cooling unit x Suction tube

Torque: 32 N-m (330 kgf•cm. 24 ft-lbf)

Expansion valva x Evaporator

Torque: 5.4 N•m (55 kgf-cm, 48 ft-lbf)

Suction line
•
Torque: 32 N•m (330 kgf-cm. 24 ft-lbf)

Liquid l i n e

Torque: 1 4 N-m ( 1 4 0 kgf-cm. 1 0 ft-lbf)

4. EVACUATE AIR IN REFRIGERATION SVSTEM AND

CHARGE WITH REFRIGERANT

Specifled amount:

600 ± 50g ( 2 1 . 1 6 ± 1 . 7 6 oz.)

5. INSPECT FOR LEAKAGE OF REFRIGERANT

Using a gas leak detector, check for leakage of refrig­

erant.

6. INSPECT AIR C O N D I T I O N I N G OPERA TION

•
 AC-23
AIR C O N D I T I O N I N G SYSTEM - COOLING U N I T

COOLING UNIT
AC1Nl-02

COOLING U N I T REMOVAL

• 1. DISCHARGE

TION SYSTEM

INSTALLATION
REFRIGERANT FROM REFRIGERA­

H I N T : Evacuate air from refrigeration

system.

Charge system with refrigerant and inspect for leak­

age of refrigerant.

Specified amount:

600 ± 50 g { 2 1 . 1 6 ± 1.76 oz.)

2. DISCONNECT SUCTION TUBE ANO LIQUID TUBE

FROM C O O L I N G UNIT FITTINGS

Torque:

Liquid tube: 1 4 N•m ( 1 4 0 kgf,cm, 1 0 ft,lbf)

Suction tube: 32 N•m (330 kgf,cm, 24 ft,lbf)

REMOVAL NOTICE: Cap the open flttings lmmediately to

keep moisture or dirt out of the system.

N14189
INSTALLATION H I N T : Lubricate 2 new 0 - r i n g s with

compressor oil and install the tubas.

3. REMOVE 2 G R O M M E T S

4. REMOVE DRAIN PIPE GROMMET

5. REMOVE GLOVE COMPARTMENT PARTS

,. 6.

(a)
(See page B 0 - 2 7 )

REMOVE C O O L I N G U N I T

Disconnect the connectors.

(b) Remove the 3 screws, bolt a n d the c o o l i n g unit.

ACUU-Ol

COOLING UNIT DISASSEMBLY

♦ Packing--o·
.· • •'-.....,�•----
----Upper Unit Case

. IS

' ,-!,��
Evaporator
Wfre Hamess�

-' • 0-ring

Thermistor �
'
�Expansion Valve

�0-ring

A/C Amplifier �

� Pressure Switch

�
o
w
l
r
e Unit Case

• ♦ Non-reusable part
Blower Resistor -----­
•
•
[F Packing

N142'l!
AC-24
AIR C O N D IT I O N I N G SYSTEM - C O O LI N G U N IT , HEATER U N IT

1. REMOVE THESE PARTS

(a) A/C amplifier.

(b) Wire harness.

2.

3.
REMOVE BLOWER RESISTOR

Remove the 2 screws and blower resistor.

SEPARATE UPPER ANO LOWER U N I T CASE

•
(a) Using a knife, cut off the each packing.

(b) Remove 3 clips and 3 screws.

(e) Separata the upper and lower unit case.

4. REMOVE EVAPORATOR FROM LOWER U N I T CASE

ASSEMBLY HIN T: lf evaporator was replaced, add

compressor oil to compressor.

Add 40 - 50 ce ( 1 . 4 - 1 . 7 fl.oz.)

Compressor oil:

N D - O I L 8 or equivalent

5. REMOVE THERMISTOR

Pull out the thermistor from evaporator.

6. REMOVE PRESSURE SWITCH

ASSEM BL Y HINT: Lubricate a new O - ring with corn­

pressor oil and install the switch.

7. REMOVE EXPANSION VALVE

Using a hexagon wrench, remove the 2 bolts and

separata the expansion valva and evaporator.

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

INSTALLATION H I N T : Lubricate 4 new 0 - r i n g s with •

compressor oil and install the tubas.

N14250

ACHP'-01

COOLING U N I T ASSEMBLY

Assembly is in the reverse order of disassembly.

ACHQ-01

C O O L I N G U N I T INSTALLATION

lnstallation is in the reverse order of removal.

HEATER U N I T
ACUll-01

HEATER U N I T R E M O V A L

1. REMOVE COOLING UNIT

(See page AC-23)

2. DRAIN E N G I N E COOLANT FROM RADIATOR •

REMOVAL HINT: lt is not necessary to d r a i n out all

the coolant.
 AC-25
AIR C O N D I T I O N I N G SYSTEM - HEATER U N I T

IN
3. D I S C O N N E C T WATER HOSES FROM HEATER RA­

DIA TOR PIPES

Heater Radiato�
Hose Clip Pipe � INSTALLATION HINT:

• r··· --- ------- 1 OUT ªº' - ,20•

•

•
Push the water hose onto the heater radiator pipe

as far as the ridge on the pipe.

lnstall the hose c l i p i n a position, as shown in the

illustration.
,,_·�:::�ose ��-

4. REMOVE INSTRUMENT PANEL ANO REINFORCE­

MENT

(See page B 0 - 2 7 )

5. REMOVE DEFROSTER DUCT HEATER TO REGIS­

TER N0.4

6. REMOVE HEATER U N I T

Remove the 2 bolts, t h e nut and the hsater unit.

N14284

AC1M.-oa

HEATER U N I T D I S A S S E M B LY

•
i---- Heater Radiator

Heater

Unit Case ----n:

1----Air Vent Duct

Nl<l2'l0

1. REMO VE HEA TER RADIATOR

(a) Remove the 2 screws and 2 platas.

(b) P u ll out the heater radiator.

2. REMOVE AIR VENT DUCT

Remove the 2 screws and duct .

AC211-01

• HEATER U N I T ASSEMBLY

Assembly is in the reverse order of d i s a s s e m b l y .

AC-26
AIR CONDITIONING SYSTEM - HEATER UNIT, BLOWER U N IT

ACHT-01

HEATER U N I T INSTALLATION

lnstallation is in the reverse order of removal.

BLOWER U N I T
--oc
BLOWER U N I T REMOVAL

1. REMOVE GLOVE COMPARTMENT PARTS

(See paga B0-27)

2. REMOVE C O O LI N G UNIT

(See paga AC-23)

3. REMOVE BLOWER UNIT

Nl4421
(a) Disconnect the connector from the blower motor.

(b) Disconnect the air inlet damper control cable from the

blower motor.

INSTALLATION HINT: For installing the control cable,

refer to • HEATER CONTROL CABLES ADJUST­

MENT•.

•
(c) Remove the nut and bolt, and the blower unit.
AC1t11-•

BLOWER U N I T D I S A S S E M B L Y

o REMOVE BLOWER MOTOR

Remove the 3 screws and blower motor.

Blower Motor

N14183
216847

--01

BLOWER U N I T A S S E M B L Y

Assembly is in the reverse order of disassembly .

ACZtv-01

•
BLOWER U N I T INSTALLATION

lnstallation is in the reverse order of removal.

 AC-27
AIR C O N D I T I O N I N G SVSTEM - COMPRESSOR

COMPRESSOR
AC111M-01

O N - V E H I C L E INSPECTION

•
Magnetic Clutch:

1. M A K E THESE VISUAL CHECKS:

(a) Leakage of grease from the clutch bearing.

(b) S i g n s of oil on the pressure plata or rotor.

Repair or replace, as necessary.

2. INSPECT MAGNETIC CLUTCH BEARING FOR

NOISE

(a) Start a n g i n a .

(b) Check for a b n o r m a l noise from n e a r the compressor

when the A/C switch is OFF.

lf a b n o r m a l noise is being emitted, replace the mag­

netic clutch.

3. I N S P E C T MAGNETIC C L U T C H

(a) Disconnect the connector from the magnetic clutch.

(b) Connect the positiva ( + ) lead from the battery to the

terminal on the magnetic clutch connector and the

•
negativa ( - ) lead to the body ground.

(e) Check that the magnetic clutch is energizad.

lf operation is not as specified, replace the m a g n e t i c

clutch.

Nl:3000

Compressor:

1. I N S T ALL M A N I F O L D G A U G E SET

(See page A C - 8 )

2. START E N G I N E

3. I N S P E C T C O M P R E S S O R FOR METALLIC S O U N D

Check if there is a metallic sound from the compressor

w h e n the A/C switch is on.

lf metallic sound is heard, replace the compressor

assembly.

4. INSPECT PRESSURE OF REFRIGERATION SYSTEM

See " REFRIGERANT SYSTEM INSPECTION WITH

M A N I F O L D G A U G E SET" on paga A C - 1 4

5. STOP E N G I N E

6. I N S P E C T VISUALL Y FOR LEAKAGE OF REFRIGER­

ANT FROM SAFETY SEAL

lf there is any leakage, replace the compressor assem­

bly.
AC-28
AIR C O N D I T I O N I N G SYSTEM - COMPRESSOR

AC10M-OI

COMPRESSOR REMOVAL

2RZ-FE Engine ♦ O-ring

Compressor Bracket
_ // ✓
i () /�/
•
3RZ-FE Engine � _ - �

Suction Hose �:.J. ,- ,<27i>,

Discharge H o s e � , ✓--
, ��/

I I � -, ,,,,
if,
I
,_ __ .;,
.,,,,, ,,.. �
.:O.:'-"'-'T'-lÑ , ....._.. .,,. ""

✓�: ✓ '

✓/// "@�

✓
Cornpressor
ldle Pulley

D Orive Belt

•
N16460
N16459

♦ Non-reusable part

216645

1. RUN E N G I N E AT IDLE SPEED WITH A/C ON FOR

APPROX. 1 O M I N U T E S WITH A/C ON

2. STOP E N G I N E

3. DISCONNECT NEGATIVE (-) TERMINAL CABLE

FROM BATTERY

4. D I S C O N N E C T CLUTCH LEAD WIRE FROM W I R I N G

HARNESS

5. DISCHARGE REFRIGERANT FROM REFRIGERA­

TION SYSTEM

6. DISCONNECT 2 HOSES FROM COMPRESSOR SER­

VICE VALVES

NOTICE: Cap the open fitting immediately to keep mois­

ture or dirt out of the system.

•
7. REMOVE COMPRESSOR
 AC-29
AIR C O N D I T I O N I N G SYSTEM - COMPRESSOR

(a) Remove the fa n s h r o u d .

(b) Loosen the drive belt .

(e) Remove the compressor m o u n t i n g bolts a n d the com­

• 8.
pressor.

REMOVE COMPRESSOR BRACKET

2 R Z - F E , 3 R Z - F E Engine:

Remove the 4 bolts a n d c o m p r e s s o r brakcet.

5 V Z - F E Engine:

Remove the 5 bolts a n d compressor brakcet.

AC111N-01

MAGNETIC CLUTCH DISASSEMBLY

Stator

Rotor

Pressure Plate

Shim

•
Compressor
� �
�

N12543

1. REMOVE PRESSURE PLATE

(a) U s i n g SST a n d socket w r e n c h , remove the shaft bolt.

Torque: 1 4 N-m ( 1 4 0 kgf-cm, 1 0 ft•lbf)

SST 0 7 1 1 2 - 7 6 0 6 0

AC0943

(b) lnstall a SST on the pressure plate.

SST
SST 0 7 1 1 2 - 6 6 0 4 0

•
AC0944
AC-30
A I R C O N D I T I O N I N G SYSTEM - COMPRESSOR

(e) Using SST and scckst wranch, remove the pressure

plata.

SST 0 7 1 1 2 - 7 6 0 6 0 •

SST

AC0946

(d) Ramova the shims from the pressurJ plata.

1

00)946

2. REMOVE ROTOR

(a) U s i n g SST, ramove the snap r i n g .

SST 0 7 1 1 4 - 8 4 0 2 0

•
AC0947

ASSEMBL Y NOTICE: The snap rlng sho�ld be installed so

i
that its beveled side faces up. 1

t-09370

(b) U s i n g a plastic h a m m a r , tap the rotot off the shaft.

DISASSEMBLY NOTICE: Be careful ndt to damage the

1

pulley when tapping on the rotor. ·

•
AC1743
 AC-31
AIR C O N D I T I O N I N G SYSTEM - COMPRESSOR

3. REMOVE STATOR

(a) Disconnect the stator lead wire from the c o m p r e s s o r

housing .

•
AC1744

) (b) U s i n g SST, remove the snap r i n g .

SST 0 7 1 1 4 - 8 4 0 2 0
SST

ASSEMBL Y NOTICE: The snap ring should be installed so

that its beveled side faces up.

t-1)9370

(e) Remove the stator.

Stator

�1

ACIN'-01

M A G N E T I C C L U T C H A S S E M B LY

Assembly is in the reverse order of disassembly.

C H E C K CLEARANCE OF MAGNETIC C L U T C H

(a) Set the dial indicator to the pressure plata of the

magnetic clutch.
Dial lndicator
(b) Connect t h e m a g n e t i c c l u t c h lead wire to the positiva

( + ) terminal of t h e battery.

l-04963
AC-32
AIR C O N D I T I O N I N G SYSTEM - COMPRESSOR

(e) Check the clearance between the pressure plata and

rotor when connecting the negativa (-) terminal to

the battery.

Standard clearance:

lf
0.5

the
± 0 . 1 5 mm (0.020

clearance is not
± 0.0059 In.)

within standard clearance.

•
adjust the clearance using s h i m s to obtain the stand­

ard clearance.

Shim Thickness:

0.1 mm (0.004 in.)

0.3 mm (0.012 in.)

0.5 mm (0.020 in.)

ACt0N-OI

COMPRESSOR INSTALLATION

1. INST ALL COMPRESSOR BRACKET

lnstall the compressor bracket with the mounting

bolts and nut.

Torque:

2RZ- FE, 3RZ- FE:

Bolt: 48 N•m (489 kgf•cm, 35 ft•lbf)

Pulley nut: 40 N-m (408 kgf-cm, 30 ft-lbf)

•
5 V Z - F E : 47 N•m (479 kgf•cm, 35 ft-lbf)

2. INST ALL COMPRESSOR

lnstall the compressor wlth the 4 bolts.

Torque: 25 N•m (250 kgf•cm, 1 8 ft-lbf)

3. INSTALL AND INSPECT COMPRESSOR DRIVE BEL T

(See page A C - 2 0 )

4. C O N N E C T DISCHARGE HOSE AND S U C T I O N H O S E

TO COMPRESSOR

Torque: 1 O N-m ( 1 0 0 kgf-cm, 7 ft•lbf)

HINT: Lubricate 2 new 0 - rings with compressor oíl

and install the hoses.

5. CONNECT MAGNETIC CLUTCH C O N N E C T O R

6. CONNECT NEGATIVE (-) TERMINAL CABLE TO

BATTERY

7. CHARGE SYSTEM WITH REFRIGERANT AND IN­

SPECT FOR LEAKAGE OF REFRIGERANT

Specified amount:

600 ± 50 g { 2 1 . 1 6 ± 1 . 7 6 oz.)

•
 AC-33
AIR C O N D I T I O N I N G SYSTEM - RECEIVER

RECEIVER
AC1M-oa

•
O N - V E H I C L E INSPECTION

I N S P E C T FITTING FOR LEAKAGE

Usin g a gas leak detector, check for leakage.

lf there is leakage, check the t i g h t e n i n g torque at the

joints.

N\4185

ACtNI-OI

RECEIVER REMOVAL

1. DISCHARGE REFRIGERANT FROM REFRIGERA­

TION SYSTEM

INSTALLATION H I N T : Evacuate air from refrigeration

system.

Charge system with refrigerant and inspect for leak­

age of refrigerant.

Specified amount:

600 ± 50 g ( 2 1 . 1 6 ± 1 . 7 6 oz.)

2. D I S C O N N E C T 2 L I Q U I D TUBES FROM RECEIVER

(a) Remove the u n i o n nut from the condensar.

Torque: 1 4 N•m ( 1 4 0 kgf-cm, 1 0 ft•lbf)

(b) Remove the 2 bolts from receiver .

Torque: 6.0 N•m (60 kgf•cm, 52 ln.-lbf)

• INSTALLATION H I N T : Lubricate 3 new 0 - r i n g s with

compressor oil to the compressor.

REMOVAL NOTICE: Cap the open fitting lmmediately to

keep moisture or dirt out of system.

N14184

3. REMOVE RECEIVER FROM RECEIVER HOLDER

Remove the holder bolt and pull the receiver upward

from the holder.

INSTALLATION HINT: lf receiver was replaced, add

compressor oil to compressor.

Add 20 ce (O. 71 fl.oz.)

Compressor oil:

N D - O I L 8 or equivalent

Acatw-Ot

RECEIVER INSTALLATION

l n s t a ll a t i o n is in the reverse order of r e m o v a l .

AC-34
AIR C O N D I T I O N I N G SYSTEM - CONDENSER

CONDENSER
AC11111-0I

O N - V E H I C L E INSPECTION

1. INSPECT

OAMAGE
CONDENSER FINS FOR

lf the fins are clogged, wash them with water and dry
BLOCKAGE OR

•
with compressed air.

NOTICE: Be careful not to damage the fins.

lf the fins are bent straighten them with a screwdriver

or pliers.

2. INSPECT C O N O E N S E R ANO FITTINGS FOR LEAK-

AGE

Using a gas leak detector, check for leakage.

lf there is leakage, check the tightening torque at the

joints.

C O N D E N S E R REMOVAL !,
1:

1. OISCHARGE REFRIGERANT FROM REFRIGERA­

TION SYSTEM

INSTALLATION HINT: Evacuate air from refrigeration

system.

Charge system with refrigerant and inspect for leak­

age of refrigerant.

Specifled amount:

± ±

•
600 50 g ( 2 1 . 1 6 1 . 7 6 oz.)

2. REMOVE THESE PARTS:

• Radiator Grille

• Hood Lock

• Front B u m p e r Filler

3. OISCONNECT LIQUID TUBE ANO DISCHARGE

HOSE FROM C O N D E N S E R FITTING

Torque:

Discharge hose: 1 O N-m ( 1 0 0 kgf-cm, 7 ft-lbf)

Liquid tube: 1 4 N•m ( 1 4 0 kgf•cm, 1 0 ft•lbf)

REMOVAL NOTICE: Cap open the flttings immediately to

keep moisture out of the system.

INSTALLATION H I N T : Lubricate 2 new 0 - r i n g s with

compressor oil and install the tubes.

4. REMOVE C O N D E N S E R

Remove the 2 condenser mounting bolts and pull out

the condenser.

INSTALLATION H I N T : lf condenser was replaced, add

compressor oil to the compressor.

Add 40 - 50 ce ( 1 . 4 - 1 . 7 fl.oz.)

Compressor oil:

N D - O I L 8 or equivalent
•
 AIR C O N D I T I O N I N G SYSTEM - EVAPORATOR, HEATER RADIATOR,
AC-35
WATER VALVE

ACHY-ot

CONDENSER INSTALLATION

lnstallation is in the reverse order of removal.

EVAPORATOR AC011-0C

EVAPORATOR I N S P E C T I O N

1. C H E C K EVAPORATOR F I N S FOR BLOCKAGE

lf the fins are clogged, olean them with compressed

air.

NOTICE: Never use water to clean the evaporator.

2. C H E C K FITTINGS FOR C R A C K S OR SCRATCHES

Repair as necessary.

AC1Kll-0Cl

EVAPORATOR R E M O V A L A N D

I N S T ALLA T I O N

(See page AC - 23)

HEATER RADIATOR
ACtRT-Ot

HEATER RADIATOR REMOVAL A N D

I N S T ALLA T I O N

•
(See page A C - 25)
AC1U-OZ

HEATER RADIATOR INSPECTION

INSPECT FINS FOR BLOCKAGE

lf the fins are clogged, clean them with compressed

air.

WATERVALVE
ACtU-04

WATER VALVE R E M O V A L

1. DRAIN E N G I N E C O O L A N T FROM RADIA TOR

REMOVAL HINT: lt is not necessary to drain out all

the coolant.

2. D I S C O N N E C T WATER VALVE CONTROL CABLE

INSTALLATION H I N T : For installing the control cable,

N13326 refer to .HEATER C O N T R O L C A B L E S ADJUSTMENT"

3. D I S C O N N E C T WATER HOSE

4. REMOVE WATER VALVE

Hose Clip
(a) Disconnect the water hose from the heater radiator
Heater Radiator Pipe
pipe.

(b) Remove the bolt and the water valva.

I N S T A L L A T I O N HINT:

©
•
• Push the water hose onto the heater radiator pipe

as far as the ridge on the pipe.

Water Hose • lnstall the hose c l i p in a position as shown in the

l'KJII 17 ill ustration.

AC-36 AIR C O N D I T I O N I N G SYSTEM - WATER VALVE .

. V A C U U M SWITc�::NVSION VA-...)E,
· A L VE {YS'll

ACffZ-01

WATER V ALVt. lftlS.T ALL�T�N

lnstallation is in the reverse order of removal •

E X P A N S I O N VALVE
liiCOJA-O'J'
•
ON-VEHICLE INSPECTION

1. CHECK QUANTITY OF GAS DURING REFRIGERA­

TION CYCLE

2. INSTALL MANIFOLD G A U G E SET

3. RUN ENGINE

Run the angina at 1,500 rpm for at least 5 minutes.

Then check that the high pressure reading is 1.37 -

2,
1.57 MPa (14 - 1 6 kgf/cm 199 - 228 psi).

4. CHECK EXPANSION VALVE ,¡ /

lf the expansion valva is faulty, the low pressure

reading will drop to O kPa (O kgf/cm2. O psi).

HINT: When the low pressure drops to O kPa (O kgf/

cm2. O psi). feel the receiver's IN and OUT sidas for

zero temperatura differ e n ce.

EXPANSION

I N S T ALLA T I O N
VALVE REMOVAL ANO
ACal0-01

•
(See page A C - 23)

5 . V A C U U M S W I T C H I N G VALVE (VSY.!_
0,

VSV INSPECTION

1. REMOVE VSV

(a) Di s c onn e ct the v a c uu m hos e s a n d th e c o n n ec t o r from

th e VSV.

(b) Re mov e the b olt and th e VSV.

N13082

Except SVZ-FE

•
P15TT5
215457
 AC-37
AIR C O N D I T I O N I N G SYSTEM - EVACUUM S W I T C H I N G VALVE (VSV)

2. C H E C K VACUUM C I R C U I T C O N T I N U I T Y IN VSV BY

BLOWING AIR INTO PIPES

(a) Connect the VSV t e r m i n a l s to the battery t e r m i n a l s ,

• (b)
as shown in the illustration.

Blow into

pipe "B".
pipe "A" and check that air comes out of

1'[6728

(c) D i s c o n n e c t the battery.

(d) Blow into pipe .,, A" and check that a i r does not c o m e

out of pipe "B".

lf a problem is fo u n d , replace the VSV.

1'[6727

3. C H E C K FOR SHORT C I R C U I T ·
Ohmmeter
U s i n g an ohmmeter, check that there is no continuity

between either t e r m i n a l s a n d the VSV body.

lf there is continuity, replace the VSV .

• o

l'C6729

4. C H E C K FOR OPEN C I R C U I T
Ohmmeter
U s i n g an o h m m e t e r , measure resistance between the

2 terminals.

Standard resistance:

30 -34 O at 20ºC (68ºF)

o
lf resistan ce value is not as specified, re place the VSV.

1()5726

•
AC-38
AIR C O N D IT I O N I N G SYSTEM - BLO ER MOTOR, BLOWER RESISTOR

BLO
ACOWQ-04

BLOW R MOTOR REMOVAL A N D

{Se page •eLOWER UNtT• A C - 2 6 ) •

ACOIN-OI

MOTOR I N S P E C T I O N

INS ECT BLOWER MOTOR OPERA TION

Connect the positiva ( +) lead from the battery to

ter inal 1 and the negativa (-) lead to terminal 2,

the check that the motor operation is smooth.

El:1735

ER RESISTOR
ACOl'X-OI

BLO ER R E S I S T O R R E M O V A L

1 . OVE GROVE COMPARTMENT PARTS

•
(Se page B O - 2 7 )

2. RE OVE BLOWER RESISTOR

(a) Dis onnect the connector.

(b) Re ove the 2 screws and the blower resistor.

N\4253

ACOl'Y-ot

BLO ER R E S I S T O R I N S P E C T I O N

PECT BLOWER RESISTOR CONTINUITY

Tester connection Specified condition

1 - 2 - 3 - 4 Continuity

lf ontinuity is not as specified, replace the blower

H-4-2

ACU.t-ot

BLO ER R E S I S T O R I N S T A L L A T I O N

In tallation is in the reverse order of removal .

•
 ,AC-39
AIR C O N D I T I O N I N G SYSTEM - P R E S S U R E SWITCH, T H E R M I S T O R

PRESSURE SWITCH

O N - V E H I C L E INSPECTION

• 1.

2.
INSTALL MANIFOLD G A U G E SET

(See page A C - 8 )

REMOVE GLOVE COMPARTMENT DOOR

Remove the 2 screws and the glove compartment

door.

3. DISCONNECT CONNECTOR FROM PRESSURE

SWITCH

4. R U N E N G I N E AT APPROX. 1 , 5 0 0 RPM

Low Pressure Side High Pressure Side 5. I N S P E C T PRESSURE SWITCH OPERATION

0 . 1 9 6 MPa 3 . 1 3 6 MPa
2, 2, Check continuity between 3 and 4 terminals when
12.0 kgf/cm 28.4 psi) (32 kgf/cm 455 psi)

ON (Continuityl
refrigerant pressure is c h a n g a d , as shown, in the illus­

tration.

lf operation is not as specified, replace the pressure

1 1 l l
0.225 MPa 2.548 MPa
switch.
2, 2
( 2 . 3 kgf/cm 32.7 psi) (26 kgf/cm , 369.7 psi)

OFF (No continuityl OFF (No continuity) 6. STOP ENGINE ANO REMOVE MANIFOLD GAUGE

204647 SET

7. C O N N E C T CONNECTOR TO PRESSURE SWITCH

8. INSTALL GLOVE COMPARTMENT DOOR

lnstall the glove compartment door with the 2 screws .

• PRESSURE SWITCH REMOVAL ANO

INSTALLATION
ACOU-Ot

(See • c o O L I N G UNIT• on page A C - 2 3 )

THERMISTOR
ACtKU-04

O N - V E H I C L E INSPECTION

1. REMOVE GLOVE COMPARTMENT D O O R

Remove the 2 bolts and the glove compartment door.

2. DISCONNECT CONNECTOR OF T H E R M I S T O R

3. CHECK RESIST ANCE OF THERMISTOR

Measure resistance between 1 a n d 2 terminals.

Standard resistance:

1,500 O at 25 º C (77ºF)

lf resistance is not as specified, replace the thermis­

tor .

ACIKV-OI

THERMISTOR REMOVAL ANO

• INST ALLATION

(See page A C - 2 3 )
 AIR C O N D I T I O N I N G SYSTEM - THER ISTOR, RELAY,
AC-40
AIR C N D I T I O N I N G C O N T R O L ASSEMBLY

ACtKW-OC

THER ISTOR INSPECTION

Thermometer

INS ECT THERMISTOR RESIST ANCE

(a) Pla e the thermistor in cold water, and while c h a n g i n g

the temperatura of the water, measure resistance at ••

the connector and at the sama time, measure temper­

atu e of the water with a thermometer.

Ohmmeter
(b) Co pare the 2 readings on the chart.
Thermistor More than

1 O cm (3.94 in.) Aco11s lf r sistance value is not as specified, replace the

(0)
[

5000

4500

CII 4000
�
3500
-..... ...
1
--
3000

2500
·;;¡

2000
� 1 5 00

1000
-
500

o
o s 1 o 1 s 20 25 < e>
32 41 50 59 68 77 (ºF)

Temperature
AC1701 204352

AOa?l-01

INSPECTION

1. OVE RELAY

•
2. IN PECT HEATER MAIN RELA Y CONTINUITY

e ndition Tester connection Specified condition

1 - 3
e nstant Continuity
2 - 4

Apply B between

B
4 - 5 Continuity
terminal 1 and 3.

5 •4

BE1850 BE1844 lf ontinuity is not as specified, replace the relay.

206166

AIR ONDITIONING CONTROL

ASS MBLY
ACOLt-oe

ON- EHICLE INSPECTION

IN PECT A/C CONTROL LEVERS OPERATION

•
M ve the control levers to left and right, and c h e c k for

sti fness and binding through the full ranga of the

le ers.

N14182

! i
 AC-41
AIR CONDITIONING SVSTEM -- AIR C O N D I T I O N I N G CONTROL A S S E M B L V

AOILl-oa

A/C C O N T R O L A S S E M B L Y R E M O V A L

1. DISCONNECT HEATER CONTROL CABLES

•
Nt418t

2. REMOVE THESE PARTS:

(a) Heater control knobs

(b) A/C switch

(c) A/C control panel

Nt6684

3. REMOVE INSTRUMENT PANEL CENTER LOWER

FINISH PANEL

4. REMOVE A/C CONTROL ASSEMBL Y

Remove the 3 screws and A/C control assembly t h e n

d i s c o n n e c t the the connector.

•
AC27'-01

A/C C O N T R O L A S S E M B L Y I N S P E C T I O N

1. INSPECT BLOWER SPEED C O N T R O L SWITCH C O N ­

TINUITY

Terminal lllumination
1 2 6 6 8

"
OFF
Switch position
"- 3 4

re •
LO

0
tMll

IM21
o
o- k5
-"-
....,

o- t-v- i-o
LO ��

SH-8-2 H1 O- LO- f---0

lf continuity is not as specified, replace the blower

• speed control switch.

AC-42
AIR C O N D I T I O N I N G SYSTEM - AIR C N D IT I O N I N G CONTROL ASSEMBL Y

2. INS ECT A/C SWITCH C O N T I N U I T Y

Tester connection Specified condition

No continuity

4 - 5

4 - 6

1 - 3
Continuity

Continuity
•
lf c ntinuity is not as specified, replace the A/ C
AC2849 S-6- 2

snm

AC271-01

HES REMOVAL

1. OVE BLOWER SPEED C O N T R O L SWITCH

(a) ove the i ll u m i n a t i o n l i gh t from the heater control

ass mbly.

(b) Usi g a screwdriver, pry loose the c l i p and p u s h out

the blower speed control switch to rear of the heater

co trol assembly.

RE OVAL H I N T : Tape the screwdriver tip before use.

2. OVE A/C SWITCH

Usi g a screw driver, pry loose the c l i p and remove

the A/C switch.

RE OVAL H I N T : Tape the screwdriver tip before use .

•
lffin:)

ACZ71-01

SWIT HES INSTALLATION

lns allation is in the reverse order of removal.

ACl77-01

A/C O N T R O L A S S E M B LY

INST LLA T I O N

lns allation is in the reverse order of removal •

•
 AC-43
AIR C O N D I T I O N I N G SYSTEM - A I R C O N D I T I O N I N G CONTROL A S S E M B L Y

AC211-0I

HEATER C O N T R O L CABLES
· � .

- ADJUSTMENT

•
H
1. SET A/ C CONTROL LEVERS IN THESE CONDI-

TIONS:

(a) Air inlet control levar · F R E S H " position.

Clamp
(b) Mode control levar "FACE" position

(c) Temperatura control levar ·coOL" position.

Nl4186
2. ADJUST AIR INLET DAMPER CONTROL CABLE

Set the air inlet damper on "FRESH" position, install

the control cable and lock the clamp.

3. ADJUST M O D E DAMPER CONTROL CABLE

,;----.:....-clamp Set the moda d a m p e r on •FACE• position, install the

control cable and lock the c l a m p .

Nl419'.l

4. ADJUST AIR MIX DAMPER CONTROL CABLE

Set the air mix damper on ·w ARM· position, install

the control cable and lock the c l a m p .

•
--:::;
=-----' '"'--- Clamp

Nl4187

6. ADJUST WATER VALVE CONTROL CABLE

Set the water valva on "WARM" position, install ths

control cable a n d lock the c l a m p .

•
AC-44
AIR C O N D I T I O N I N G SYSTEM - ,._ I R C O N D I T I O N I N G A M P LI F I E R

Wire harness side

AIR CONDITIONING AMPLIFIER
ACOLD-OJ

O N - " EHICLE INSPECTION

•
- - -,,
INS �ECT AMPLIFIER C I R C U I T
lJ LI
1 rm ITTil 1
(a) Disc onnect the a m p l i fi e r connector and inspect the
l '5 1 6 711 9 a OI
con nsctor on wire harness sida, as shown in the chart

bale w.

Tes conditions:
e-10-1

215513 • l g n i t i o n switch O N

• Temperatura control levar MAX COOL

Blower control levar H I

•
• A/C switch ON

Tester connection Conditio, Specified condition

4 - Ground Constant Continuity

3 - ECM terminal ACT Constant Continuity

8 - ECM terminal AC1 Constant Continuity

9 - Ground Constant 40 O at 25 ºC (77 º F)

2 - 10 Constant 1.5 kO at 25 ºC (77 ºF)

5 - Ground A/C switch ON Battery positiva voltage

5 - Ground A/C switch OFF No voltage

•
lf e ircuit is as specified, try replacing the a m p li f i a r

wit , a new ona. lf tha circuit is not as spacified,

i n s ] iect tha circuits connectad to other parts.

(b) Cor nect tha connactor to A/C a m p l i f i e r a n d inspect

From back side

wir ¡ harness sida connector from the back sida, as

sha wn.

� Tes t conditions:

ITTi1 ü7J nrn • lgnition switch ON

• o¡ , • 17 6 l '5
• A/C switch ON

• Temperatura control d i a l MAX C O O L

• Blower control levar H I

e-10-2
215514 • lnstall m a n i fo l d g a u g e set

Tester connection Conditic n Specified condition

1 - Ground Refrigerant pressure 196 - 3 .4 1 0 kPa Battery positiva voltage

Refrigerant pressure
1 - Ground No voltage
less than 1 9 6 kPa or mo e than 3. 140 kPa

lf e ircuit is not as specified, replaca the A/C a m p l i fi e r .

•
i '
 AC-45
AIR C O N D I T I O N I N G SYSTEM - AIR C O N D IT I O N I N G A M P LI F I E R

ACtLC-OI

A M P L I F I E R REMOVAL

w 1. R E M O V E GLOVE C O M P A R T M E N T D O O R

•
Remove the 2 screws and the glove compartment

1 door.

N14047

2. REMOVE A/C A M P L I F I E R

(a) D i s c o n n e c t the connector from the amplifier.

(b) Remove amplifier cover.

(e) Remove the a m p l i fi e r from the cooling u n i t .

AC.171-01

AMPLIFIER INST ALLATION

lnstallation is in the reverse order of removal .

•
 ..
.,

·'

AC-46
AIR CONDITIONING SYSTEM - SERVICE SPECIFICA TIONS .'
;

¡}

if.

>.�
SERVICE SPECIFICATIONS
ACOIJ-00

S E R V I C E DATA

Refrigerant charge volume

Orive belt tension

N e w b , lt
600

160
±

±
50 g ( 2 1.1 6

25 lbf
± 1.76 oz.)

•
/
,

Used b• lt 100 ± 20 lbf

'

ldle up speed -
1
2RZ-FE, 3 R Z - I E 900 ± 50 rpm ,
¡

6VZ-I E 860 ± 50 rpm '

Magnetic clutch .clearance 0.6 ± 0 . 1 5 mm (0.020 ± 0.0069 in.)

'
ACaA-OT

TORQUE SPECIFICATIONS

Part tightened N,m kgf-cm ft-lbf

Compressor and Compressor Bracket x Engine 37 375 27

Compressor x Compressor bracket 25 250 18

Compressor bracket x Engine ( 2 R Z - F E , 3 R Z - F E ) 48 489 35

Compressor bracket x Engine (5VZ- FE) 47 479 35

ldle pulley lock nut (2RZ- FE, 3RZ - FE) 40 408 30

Suction and Discharge hose x Compressor 10 100 7

Suction hose x A/C unit 32 330 24

Discharge tube x Condenaer 10 100 7

Liquid tube x Receiver 8.0 60 52 in.•lbf

•
Liquid tube x Condenser 10 100 7

Liquid tube x A/C unit 14 140 10

Expansion valve x Evaporator 5.4 56 48in.•lbf

Expansion valve x Liquid tube 14 140 10

..