Manual A/C Mitsubishi Lancer

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The document discusses servicing procedures for heating, air conditioning, and ventilation systems. It covers components like the heater unit, evaporator, compressor, condenser, and provides specifications.

The document discusses servicing procedures for various components that are part of vehicle heating, air conditioning, and ventilation systems.

Some of the components covered in the document include the heater unit, evaporator, compressor, condenser, blower motor, refrigerant lines, and ventilators.

55-1

GROUP 55

HEATER, AIR
CONDITIONING AND
VENTILATION
CONTENTS

GENERAL DESCRIPTION. . . . . . . . . 55-3 PERFORMANCE TEST . . . . . . . . . . . . . . . 55-95


REFRIGERANT LEAK REPAIR
SERVICE PRECAUTIONS. . . . . . . . . 55-4 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-96
CAUTION LABELS . . . . . . . . . . . . . . . . . . . 55-4 COMPRESSOR NOISE CHECK . . . . . . . . . 55-97
POWER RELAY CHECK. . . . . . . . . . . . . . . 55-97
MANUAL A/C DIAGNOSIS . . . . . . . . 55-5 IDLE-UP OPERATION CHECK. . . . . . . . . . 55-98
INTRODUCTION TO HEATER, A/C AND CLEAN AIR FILTER REPLACEMENT
VENTILATION DIAGNOSIS . . . . . . . . . . . . 55-5 PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 55-99
HEATER, A/C AND VENTILATION
DIAGNOSTIC TROUBLESHOOTING HEATER CONTROL ASSEMBLY
STRATEGY. . . . . . . . . . . . . . . . . . . . . . . . . 55-5 AND A/C SWITCH . . . . . . . . . . . . . . . 55-99
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 55-5 REMOVAL AND INSTALLATION . . . . . . . . 55-99
SYMPTOM PROCEDURES . . . . . . . . . . . . 55-6 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-101
CHECK AT ECU TERMINAL . . . . . . . . . . . 55-91 DISASSEMBLY AND ASSEMBLY . . . . . . . 55-101

SPECIAL TOOLS. . . . . . . . . . . . . . . . 55-92 HEATER UNIT, HEATER CORE,


BLOWER ASSEMBLY AND
ON-VEHICLE SERVICE. . . . . . . . . . . 55-93 EVAPORATOR UNIT . . . . . . . . . . . . . 55-103
REFRIGERANT LEVEL TEST . . . . . . . . . . 55-93 REMOVAL AND INSTALLATION . . . . . . . . 55-103
A/C COMPRESSOR CLUTCH TEST . . . . . 55-93 HEATER UNIT DISASSEMBLY AND
RECEIVER DRIER TEST . . . . . . . . . . . . . . 55-93 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 55-104
PRESSURE SWITCH CHECK . . . . . . . . . . 55-94 BLOWER ASSEMBLY DISASSEMBLY
AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 55-105
COMPRESSOR DRIVE BELT
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 55-94
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 55-94 Continued on next page
55-2

BLOWER MOTOR, RESISTOR CONDENSER AND CONDENSER


AND OUTSIDE/INSIDE AIR FAN MOTOR. . . . . . . . . . . . . . . . . . . . 55-116
SELECTION DAMPER CONTROL REMOVAL AND INSTALLATION . . . . . . . . 55-116
MOTOR . . . . . . . . . . . . . . . . . . . . . . . 55-106 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . 55-117
REMOVAL AND INSTALLATION . . . . . . . . 55-106
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-107 REFRIGERANT LINE . . . . . . . . . . . . . 55-118
REMOVAL AND INSTALLATION . . . . . . . . 55-118
EVAPORATOR ASSEMBLY . . . . . . . 55-109
REMOVAL AND INSTALLATION . . . . . . . . 55-109 VENTILATORS . . . . . . . . . . . . . . . . . . 55-120
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-110 REMOVAL AND INSTALLATION . . . . . . . . 55-120

COMPRESSOR ASSEMBLY AND SPECIFICATIONS . . . . . . . . . . . . . . . 55-121


TENSION PULLEY. . . . . . . . . . . . . . . 55-111 FASTENER TIGHTENING
REMOVAL AND INSTALLATION . . . . . . . . 55-111 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . 55-121
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-113 GENERAL SPECIFICATION . . . . . . . . . . . . 55-122
DISASSEMBLY AND ASSEMBLY . . . . . . . 55-113 SERVICE SPECIFICATIONS . . . . . . . . . . . 55-122
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55-115 LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . 55-122
HEATER, AIR CONDITIONING AND VENTILATION
GENERAL DESCRIPTION
55-3
GENERAL DESCRIPTION
M1552000100414
The heater system uses a two-way-flow full-air-mix CAUTION
system that features high performance and low oper- Keep R-134a containers upright when charging
ating noise. It includes an independent face air blow- the system.
ing function. In addition, an air purifier has been In most instances, moderate heat is required to bring
included. RS is equipped with a heater. GSR is the pressure of the refrigerant in its container above
equipped with an air conditioner. the pressure of the system when charging or adding
refrigerant.
SAFETY PRECAUTIONS A bucket or large pan of hot water not over 40° C
WARNING (104.0° F) is all the heat required for this purpose. Do
Wear safety goggles and gloves when servic- not heat the refrigerant container with a blow torch or
ing the refrigeration system to prevent any other means that would raise temperature and
severe damage to eyes and hands. pressure above this temperature. Do not weld or
Because R-134a refrigerant is a hydro-fluorocarbon steam clean on or near the system components or
(HFC) which contains hydrogen atoms in place of refrigerant lines.
chlorine atoms, it will not cause damage to the ozone WARNING
layer. The leak detector for R-134a should be used
Ozone filters out harmful radiation from the sun. To to check for refrigerant gas leaks.
assist in protecting the ozone layer, Mitsubishi CAUTION
Motors Corporation recommends an R-134a refriger- Do not allow liquid refrigerant to touch bright
ant recycling device. metal or it will be stained.
Refrigerant R-134a is transparent and colorless in When metering R-134a into the refrigeration system
both the liquid and vapor state. Since it has a boiling keep the supply tank or cans in an upright position. If
point of −29.8° C (−21.64° F) at atmospheric pres- the refrigerant container is on its side or upside
sure, it will be a vapor at all normal temperatures and down, liquid refrigerant will enter the system and
pressures. The vapor is heavier than air, non-flam- damage the compressor.
mable, and non-explosive. The following precautions Refrigerant will tarnish bright metal and chrome sur-
must be observed when handling R-134a. faces, and in combination with moisture can severely
WARNING corrode all metal surfaces.
Do not heat R-134a above 40° C (104.0° F) or
it may catch fire and explode. OPERATION
R-134a evaporates so rapidly at normal atmospheric .

pressures and temperatures that it tends to freeze CONDENSER FAN AND RADIATOR FAN
anything it contacts. For this reason, extreme care CONTROL
must be taken to prevent any liquid refrigerant from For the operation of each fan, refer to GROUP 14,
contacting the skin and especially the eyes. Always Diagnosis - Symptom Chart P.14-4.
wear safety goggles when servicing the refrigeration
part of the A/C system. Keep a bottle of sterile min-
.

COMPRESSOR CONTROL
eral oil handy when working on the refrigeration sys-
tem. When operating the A/C switch
1. Should any liquid refrigerant get into the eyes, use • The air thermo sensor, which senses the temper-
a few drops of mineral oil to wash them out. ature of the air flowing out of the evaporator,
R-134a is rapidly absorbed by the oil. deactivates the compressor at 3.2 ° C (37.7 ° F)
2. Next splash the eyes with plenty of cold water. or below.
• The dual pressure switch turns OFF when the
3. Call your doctor immediately even though irritation
refrigerant pressure becomes excessively high or
has ceased after treatment.
low, thus protecting the compressor circuit. (See
Table below.)
• When the air thermo sensor is activated, the dual
pressure switch is ON, and the ignition switch,
blower switch, and A/C switch are ON, the A/C
compressor clutch relay is energized.

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55-4 HEATER, AIR CONDITIONING AND VENTILATION
SERVICE PRECAUTIONS

When operating the air outlet selection control


knob
• When the air outlet selection control knob is
moved to DEFROSTER or DEFROSTER/FOOT
position, the defroster switch, which is connected
in series to the A/C switch, is turned on. Com-
pressor controls other than the above are the
same as when operating the A/C switch.
A/C COMPRESSOR CLUTCH RELAY ON CONDI-
TIONS
Ignition switch (IG2) ON NOTE: A/C compressor clutch relay is
Blower switch ON de-energized when any one switch, sensor
or control unit shown on the left turns off.
A/C switch or defroster switch ON
NOTE: The *marked device measures the
Air thermo sensor *
temperature of the outlet air, and according
Dual pressure Low-pressure side 221 kPa ON to the control characteristics of the A/C
switch (32.1 psi) or higher compressor clutch for the compressor, the
High-pressure side 2,350 kPa ON A/C-ECU outputs the "HI" signal (12V).
(341.4 psi) or below When air of 3.2° C (37.7° F) or less blows out
of the evaporator, the compressor A/C
A/C compressor clutch relay driving transistor (within ON compressor clutch will be turned off.
engine control module)

SERVICE PRECAUTIONS
CAUTION LABELS
M1552017400053
The refrigerant gas warning label must be adhered in the loca-
tion shown in the figure on the left. Follow the instructions on
the label when servicing.

AC211838AB

1 2 3 NO. CONTENT
1 Name of A/C manufacturer
2 Amount of refrigerant
3 Name of compressor oil
4 Parts number

3 2 4 AC200079 AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-5
MANUAL A/C DIAGNOSIS
INTRODUCTION TO HEATER, A/C AND VENTILATION DIAGNOSIS
M1552012200292
Air is drawn into the heater assembly from either the If the system does not cool properly, look for a prob-
outside, or from the inside of the passenger cabin if lem with the refrigerant, blower or air distribution sys-
DEFROST, maximum cooling or RECIRCULATION tems. If the system does not heat properly, look for a
are selected. The air is then forced through the evap- problem with the coolant, blower or air distribution
orator where heat is removed, cooling and de-humid- systems. In either case, all system fuses, circuit
ifying the air. Depending on the temperature breaker and relays should be checked.
selected, a portion of this air is then forced through
the heater core to achieve the selected discharge
temperature.
HEATER, A/C AND VENTILATION DIAGNOSTIC TROUBLESHOOTING STRATEGY
M1552009600319
Use these steps to plan your diagnostic strategy. If 2. Verify that the condition described by the
you follow them carefully, you will be sure that you customer exists.
have exhausted most of the possible ways to find a 3. Find the malfunction by following the Symptom
heater, A/C and ventilation fault. Chart.
1. Gather information from the customer. 4. Verify malfunction is eliminated.
SYMPTOM CHART
M1552009900547

SYMPTOM INSPECTION REFERENCE


PROCEDURE PAGE
When the ignition switch is "ON" the A/C does not operate. 1 P.55-6
When the air outlet selection control knob is moved to defroster or 2 P.55-6
defroster/foot position, the A/C or the outside/inside air selection damper
motor does not operate.
Outside/inside air selection is not possible. 3 P.55-7
When the A/C is operating, temperature inside the passenger 4 P.55-15
compartment does not decrease (cool air is not emitted).
Blower fan and motor does not turn. 5 P.55-38
Blower air volume cannot be changed. 6 P.55-51
Defroster function does not operate. 7 P.55-57
Rear window defogger timer function does not operate. 8 P.55-69
Malfunction of the heater control power supply system. 9 P.55-70
Condenser fan does not operate. 10 P.55-75

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55-6 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: When the Ignition Switch is "ON" the A/C Does Not Operate.
. .

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS


The blower system or the compressor system may • Malfunction of blower motor
be defective if there is no cool air coming from the • Malfunction of A/C compressor
vents.

DIAGNOSIS

Check 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.
Q: Does the blower motor operate when the blower switch
is moved to the "HI" position?
YES : Refer to Inspection procedure 4 "When the A/C is
operating, Temperature inside the Passenger
compartment does not decrease (cool air not
emitted)" P.55-15.
NO : Refer to Inspection procedure 5 "Blower fan and
motor does not turn" P.55-38.

INSPECTION PROCEDURE 2: When the Air Outlet Selection Control Knob is Moved to Defroster or
Defroster/Foot Position, the A/C or the Outside/inside Air Selection Damper Motor does not operate.
. .

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS


If the outside/inside air selection damper motor does • Malfunction of the heater control
not operate normally, the outside/inside air selection • Malfunction of the outside/inside air selection
damper motor system may be defective. damper motor

DIAGNOSIS

Check operations of the outside/inside air selection


damper control motor.
(1) Turn the ignition switch to the "ON" position.
(2) Outside/Inside Air Selection Damper Motor Switch: This is
used to switch from the inside air to outside air or vice
version.
(3) Check to see that the outside/inside air selection damper
motor operates normally.
Q: Does the outside/inside air selection damper control
motor work normally?
YES : Replace the heater control.
NO : Refer to Inspection procedure 3 "Inside / Outside Air
selection is not possible" P.55-7.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-7

INSPECTION PROCEDURE 3: Outside/Inside Air Selection is not possible.

Outside/Inside Air Selection Damper Control Motor Circuit

IGNITION
SWITCH (IG2)

JUNCTION
BLOCK

JOINT
CONNECTOR (2)

OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL
MOTOR

HEATER CONTROL
A/C SWITCH, OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL AND ILL

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55-8 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTORS: C-07, C-10 CONNECTORS: C-16, C-101

C-07 C-101(L)

C-10

C-16(B)

AC211266 AC AC211265 AD

CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)

C-211

C-210

AC402065 AB

. .

CIRCUIT OPERATION TROUBLESHOOTING HINTS


The outside/inside air selection damper motor is • Malfunction of the outside/inside air selection
energized through the ignition switch (IG2). The damper motor
motor is controlled by the heater control. • Malfunction of the heater control
.
• The wiring harness or connectors may have
TECHNICAL DESCRIPTION loose, corroded, or damaged terminals, or termi-
If the outside/inside air selection damper motor does nals pushed back in the connector
not operate normally, the outside/inside air selection
damper motor system may be defective.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

STEP 1. Check the rear window defogger and A/C


operations.
Q: Do the rear window defogger and A/C work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 9 "Malfunction of the
heater control Power Supply system P.55-70."

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-9

STEP 2. Check the outside/inside air selection damper


control motor.
CAUTION
Cut off the battery voltage when the damper is in the inside
or outside air position.
Check the outside/inside air selection damper control motor by
the following procedures.

LEVER POSITION BATTERY LEVER


INSIDE AIR CONNECTION OPERATION
OUTSIDE AIR
At the inside • Connect The lever moves
position terminal 7 to the from the inside
positive battery position to the
terminal outside position
• Connect
terminal 6 to the
AC201501AB negative battery
terminal
At the outside • Connect The lever moves
position terminal 7 to the from the outside
positive battery position to the
terminal inside position
• Connect
terminal 4 to the
negative battery
terminal

Q: Does the outside/inside air selection damper control


motor work normally?
YES : Go to Step 3.
NO : Replace the outside/inside air selection damper
control motor. Check that the outside/inside air
selection damper control motor works normally.

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55-10 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 3. Measure the voltage at outside/inside air selection


damper control motor connector C-07.
(1) Disconnect outside/inside air selection damper control
CONNECTOR: C-07
motor connector C-07, and measure the voltage at the
C-07 harness side.
HARNESS SIDE (2) Turn the ignition switch to the "ON" position.
CONNECTOR
C-07
3 2 1
7 6 5 4

AC211266 AB

(3) Measure the voltage between terminal 7 and ground.


CONNECTOR C-07 • The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 6.
3 2 1
7 6 5 4 NO : Go to Step 4.

AC202915AB

STEP 4. Check outside/inside air selection damper control


motor connector C-07 for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
Q: Is outside/inside air selection damper control motor
CONNECTOR: C-07
connector C-07 in good condition?
C-07 YES : Go to Step 5.
HARNESS SIDE
CONNECTOR
NO : Repair or replace the connector. Refer to GROUP
C-07 00E, Harness Connector Inspection P.00E-2. Check
3 2 1 that the outside/inside air selection damper control
7 6 5 4 motor works normally.

AC211266 AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-11

STEP 5. Check the wiring harness between outside/inside


air selection damper control motor connector C-07
(terminal 7) and the ignition switch (IG2).
CONNECTORS: C-07, C-10

C-07

C-10

HARNESS SIDE CONNECTOR


C-07
3 2 1
7 6 5 4

HARNESS SIDE CONNECTOR


C-10
2 1
7 6 5 4 3

AC211308AB

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55-12 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTOR: C-101 NOTE: Also check intermediate connector C-10, joint connec-
tor (2) C-101, junction block connectors C-210 and C-211 for
C-101(L)
loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If intermediate connector C-10, joint con-
nector (2) C-101, junction block connectors C-210 or C-211 is
damaged, repair or replace the connector as described in
GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between outside/inside air
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
selection damper control motor connector C-07
AC211265 AP (terminal 7) and the ignition switch (IG2) in good
condition?
CONNECTORS: C-210, C-211
YES : It can be assumed that this malfunction is intermittent.
JUNCTION BLOCK (FRONT VIEW)
Refer to GROUP 00, How to Cope with intermittent
C-211
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the
outside/inside air selection damper control motor
C-210
works normally.

HARNESS SIDE

C-210 C-211
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3

AC402066 AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-13

STEP 6. Check outside/inside air selection damper control


motor connector C-07 and heater control connector C-16
for loose, corroded or damaged terminals, or terminals
pushed back in the connector.
Q: Is outside/inside air selection damper control motor
CONNECTOR: C-07
connector C-07 and heater control connector C-16 in
C-07 good condition?
HARNESS SIDE
CONNECTOR
YES : Go to Step 7.
C-07 NO : Repair or replace the connector. Refer to GROUP
3 2 1 00E, Harness Connector Inspection P.00E-2. Check
7 6 5 4 that the outside/inside air selection damper control
motor works normally.

AC211266 AB

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

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55-14 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 7. Check the wiring harness between outside/inside


air selection damper control motor connector C-07
(terminals 6 and 4) and heater control connector C-16
(terminals 3 and 2).
CONNECTORS: C-07, C-10

C-07

C-10

HARNESS SIDE CONNECTOR


C-07
3 2 1
7 6 5 4

HARNESS SIDE CONNECTOR


C-10
2 1
7 6 5 4 3

AC211308AB

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

NOTE: Also check intermediate connector C-10 for loose, cor-


roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connectors C-10 is damaged, repair
or replace the connector as described in GROUP 00E, Harness
Connector Inspection P.00E-2.
Q: Is the wiring harness between outside/inside air
selection damper control motor connector C-07
(terminal 6 and 4) and heater control connector C-16
(terminal 3 and 2) in good condition?
YES : Replace the heater control, and check that the
outside/inside air selection damper control motor
works normally.
NO : Repair the wiring harness. Check that the
outside/inside air selection damper control motor
works normally.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-15

INSPECTION PROCEDURE 4: When the A/C is Operating, Temperature Inside the Passenger
Compartment does not Decrease (Cool Air is not Emitted).

A/C Compressor and Air Thermo Sensor Circuit

IGNITION BLOWER AIR THERMO


(OUTLET SIDE) (INLET SIDE) SENSOR
BATTERY SWITCH (IG2) SWITCH

RELAY JUNCTION
BOX BLOCK

HEATER
A/C SWITCH, OUTSIDE/INSIDE CONTROL
AIR SELECTION DAMPER
JOINT CONTROL AND ILLUMINATION
CONNECTOR (2)

LOW- DUAL
PRESSURE
SIDE PRESSURE
A/C SWITCH
COMPRESSOR
RELAY

HIGH-
PRESSURE
SIDE

A/C
REFRIGERANT
TEMPERATURE
SWITCH

A/C
COMPRESSOR
CLUTCH ENGINE
CONTROL
MODULE

A/C
COMPRESSOR

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55-16 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTORS: A-13, A-29 CONNECTORS: A-25,


A-36
A-25(BR)

A-13(B)

A-29(B)

AC211262 AH A-36(B) AC211261AD

CONNECTOR: B-13X CONNECTORS: C-10, C-111, C-119, C-121

B-13X
C-10

C-121(Y)

C-119(Y)
C-111
AC211358AC AC211266 AJ

CONNECTORS: C-16, C-101, C-124, C-125 CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)
C-101(L)
C-211
C-125

C-16(B)
C-210
C-124

AC211265 AU AC402065 AB

• Malfunction of the A/C compressor clutch relay


.

TECHNICAL DESCRIPTION (COMMENT) • Malfunction of the A/C refrigerant temperature


If cool air is not distributed when the A/C switch is on, switch
the air thermo sensor or the A/C compressor clutch • Malfunction of the A/C compressor clutch
relay system may be defective. • Malfunction of the heater control
. • Malfunction of the ECM
TROUBLESHOOTING HINTS • The wiring harness or connectors may have
• Malfunction of the air thermo sensor loose, corroded, or damaged terminals, or termi-
• Malfunction of the dual pressure switch nals pushed back in the connector.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-17

STEP 1. Check the rear window defogger and


outside/inside air selection damper control motor
operation.
Q: Do the rear window defogger and outside/inside air
selection damper control motor work normally?
YES : Go to Step 2.
NO : Refer to Inspection procedure 9 "Malfunction of the
heater control power supply system" P.55-70.

STEP 2. Check the blower motor operation.


Q: Does the blower motor work normally?
YES : Go to Step 3.
NO : Refer to Inspection procedure 5 "Blower Fan and
motor does not turn P.55-38."

STEP 3. Check the A/C compressor.


Check the A/C compressor for compressor oil leaks.
Q: Is the check result satisfactory?
YES : Go to Step 4.
NO : Replace the A/C compressor or the expansion valve.

STEP 4. Check the A/C compressor clutch relay continuity.


A/C COMPRESSOR RELAY
Follow the table below to check the A/C compressor clutch
relay for continuity.
BATTERY VOLTAGE TESTER SPECIFIED
CONNECTION CONDITION
Not applied 1−4 Open circuit
• Connect terminal 2 to 1 − 4 Less than 2
the positive battery ohms
terminal
• Connect terminal 3 to
the negative battery
TRIANGLE MARK terminal

Q: Is the A/C compressor clutch relay in good condition?


1
1
X
2
4
YES : Go to Step 5.
3 4 NO : Replace the A/C compressor clutch relay. Check that
2 3
the A/C works normally.

FRONT OF
VEHICLE
AC211359AE

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55-18 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 5. Measure the voltage at A/C compressor connector


A-36.
CONNECTOR: A-36
(1) Disconnect A/C compressor connector A-36 and measure
the voltage at the harness side.
HARNESS SIDE
CONNECTOR
A-36
1

A-36(B) AC211261AB

CONNECTOR: C-121 HARNESS SIDE (2) Disconnect engine control module connector C-121, and
CONNECTOR ground terminal 8.
C-121 (3) Turn the ignition switch to the "ON" position.
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 242322 21 20 191817 16 15 14

C-121(Y)

AC211266 AE

CONNECTOR: C-121
(HARNESS SIDE)

AC310671AB

(4) Measure the voltage between terminal 1 and ground.


CONNECTOR A-36 • The measured value should be approximately 12 volts
(HARNESS SIDE)
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 16.
1 NO : Go to Step 6.

AC201110 AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-19

STEP 6. Measure the voltage at A/C compressor clutch


relay connector B-13X.
CONNECTOR: B-13X
(1) Disconnect A/C compressor connector B-13X and measure
the voltage at the relay box side.
(2) Turn the ignition switch to the "ON" position.
B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

(3) Measure the voltage between terminal 2 and ground.


CONNECTOR B-13X
(RELAY BOX SIDE)
• The measured value should be approximately 12 volts
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 9.
NO : Go to Step 7.

2 1
X
4 3 TRIANGLE
MARK
AC202854AC

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55-20 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 7. Check A/C compressor clutch relay connector


B-13X for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: B-13X
Q: Is A/C compressor clutch relay connector B-13X in
good condition?
YES : Go to Step 8.
B-13X NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
that the A/C works normally.

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

STEP 8. Check the wiring harness between A/C


compressor clutch relay connector B-13X (terminal 2) and
the ignition switch (IG2).
CONNECTOR: B-13X

B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-21
CONNECTORS: C-101, C-124
NOTE: Also check intermediate connector C-124, joint connec-
tor (2) C-101, junction block connectors C-210 and C-211. If
intermediate connector C-124, joint connector (2) C-101, or
C-101(L) junction block connectors C-210 or C-211 is loose, corroded or
damaged terminals, or terminals pushed back in the connec-
tor., repair or replace the connector as described in GROUP
00E, Harness Connector Inspection P.00E-2.
C-124
Q: Is the wiring harness between A/C compressor clutch
relay connector B-13X (terminal 2) and the ignition
switch (IG2) in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
HARNESS SIDE CONNECTOR
Malfunctions P.00-13.
C-101
NO : Repair the wiring harness. Check that the A/C works
11 10 9 8 7 6 5 4 3 2 1
normally.
22 21 20 19 18 17 16 15 14 13 12

C-124
1312 11 10 9 8 7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14

AC211307AB

CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)
C-211

C-210

HARNESS SIDE

C-210 C-211
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3

AC402066 AB

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55-22 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 9. Measure the voltage at A/C compressor clutch


relay connector B-13X.
CONNECTOR: B-13X
(1) Disconnect A/C compressor clutch relay connector B-13X
and measure the voltage at the relay box side.

B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

(2) Measure the voltage between terminal 1 and ground.


CONNECTOR B-13X • The measured value should be approximately 12 volts
(RELAY BOX SIDE)
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 12.
NO : Go to Step 10.

2 1
X
4 3 TRIANGLE
MARK
AC202857AC

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-23

STEP 10. Check A/C compressor clutch relay connector


B-13X for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: B-13X
Q: Is A/C compressor clutch relay connector B-13X in
good condition?
YES : Go to Step 11.
B-13X NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
that the A/C works normally.

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

STEP 11. Check the wiring harness between A/C


compressor clutch relay connector B-13X (terminal 1) and
the battery.
CONNECTOR: B-13X

B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

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55-24 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

NOTE: Also check intermediate connector A-29. If intermediate


CONNECTOR: A-29
connector A-29 is loose, corroded or has damaged terminals,
or terminals pushed back in the connector, repair or replace the
HARNESS SIDE connector as described in GROUP 00E, Harness Connector
CONNECTOR Inspection P.00E-2.
A-29
Q: Is the wiring harness between A/C compressor clutch
4 3 2 1
A-29(B)
relay connector B-13X (terminal 1) and the battery in
8 7 6 5
good condition?
YES : It can be assumed that this malfunction is intermittent.
AC211262 AC Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

STEP 12. Check A/C compressor clutch relay connector


B-13X and A/C compressor connector A-36 for loose,
corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: A-36
Q: Is A/C compressor clutch relay connector B-13X and
A/C compressor connector A-36 in good condition?
HARNESS SIDE YES : Go to Step 13.
CONNECTOR NO : Repair or replace the connector. Refer to GROUP
A-36
00E, Harness Connector Inspection P.00E-2. Check
1
that the A/C works normally.

A-36(B) AC211261AB

CONNECTOR: B-13X

B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-25

STEP 13. Check the wiring harness between A/C


compressor clutch relay connector B-13X (terminal 4) and
A/C compressor connector A-36 (terminal 1).
CONNECTOR: A-36

HARNESS SIDE
CONNECTOR
A-36
1

A-36(B) AC211261AB

CONNECTOR: B-13X

B-13X

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

CONNECTOR: A-13
NOTE: Also check intermediate connector A-13. If intermediate
connector A-13 is loose, corroded or has damaged terminals,
or terminals pushed back in the connector., repair or replace
the connector as described in GROUP 00E, Harness Connec-
HARNESS SIDE
CONNECTOR tor Inspection P.00E-2.
A-13(B)
A-13 Q: Is the wiring harness between A/C compressor clutch
4 3 2 1 relay connector B-13X (terminal 4) and A/C compressor
8 7 6 5
connector A-36 (terminal 1) in good condition?
YES : Go to Step 14.
AC211262 AF NO : Repair the wiring harness. Check that the A/C works
normally.

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55-26 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 14. Check engine control module connector C-121


and A/C compressor clutch relay connector B-13X for
loose, corroded or damaged terminals, or terminals
pushed back in the connector.
CONNECTOR: B-13X
Q: Are engine control module connector C-121 and A/C
compressor clutch relay connector B-13X in good
condition?
B-13X YES : Go to Step 15.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
that the A/C works normally.

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

CONNECTOR: C-121 HARNESS SIDE


CONNECTOR
C-121
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 242322 21 20 191817 16 15 14

C-121(Y)

AC211266 AE

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-27

STEP 15. Check the wiring harness between engine


control module connector C-121 (terminal 8) and A/C
compressor clutch relay connector B-13X (terminal 3).
CONNECTOR: B-13X
Q: Is the wiring harness between engine control module
connector C-121 (terminal 8) and A/C compressor
clutch relay connector B-13X (terminal 3) in good
B-13X condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

RELAY BOX SIDE


TRIANGLE MARK

2 1
B-13X
4 3

FRONT OF VEHICLE

AC211359AF

CONNECTOR: C-121 HARNESS SIDE


CONNECTOR
C-121
13 12 11 10 9 8 7 6 5 4 3 2 1
26 25 242322 21 20 191817 16 15 14

C-121(Y)

AC211266 AE

STEP 16. Check the A/C compressor clutch operation.


Connect the positive battery terminal to the compressor A/C
compressor clutch connector terminal and ground the battery
(-) terminal to the body of the compressor.
Q: Can the sound of the A/C compressor clutch (click) be
heard?
YES : Go to Step 17.
NO : Replace the compressor magnet clutch. Check that
the A/C works normally.
AC100769

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55-28 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 17. Check the refrigerant temperature switch.


CAUTION
Do not heat more than necessary.
(1) Dip the metal part of the refrigerant temperature switch into
engine oil and increase the oil temperature using a gas
burner or similar.

THERMOMETER

ENGINE OIL

AC203843 AB

(2) When the oil temperature reaches the standard value,


120˚C 150˚C check that voltage is supplied between the terminals.
(248˚F) (302˚F)
Standard value:
LESS THAN 2Ω ITEM TEMPERATURE
NO CONTINUITY
Less than 2 ohms Slightly below 150° C (302° F)
No continuity 150° C (302° F) or more
OIL TEMPRATURE

NOTE: When the oil temperature is 150° C (302° F) or more


AC100810 AF
and there is no continuity, the resistance will not be 2Ω or
lower until the oil temperature reduces to 120° C (248° F) or
less.
Q: Is the refrigerant temperature switch operating
properly?
YES : Go to Step 18.
NO : Replace the refrigerant temperature switch. Check
that the A/C works normally.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-29

STEP 18. Measure the voltage at heater control connector


C-16.
CONNECTOR: C-16
(1) Disconnect heater control connector C-16 and measure the
voltage at the relay box side.
(2) Turn the ignition switch to the "ON" position.
(3) Turn the blower switch to the "1(Lo)" position.
HARNESS SIDE C-16(B)
CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

(4) Measure the voltage between terminal 8 and ground.


CONNECTOR C-16 • The measured value should be approximately 12 volts
(HARNESS SIDE)
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 21.
NO : Go to Step 19.

8 7 6 5 4 3 2 1
1615 14 13 12 11 10 9
AC201124AC

STEP 19. Check blower switch connector C-125 and heater


control connector C-16 for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTORS: C-16, C-125
Q: Is blower switch connector C-125 and heater control
connector C-16 in good condition?
YES : Go to Step 20.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
C-125 that the A/C works normally.
C-16

HARNESS SIDE CONNECTOR


C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

C-125
3 2 1
6 5 4

AC211307AC

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55-30 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 20. Check the wiring harness between blower switch


connector C-125 (terminal 1) and heater control connector
C-16 (terminal 8).
CONNECTORS: C-16, C-125
Q: Is the wiring harness between blower switch connector
C-125 (terminal 1) and heater control connector C-16
(terminal 8) in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
C-125 Malfunctions P.00-13.
C-16 NO : Repair the wiring harness. Check that the A/C works
normally.

HARNESS SIDE CONNECTOR


C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

C-125
3 2 1
6 5 4

AC211307AC

STEP 21. Check the air thermos sensor (outlet side)


(1) Measure the resistance between air thermo sensor (outlet
side) terminal numbers 4 and 5 at two points or more.
(2) Check that the measured value corresponds with
approximately the shown value.
Q: Is the air thermos sensor (outlet side) in good
OUTLET SIDE
condition?
YES : Go to Step 22.
NO : Replace the air thermo sensor. Check that the A/C
works normally.

RESISTANCE
(kΩ) 25

20

15

10

5
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
TEMPERATURE ˚C (˚F)
AC100770AJ

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-31

STEP 22. Check the air thermo sensor (inlet side)


(1) Measure the resistance between air thermo sensor (inlet
side) terminal numbers 1 and 3 at two points or more.
(2) Check that the measured value corresponds with
approximately the shown value.
Q: Is the air thermo sensor (inlet side) in good condition?
YES : Go to Step 23.
NO : Replace the air thermo sensor. Check that the A/C
works normally.
INLET SIDE

RESISTANCE
(kΩ) 25

20

15

10

5
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
TEMPERATURE ˚C (˚F)
AC100770AK

STEP 23. Check air thermo sensor connector C-10 and


heater control connector C-16 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
CONNECTOR: C-10
Q: Are air thermo sensor connector C-10 and heater
control connector C-16 in good condition?
YES : Go to Step 24.
C-10 NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2. Check
CONNECTOR that the A/C works normally.
C-10
2 1
7 6 5 4 3

AC211266AG

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

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55-32 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 24. Check the wiring harness between air thermo


sensor connector C-10 (terminals 1, 3, 4 and 5) and heater
control connector C-16 (terminals 14, 16 and 13).
CONNECTOR: C-10
Q: Are the wiring harness between air thermo sensor
connector C-10 (terminals 1, 3, 4 and 5) and heater
control connector C-16 (terminals 14, 16 and 13) in good
condition?
C-10
HARNESS SIDE YES : Go to Step 25.
CONNECTOR NO : Repair the wiring harness. Check that the A/C works
C-10 normally.
2 1
7 6 5 4 3

AC211266AG

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

STEP 25. Check the dual pressure switch operation.


(1) Remove the dual pressure switch connector and connect
DUAL PRESSURE SWITCH the high/low pressure side terminals located on the harness
side as shown in the illustration.
(2) Install a gauge manifold to the high-pressure side service
valve of the refrigerant line. Refer to P.55-118.
(3) When the high/low pressure sides of the dual pressure
switch are at operation pressure (ON) the resistance should
less than two ohms between the terminals. If open circuit,
replace the switch.
ITEM SWITCH POSITION
OFF to ON ON to OFF
196 ± 20 2,940 ± 180 Low-pressure side 221 ± 20 196 ± 20
(28.4 ± 2.9) (426.7 ± 26.1) kPa (psi) (32.1 ± 2.9) (28.4 ± 2.9)
ON High-pressure side 2,350 ± 200 2,940 ± 180
kPa (psi) (341.4 ± 29.0) (426.7 ± 26.1)
OFF

221 ± 20 2,350 ± 200 Q: Is the dual pressure switch operating properly?


(32.1 ± 2.9) (341.4 ± 29.0)
YES : Go to Step 26.
kPa (psi)
AC211431AB
NO : Replace the dual pressure switch. Check that the A/C
works normally.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-33

STEP 26. Check dual pressure switch connector A-25 and


heater control connector C-16 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
CONNECTOR: A-25
Q: Are dual pressure switch connector A-25 and heater
control connector C-16 in good condition?
A-25(BR)
YES : Go to Step 27.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2. Check
CONNECTOR that the A/C works normally.
A-25
2 1

AC211261AC

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

STEP 27. Check the wiring harness between dual pressure


switch connector A-25 (terminal 1) and heater control
connector C-16 (terminal 4).
CONNECTOR: A-25

A-25(BR)

HARNESS SIDE
CONNECTOR
A-25
2 1

AC211261AC

CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

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55-34 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTOR: C-111
NOTE: Also check intermediate connector C-111 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector C-111 is damaged, repair
or replace the connector as described in GROUP 00E, Harness
HARNESS SIDE Connector Inspection P.00E-2.
CONNECTOR
C-111 Q: Is the wiring harness between dual pressure switch
5 4 3 2 1 connector A-25 (terminal 1) and heater control
13121110 9 8 7 6 connector C-16 (terminal 4) in good condition?
C-111 YES : Go to Step 28.
AC211266 AH NO : Repair the wiring harness. Check that the A/C works
normally.

STEP 28. Check dual pressure switch connector A-25 and


engine control module connector C-117 for loose,
corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: A-25
Q: Are dual pressure switch connector A-25 and engine
control module connector C-117 in good condition?
A-25(BR)
YES : Go to Step 29.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2. Check
CONNECTOR that the A/C works normally.
A-25
2 1

AC211261AC

CONNECTOR: C-117

HARNESS SIDE
CONNECTOR
C-117
77 76 75 JAE 74 73 72 71
90 89 88 8786 85 8483 82 81 807978
C-117(GR) 100 99 9897 96 95 94 93 92 91

AC505028AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-35

STEP 29. Check the wiring harness between dual pressure


switch connector A-25 (terminal 2) and engine control
module connector C-117 (terminal 83).
CONNECTOR: A-25

A-25(BR)

HARNESS SIDE
CONNECTOR
A-25
2 1

AC211261AC

CONNECTORS: C-111, C-117

C-117(GR)

C-111

HARNESS SIDE CONNECTOR

C-111
5 4 3 2 1
13121110 9 8 7 6

C-117
77 76 75 JAE 74 73 72 71
90 89 88 8786 85 8483 82 81 807978
100 99 9897 96 95 94 93 92 91

AC505030AC

CONNECTOR: C-124
NOTE: Also check intermediate connectors C-111 and C-124
for loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If intermediate connector C-111 or C-124
is damaged, repair or replace the connector as described in
GROUP 00E, Harness Connector Inspection P.00E-2.
HARNESS SIDE
Q: Is the wiring harness between dual pressure switch
CONNECTOR
C-124 connector A-25 (terminal 2) and engine control module
1312 11 10 9 8 7 6 5 4 3 2 1
C-124 connector C-117 (terminal 83) in good condition?
25 24 23 22 21 20 19 18 17 16 15 14 YES : Go to Step 30.
AC211265 CG NO : Repair the wiring harness. Check that the A/C works
normally.

TSB Revision
55-36 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 30. Check heater control connector C-16 and engine


control module connector C-119 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
CONNECTOR: C-16
Q: Are heater control connector C-16, engine control
module connector C-119 in good condition?
YES : Go to Step 31.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2. Check
C-16(B)
CONNECTOR that the A/C works normally.
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

CONNECTOR: C-119

HARNESS SIDE
CONNECTOR
C-119
47 46 45 JAE 44 43 42 41
59 58 57 5655 54 53 52 51 5049 48
C-119(GR) 68 67 66 65 64 63 62 61 60

AC505028AD

STEP 31. Check the wiring harness between heater control


connector C-16 (terminal 5) and engine control module
connector C-119 (terminal 65).
CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

CONNECTOR: C-119

HARNESS SIDE
CONNECTOR
C-119
47 46 45 JAE 44 43 42 41
59 58 57 5655 54 53 52 51 5049 48
C-119(GR) 68 67 66 65 64 63 62 61 60

AC505028AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-37
CONNECTOR: C-124
NOTE: Also check intermediate connector C-124 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector C-124 is damaged, repair
or replace the connector as described in GROUP 00E, Harness
Connector Inspection P.00E-2.
HARNESS SIDE
Q: Is the wiring harness between heater control connector
CONNECTOR
C-124 C-16 (terminal 5) and engine control module connector
1312 11 10 9 8 7 6 5 4 3 2 1
C-124 C-119 (terminal 65) in good condition?
25 24 23 22 21 20 19 18 17 16 15 14 YES : Go to Step 32.
AC211265 CG NO : Repair the wiring harness. Check that the A/C works
normally.

STEP 32. Check the refrigerant level.


Use the refrigerant recovery station to remove all of the refrig-
erant, and then calculate the amount of the refrigerant and
charge it.
Q: Is the refrigerant level correct?
YES : Go to Step 33.
NO : Correct the refrigerant level. (Refer to On-vehicle
Service P.55-93) Check that the A/C works normally.

STEP 33. Replace the heater control.


Q: Do the A/C work normally?
YES : No action is necessary and testing is complete.
NO : Replace the engine control module connector. Check
that the A/C works normally.

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55-38 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

INSPECTION PROCEDURE 5: Blower Fan and Motor does not Turn.

Blower Motor Circuit

AC212016

CONNECTOR: C-08 CONNECTORS: C-125, C-126

C-125

C-126
C-08

AC211266 AM AC211265AX

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-39
CONNECTORS: C-211, C-212, C-214, C-216
JUNCTION BLOCK (FRONT VIEW)
C-211
C-212(B)

C-214
C-216

AC402065 AC

TROUBLESHOOTING HINTS
.

TECHNICAL DESCRIPTION (COMMENT)


If the blower fan and motor does not turn when the • Malfunction of the blower relay
blower switch is operated, the blower switch may be • Malfunction of the blower switch
defective. • Malfunction of the blower motor
• The wiring harness or connectors may have
.
loose, corroded, or damaged terminals, or termi-
nals pushed back in the connector.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

STEP 1. Measure the voltage at blower motor connector


C-08.
CONNECTOR: C-08 HARNESS SIDE
(1) Disconnect blower motor connector C-08, and measure the
CONNECTOR voltage at the wiring harness side.
C-08 (2) Turn the ignition switch to the "ON" position.
1 (3) Turn the blower switch to the "HI" position.
2

C-08

AC211266 AK

(4) Measure the voltage between terminal 1 and ground.


CONNECTOR C-08 • The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 17.
1 NO : Go to Step 2.
2

AC211868 AB

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55-40 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 2. Check the blower relay continuity.


BLOWER RELAY
Follow the table below to check the blower relay for continuity.
BATTERY VOLTAGE TESTER SPECIFIED
CONNECTION CONDITION
Not applied 4−5 Open circuit
• Connect terminal 1 4−5 Less than 2 ohms
to the positive
battery terminal
• Connect terminal 3
to the negative
battery terminal

Q: Is the blower relay continuity in good condition?


YES : Go to Step 3.
5
1 2 3
4
NO : Replace the blower relay. The blower motor should
4 operate normally.
5 1 3

AC211366AB

STEP 3. Measure the voltage at blower relay connector


C-216.
CONNECTOR: C-216 (1) Disconnect blower relay connector C-216, and measure the
JUNCTION BLOCK (FRONT VIEW) voltage at the junction block side.
(2) Turn the ignition switch to the "ON" position.

JUNCTION BLOCK SIDE


C-216
C-216 3 2 1
4
5
AC402065AD

(3) Measure the voltage between terminal 1 and ground.


CONNECTOR C-216 • The measured value should be approximately 12 volts
(JUNCTION BLOCK SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 6.
NO : Go to Step 4.

3 2 1
4
5
AC201129AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-41

STEP 4. Check blower relay connector C-216 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-216 Q: Is blower relay connector C-216 in good condition?
JUNCTION BLOCK (FRONT VIEW) YES : Go to Step 5.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.
JUNCTION BLOCK SIDE
C-216
C-216 3 2 1
4
5
AC402065AD

STEP 5. Check the wiring harness between blower relay


connector C-216 (terminal 1) and the ignition switch (IG2).
CONNECTORS: C-211, C-216
JUNCTION BLOCK (FRONT VIEW)
C-211

C-216

HARNESS SIDE CONNECTOR


C-211
2 1
6 5 4 3

C-216
3 2 1
4
5

AC402066AC

NOTE: Also check junction block connector C-211 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-211 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between blower relay connector
C-216 (terminal 1) and the ignition switch (IG2) in good
condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
operate normally.

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55-42 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 6. Measure the resistance at blower relay connector


C-216.
CONNECTOR: C-216 (1) Disconnect connector C-216, and measure the resistance
JUNCTION BLOCK (FRONT VIEW) at the junction block side.

JUNCTION BLOCK SIDE


C-216
C-216 3 2 1
4
5
AC402065AD

(2) Measure the resistance value between terminal 3 and


ground.
CONNECTOR C-216
(JUNCTION BLOCK SIDE) • The measured value should be 2 ohms or less.
Q: Does the measured resistance value correspond with
this range?
YES : Go to Step 9.
3 2 1 NO : Go to Step 7.
4
5

AC201118AC

STEP 7. Check blower relay connector C-216 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-216 Q: Is blower relay connector C-216 in good condition?
JUNCTION BLOCK (FRONT VIEW) YES : Go to Step 8.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.
JUNCTION BLOCK SIDE
C-216
C-216 3 2 1
4
5
AC402065AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-43

STEP 8. Check the wiring harness between blower relay


connector C-216 (terminal 3) and ground.
CONNECTORS: C-214, C-216
JUNCTION BLOCK (FRONT VIEW)

C-214
C-216

HARNESS SIDE CONNECTOR


C-214

14 13 12 11 10 9 8 7 6 5 4 3 2 1

28 27 26 25 24 23 22 21 20 19 18 17 16 15

C-216
3 2 1
4
5
AC402066AD

NOTE: Also check junction block connector C-214 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-214 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between blower relay connector
C-216 (terminal 3) and ground in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
operate normally.

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55-44 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 9. Measure the voltage at blower relay connector


C-216.
CONNECTOR: C-216 (1) Disconnect blower relay connector C-216, and measure the
JUNCTION BLOCK (FRONT VIEW) voltage at the junction block side.

JUNCTION BLOCK SIDE


C-216
C-216 3 2 1
4
5
AC402065AD

(2) Measure the voltage between terminal 5 and ground.


CONNECTOR C-216 • The measured value should be approximately 12 volts
(JUNCTION BLOCK SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
3 2 1 YES : Go to Step 12.
4 NO : Go to Step 10.
5

AC201130AC

STEP 10. Check blower relay connector C-216 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-216 Q: Is blower relay connector C-216 in good condition?
JUNCTION BLOCK (FRONT VIEW) YES : Go to Step 11.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.
JUNCTION BLOCK SIDE
C-216
C-216 3 2 1
4
5
AC402065AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-45

STEP 11. Check the wiring harness between blower relay


connector C-216 (terminal 5) and fusible link (1).
CONNECTORS: C-212, C-216

C-212(B)

C-216

JUNCTION BLOCK (FRONT VIEW)


C-212

JUNCTION BLOCK (FRONT VIEW)


C-216
3 2 1
4
5
AC402066AE

CONNECTOR: C-126
NOTE: Also check intermediate connector C-126 and junction
block connector C-212 for loose, corroded, or damaged termi-
nals, or terminals pushed back in the connector. If intermediate
connector C-126 and junction block connector C-212 is dam-
aged, repair or replace the connector as described in GROUP
HARNESS SIDE
CONNECTOR
00E, Harness Connector Inspection P.00E-2.
C-126
C-126 Q: Is the wiring harness between blower relay connector
3 2 1
C-216 (terminal 5) and fusible link (1) in good condition?
YES : It can be assumed that this malfunction is intermittent.
AC211265 AV Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
operate normally.

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55-46 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 12. Check blower switch connector C-125 and


blower relay connector C-216 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
CONNECTOR: C-125
Q: Is blower switch connector C-125 and blower relay
connector C-216 in good condition?
YES : Go to Step 13.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2.The
CONNECTOR
C-125 C-125
blower motor should operate normally.
3 2 1
6 5 4

AC211265 AW

CONNECTOR: C-216
JUNCTION BLOCK (FRONT VIEW)

JUNCTION BLOCK SIDE


C-216
C-216 3 2 1
4
5
AC402065AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-47

STEP 13. Check the wiring harness between blower switch


connector C-125 (terminal 2) and blower relay connector
C-216 (terminal 4).
CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

CONNECTORS: C-211, C-216


JUNCTION BLOCK (FRONT VIEW)
C-211

C-216

HARNESS SIDE CONNECTOR


C-211
2 1
6 5 4 3

C-216
3 2 1
4
5

AC402066AC

NOTE: Also check junction block connector C-211 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-211 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between blower switch connector
C-125 (terminal 2) and blower relay connector C-216
(terminal 4) in good condition?
YES : Go to Step 14.
NO : Repair the wiring harness. The blower motor should
operate normally.

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55-48 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 14. Check the blower switch continuity.


Follow the table below to check the blower switch for continuity.
SWITCH TESTER CONNECTION SPECIFIED
POSITION (CONNECTOR A) CONDITION
0 (OFF) 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit
1 (LO) 1−2 Less than 2 ohms
2 (ML) 2−4 Less than 2 ohms
3 (MH) 2−5 Less than 2 ohms
AC100288
4 (HI) 2−6 Less than 2 ohms

Q: Is the blower switch continuity in good condition?


YES : Go to Step 15.
NO : Replace the blower switch. The blower motor should
operate normally.

STEP 15. Check blower switch connector C-125 and


blower motor connector C-08 for loose, corroded or
damaged terminals, or terminals pushed back in the
connector.
CONNECTOR: C-08 HARNESS SIDE
Q: Is blower switch connector C-125 and blower motor
CONNECTOR connector C-08 in good condition?
C-08 YES : Go to Step 16.
1 NO : Repair or replace the connector. Refer to GROUP
2
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.

C-08

AC211266 AK

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-49

STEP 16. Check the wiring harness between blower switch


connector C-125 (terminal 6) and blower motor connector
C-08 (terminal 1).
CONNECTOR: C-08 HARNESS SIDE
Q: Is the wiring harness between blower switch connector
CONNECTOR C-125 (terminal 6) and blower motor connector C-08
C-08 (terminal 1) in good condition?
1 YES : It can be assumed that this malfunction is intermittent.
2
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
C-08 operate normally.

AC211266 AK

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

STEP 17. Check the blower fan and motor operation.


When battery voltage is applied between the terminals, check
that the motor operates.
Q: Is the check result normal?
YES : Go to Step 18.
NO : Replace the blower motor. The blower motor should
operate normally.

AC100287

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55-50 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 18. Measure the resistance at blower motor


connector C-08.
CONNECTOR: C-08 HARNESS SIDE
(1) Disconnect blower motor connector C-08, and measure the
CONNECTOR voltage at the wiring harness side.
C-08
1
2

C-08

AC211266 AK

(2) Measure the resistance value between terminal 2 and


CONNECTOR C-08 ground.
(HARNESS SIDE) • The measured value should be 2 ohms or less.
Q: Does the measured resistance value correspond with
this range?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Go to Step 19.
AC101326AC

STEP 19. Check blower motor connector C-08 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-08 HARNESS SIDE
Q: Is blower motor connector C-08 in good condition?
CONNECTOR YES : Go to Step 20.
C-08 NO : Repair or replace the connector. Refer to GROUP
1 00E, Harness Connector Inspection P.00E-2.The
2
blower motor should operate normally.

C-08

AC211266 AK

STEP 20. Check the wiring harness between blower motor


connector C-08 (terminal 2) and ground.
CONNECTOR: C-08 HARNESS SIDE
Q: Is the wiring harness between blower motor connector
CONNECTOR C-08 (terminal 2) and ground in good condition?
C-08 YES : It can be assumed that this malfunction is intermittent.
1 Refer to GROUP 00, How to Cope with intermittent
2
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
operate normally.
C-08

AC211266 AK

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-51

INSPECTION PROCEDURE 6: Blower Air Volume cannot be Changed.

Blower Switch and Resistor Circuit

BLOWER
RELAY

BLOWER
SWITCH

RESISTOR

BLOWER
MOTOR

CONNECTORS: C-08, C-09 CONNECTOR: C-125

C-09 C-125

C-08

AC211266 AO AC211265 AY

. .

TECHNICAL DESCRIPTION (COMMENT)


If the blower air amount can not be changed when
the blower switch is operated, the blower switch may
be defective.
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55-52 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

TROUBLESHOOTING HINTS • The wiring harness or connectors may have


• Malfunction of the resistor loose, corroded, or damaged terminals, or termi-
• Malfunction of the blower switch nals pushed back in the connector

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

STEP 1. Check that the blower motor operates 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.
Q: Does the blower motor operate when the blower switch
is moved to the "HI" position?
YES : Go to STEP 4.
NO : Go to STEP 2.

STEP 2. Check blower switch connector C-125 and blower


motor connector C-08 for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: C-08 HARNESS SIDE
Q: Are blower switch connector C-125 and blower motor
CONNECTOR connector C-08 in good condition?
C-08 YES : Go to Step 3.
1 NO : Repair or replace the connector. Refer to GROUP
2
00E, Harness Connector Inspection P.00E-2.The
blower motor should operate normally.

C-08

AC211266 AK

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-53

STEP 3. Check the wiring harness between blower switch


connector C-125 (terminal 6) and blower motor connector
C-08 (terminal 1).
CONNECTOR: C-08 HARNESS SIDE
Q: Is the wiring harness between blower switch connector
CONNECTOR C-125 (terminal 6) and blower motor connector C-08
C-08 (terminal 1) in good condition?
1 YES : The blower motor should operate normally.
2
NO : Repair the wiring harness. The blower motor should
operate normally.

C-08

AC211266 AK

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

STEP 4. Check the resistor resistance value.


Use an ohmmeter to measure the resistance between the ter-
minals as indicated below. Check that the measured value is at
the standard value.
1 2 Standard value:
3 4
MEASUREMENT TERMINAL STANDARD VALUE Ω
Between terminals 2 and 4 (LO) 2.54
Between terminals 1 and 2 (ML) 1.24
AC211875 Between terminals 3 and 2 (MH) 0.6

Q: Is the measured value at the standard value?


YES : Go to Step 5.
NO : Replace the resistor. The blower motor should
operate normally.

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55-54 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 5. Check the blower switch continuity.


Follow the table below to check the blower switch for continuity.
SWITCH TESTER CONNECTION SPECIFIED
POSITION (CONNECTOR A) CONDITION
0 (OFF) 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit
1 (LO) 1−2 Less than 2 ohms
2 (ML) 2−4 Less than 2 ohms
3 (MH) 2−5 Less than 2 ohms
AC100288
4 (HI) 2−6 Less than 2 ohms

Q: Is the blower switch continuity in good condition?


YES : Go to Step 6.
NO : Replace the blower switch. The blower motor should
operate normally.

STEP 6. Check blower switch connector C-125 and resistor


connector C-09 for loose, corroded or damaged terminals,
or terminals pushed back in the connector.
CONNECTOR: C-09
Q: Are blower switch connector C-125 and resistor
connector C-09 in good condition?
HARNESS SIDE YES : Go to Step 7.
CONNECTOR NO : Repair or replace the connector. Refer to GROUP
C-09 00E, Harness Connector Inspection P.00E-2.The
2 1 blower motor should operate normally.
C-09 4 3

AC211266 AN

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-55

STEP 7. Check the wiring harness between blower switch


connector C-125 (terminals 1, 4 and 5) and resistor
connector C-09 (terminals 4, 1 and 3).
CONNECTOR: C-09
Q: Is the wiring harness between blower switch connector
C-125 (terminals 1, 4 and 5) and resistor connector C-09
(terminals 4, 1 and 3) in good condition?
HARNESS SIDE
CONNECTOR YES : Go to Step 8.
C-09 NO : Repair the wiring harness. The blower motor should
2 1 operate normally.
C-09 4 3

AC211266 AN

CONNECTOR: C-125

HARNESS SIDE
CONNECTOR
C-125 C-125
3 2 1
6 5 4

AC211265 AW

STEP 8. Check resistor connector C-09 and blower motor


connector C-08 for loose, corroded or damaged terminals,
or terminals pushed back in the connector.
Q: Are resistor connector C-09 and blower motor
CONNECTORS: C-08, C-09
connector C-08 in good condition?
YES : Go to Step 9.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. The
blower motor should operate normally.

C-09

C-08

HARNESS SIDE CONNECTOR

C-08
1
2

C-09
2 1
4 3

AC211308 AD

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55-56 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 9. Check the wiring harness between blower motor


connector C-08 (terminal 1) and resistor connector C-09
(terminal 2).
Q: Is the wiring harness between blower motor connector
CONNECTORS: C-08, C-09
C-08 (terminal 1) and resistor connector C-09 (terminal
2) in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. The blower motor should
C-09 operate normally.
C-08

HARNESS SIDE CONNECTOR

C-08
1
2

C-09
2 1
4 3

AC211308 AD

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-57

INSPECTION PROCEDURE 7: Defroster Function Does Not Operate.

Rear Window Defogger Circuit

IGNITION FUSIBLE
SWITCH (IG2) LINK 1

JUNCTION
BLOCK

REAR
WINDOW
DEFOGGER
RELAY

REAR WINDOW
DEFOGGER
HEATER CONTROL
REAR WINDOW
DEFOGGER SWITCH, ILL

TSB Revision
55-58 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTORS: C-16, C-126 CONNECTORS: C-211, C-212,


C-214, C-215, C-217
C-211
C-212(B)

C-16
C-215
C-126 C-214

C-217
AC211265AZ AC402065AE

CONNECTORS: F-06, F-16

F-06(B)
F-16

AC310422 AD

TROUBLESHOOTING HINTS
.

TECHNICAL DESCRIPTION (COMMENT)


If the rear window defogger does not operate when • Malfunction of the heater control
the rear window defogger switch is turned on, the • Malfunction of the rear window defogger relay
rear window defogger relay system may be defec- • The wiring harness or connectors may have
tive. loose, corroded, or damaged terminals, or termi-
nals pushed back in the connector.
.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

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 : Refer to Inspection procedure 9 "Malfunction of the
heater control Power Supply system" P.55-70.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-59

STEP 2. Measure the voltage at rear window defogger


connector F-16.
CONNECTOR: F-16 (1) Disconnect rear window defogger connector F-16, and
measure the voltage at the junction block side.
(2) Turn the ignition switch to the "ON" position.
F-16
(3) Turn the rear window defogger switch to the "ON" position.
HARNESS SIDE
CONNECTOR
F-16
1

AC310422AB

(4) Measure the voltage between terminal 1 and ground.


• The measured value should be approximately 12 volts
(battery positive voltage).
CONNECTOR : F-16 Q: Is the measured voltage approximately 12 volts?
(HARNESS SIDE) YES : Go to Step 14.
NO : Go to Step 3.

AC202846 AB

STEP 3. Check the rear window defogger relay continuity.


REAR WINDOW
Follow the table below to check the rear window defogger relay
DEFOGGER RELAY for continuity.
BATTERY VOLTAGE TESTER SPECIFIED
CONNECTION CONDITION
Not applied 4−5 Open circuit
• Connect terminal 1 to 4 − 5 Less than 2 ohms
the positive battery
terminal
• Connect terminal 3 to
the negative battery
terminal

Q: Is the rear window defogger relay in good condition?


5
3 2 1 4 YES : Go to Step 4.
4 NO : Replace the rear window defogger relay. The rear
1 3
5 window defogger system should work normally.

AC005495AD

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55-60 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 4. Measure the voltage at rear window defogger relay


connector C-215.
CONNECTOR: C-215 (1) Disconnect rear window defogger relay connector C-215,
JUNCTION BLOCK (FRONT VIEW) and measure the voltage at the junction block side.

JUNCTION BLOCK SIDE


C-215
C-215 3 2 1
4
5
AC402065 AF

(2) Measure the voltage between terminal 5 and ground.


CONNECTOR C-215
• The measured value should be approximately 12 volts
(JUNCTION BLOCK SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
3 2 1 YES : Go to Step 7.
4 NO : Go to Step 5.
5

AC201130 AE

STEP 5. Check rear window defogger relay connector


C-215 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: C-215 Q: Is rear window defogger relay connector C-215 in good
JUNCTION BLOCK (FRONT VIEW) condition?
YES : Go to Step 6.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. The
JUNCTION BLOCK SIDE rear window defogger system should work normally.
C-215
C-215 3 2 1
4
5
AC402065 AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-61

STEP 6. Check the wiring harness between rear window


defogger relay connector C-215 (terminal 5) and the
battery.
CONNECTORS: C-212, C-215
JUNCTION BLOCK (FRONT VIEW)

C-212(B)

C-215

HARNESS SIDE CONNECTOR


C-212

JUNCTION BLOCK SIDE


C-215
3 2 1
4
5

AC402066AF

CONNECTOR: C-126
NOTE: Also check junction block connector C-212 and inter-
mediate connector C-126 for loose, corroded, or damaged ter-
minals, or terminals pushed back in the connector. If junction
block connector C-212 and intermediate connector C-126 is
damaged, repair or replace the connector as described in
HARNESS SIDE
CONNECTOR
GROUP 00E, Harness Connector Inspection P.00E-2.
C-126
C-126 Q: Is the wiring harness between rear window defogger
3 2 1
relay connector C-215 (terminal 5) and the battery in
good condition?
AC211265 AV YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the rear
window defogger system works normally.

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55-62 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 7. Measure the voltage at rear window defogger relay


connector C-215.
CONNECTOR: C-215 (1) Disconnect rear window defogger relay connector C-215,
JUNCTION BLOCK (FRONT VIEW) and measure the voltage at the junction block side.
(2) Turn the ignition switch to the "ON" position.

JUNCTION BLOCK SIDE


C-215
C-215 3 2 1
4
5
AC402065 AF

(3) Measure the voltage between terminal 1 and ground.


CONNECTOR C-215 • The measured value should be approximately 12 volts
(JUNCTION BLOCK SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 10.
NO : Go to Step 8.

3 2 1
4
5
AC201129AE

STEP 8. Check rear window defogger relay connector


C-215 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: C-215 Q: Is rear window defogger relay connector C-215 in good
JUNCTION BLOCK (FRONT VIEW) condition?
YES : Go to Step 9.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
JUNCTION BLOCK SIDE that the rear window defogger system works normally.
C-215
C-215 3 2 1
4
5
AC402065 AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-63

STEP 9. Check the wiring harness between rear window


defogger relay connector C-215 (terminal 1) and ignition
switch (IG2).
CONNECTORS: C-211, C-215
JUNCTION BLOCK (FRONT VIEW)
C-211

C-215

HARNESS SIDE CONNECTOR


C-211
2 1
6 5 4 3

JUNCTION BLOCK SIDE


C-215
3 2 1
4
5
AC402066AG

NOTE: Also check junction block connector C-211 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-211 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between rear window defogger
relay connector C-215 (terminal 1) and ignition switch
(IG2) in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the rear
window defogger system works normally.

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55-64 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 10. Check rear window defogger relay connector


C-215 and rear window defogger connector F-16 for loose,
corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-215 Q: Are rear window defogger relay connector C-215 and
JUNCTION BLOCK (FRONT VIEW) rear window defogger connector F-16 in good
condition?
YES : Go to Step 11.
NO : Repair or replace the connector. Refer to GROUP
JUNCTION BLOCK SIDE 00E, Harness Connector Inspection P.00E-2. Check
C-215 that the rear window defogger system works normally.
C-215 3 2 1
4
5
AC402065 AF

CONNECTOR: F-16

F-16

HARNESS SIDE
CONNECTOR
F-16
1

AC310422AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-65

STEP 11. Check the wiring harness between rear window


defogger relay connector C-215 (terminal 4) and rear
window defogger connector F-16 (terminal 1).
CONNECTORS: C-215, C-217
JUNCTION BLOCK (FRONT VIEW)

C-215

C-217

JUNCTION BLOCK SIDE


C-215
3 2 1
4
5

HARNESS SIDE CONNECTOR


C-217
7 6 5 4 3 2 1
15 1413 12 11 10 9 8
AC402066AH

CONNECTOR: F-16

F-16

HARNESS SIDE
CONNECTOR
F-16
1

AC310422AB

NOTE: Also check junction block connector C-217 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-217 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between rear window defogger
relay connector C-215 (terminal 4) and rear window
defogger connector F-16 (terminal 1) in good condition?
YES : Go to Step 12.
NO : Repair or replace the wiring harness. Refer to
GROUP 00E, Harness Connector Inspection
P.00E-2. Check that the rear window defogger
system works normally.

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55-66 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 12. Check rear window defogger relay connector


C-215 and heater control connector C-16 for loose,
corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-16
Q: Are rear window defogger relay connector C-215 and
heater control connector C-16 in good condition?
YES : Go to Step 13.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE 00E, Harness Connector Inspection P.00E-2. Check
C-16(B)
CONNECTOR that the rear window defogger system works normally.
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

CONNECTOR: C-215
JUNCTION BLOCK (FRONT VIEW)

JUNCTION BLOCK SIDE


C-215
C-215 3 2 1
4
5
AC402065 AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-67

STEP 13. Check the wiring harness between rear window


defogger relay connector C-215 (terminal 3) and heater
control connector C-16 (terminal 1).
CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

CONNECTORS: C-214, C-215


JUNCTION BLOCK (FRONT VIEW)

C-215
C-214

HARNESS SIDE CONNECTOR


C-214

14 13 12 11 10 9 8 7 6 5 4 3 2 1

28 27 26 25 24 23 22 21 20 19 18 17 16 15

JUNCTION BLOCK SIDE


C-215
3 2 1
4
5
AC402066AI

NOTE: Also check junction block connector C-214 for loose,


corroded, or damaged terminals, or terminals pushed back in
the connector. If junction block connector C-214 is damaged,
repair or replace the connector as described in GROUP 00E,
Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between rear window defogger
relay connector C-215 (terminal 3) and heater control
connector C-16 (terminal 1) in good condition?
YES : Replace the heater control. The rear window
defogger should operate normally.
NO : Repair or replace the wiring harness. Refer to
GROUP 00E, Harness Connector Inspection
P.00E-2. Check that the rear window defogger
system works normally.

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55-68 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 14. Measure at rear window defogger connector F-06


in order to check the ground circuit to the rear window
defogger connector.
CONNECTOR: F-06 (1) Disconnect rear window defogger connector F-06, and
measure at the wiring harness side.
F-06(B)

HARNESS SIDE
CONNECTOR
F-06
1

AC310422 AC

(2) Measure the resistance value between terminal 1 and


ground.
• The measured value should be 2 ohms or less.
CONNECTOR : F-06 Q: Does the measured resistance value correspond with
(HARNESS SIDE) this range?
YES : Go to Step 17.
NO : Go to Step 15.
1

AC202847 AB

STEP 15. Check rear window defogger connector F-06 for


loose, corroded or damaged terminals, or terminals
pushed back in the connector.
CONNECTOR: F-06 Q: Is rear window defogger connector F-06 in good
condition?
F-06(B) YES : Go to Step 16.
NO : Repair or replace the connector. Refer to GROUP
HARNESS SIDE
CONNECTOR
00E, Harness Connector Inspection P.00E-2. Check
that the rear window defogger system works normally.
F-06
1

AC310422 AC

STEP 16. Check the wiring harness between rear window


defogger connector F-06 (terminal 1) and ground.
CONNECTOR: F-06 Q: Is the wiring harness between rear window defogger
connector F-06 (terminal 1) and ground in good
F-06(B) condition?
YES : It can be assumed that this malfunction is intermittent.
HARNESS SIDE
CONNECTOR
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
F-06
NO : Repair or replace the wiring harness. Refer to
1
GROUP 00E, Harness Connector Inspection
P.00E-2. Check that the rear window defogger
AC310422 AC system works normally.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-69

STEP 17. Check the rear window defogger.


(1) Let the engine run at 2,000 r/min, and check the printed
heater with the battery fully charged.
(2) Turn on the rear window defogger switch, and use a
voltmeter to measure the voltage in each printed heater at
A middle point A on the rear window glass.
• The value should be approximately 6 volts.
Q: Does the rear window defogger work normally?
YES : Check that the rear window defogger system works
normally.
NO : Repeat from Step 1.

NORMAL CHARACTERISTIC CURVE


VOLTAGE

12 V

A (CENTER POINT)
6V APPROXIMATELY
6V

0V
POSITIVE PRINTED NEGATIVE
TERMINAL HEATER TERMINAL
LINE

ABNORMAL CHARACTERISTIC CURVE


VOLTAGE

12 V OPENCIRCUIT
POINT

6V

0V
POSITIVE PRINTED NEGATIVE
TERMINAL HEATER TERMINAL
LINE
AC100595 AB

INSPECTION PROCEDURE 8: Rear window defogger Timer Function does not Operate.
. .

TECHNICAL DESCRIPTION (COMMENT) TROUBLESHOOTING HINTS


Turn ON the rear window defogger switch. If the rear • Malfunction of the heater control
window defogger does not shut off after roughly 11
minutes, then the rear window defogger timer is mal-
functioning.

DIAGNOSIS
Replace the A/C-ECU.

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55-70 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

INSPECTION PROCEDURE 9: Malfunction of the heater control Power Supply System.

Heater Control Power Supply Circuit

IGNITION
SWITCH (IG2)

JUNCTION
BLOCK

HEATER CONTROL
A/C SWITCH, OUTSIDE/INSIDE
AIR SELECTION
DAMPER CONTROL AND ILL

JOINT
CONNECTOR (3)

CONNECTOR: C-06 CONNECTOR: C-16

C-06

C-16

AC211266 AS AC211265 CH

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-71
CONNECTORS: C-211, C-214
JUNCTION BLOCK (FRONT VIEW)
C-211

C-214

AC402065 AG

TROUBLESHOOTING HINTS
.

TECHNICAL DESCRIPTION (COMMENT)


The heater control power system may be defective if • Malfunction of the heater control
the A/C, rear window defogger, and outside/inside air • The wiring harness or connectors may have
selection damper motor all do not operate normally. loose, corroded, or damaged terminals, or termi-
nals pushed back in the connector
.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

STEP 1. Measure the voltage at heater control connector


C-16.
CONNECTOR: C-16
(1) Disconnect heater control connector C-16 and measure the
voltage at the harness side.
(2) Turn the ignition switch to the "ON" position.

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

(3) Measure the voltage between terminal 10 and ground.


CONNECTOR C-16
• The measured value should be approximately 12 volts
(HARNESS SIDE)
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 4.
NO : Go to Step 2.
8 7 6 5 4 3 2 1
1615 14 13 12 11 10 9

AC201125AC

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55-72 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 2. Check heater control connector C-16 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-16
Q: Is heater control connector C-16 in good condition?
YES : Go to Step 3.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
HARNESS SIDE that the A/C works normally.
C-16(B)
CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

STEP 3. Check the wiring harness between heater control


connector C-16 (terminal 10) and the ignition switch (IG2).
CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

CONNECTORS: C-211, C-214 NOTE: Also check junction block connectors C-214 and C-211
JUNCTION BLOCK (FRONT VIEW) for loose, corroded, or damaged terminals, or terminals pushed
C-211 back in the connector. If junction block connectors C-214 and
C-211 is damaged, repair or replace the connector as
described in GROUP 00E, Harness Connector Inspection
P.00E-2.
Q: Is the wiring harness between heater control connector
C-16 (terminal 10) and the ignition switch (IG2) in good
C-214
condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
HARNESS SIDE CONNECTOR
Malfunctions P.00-13.
C-211
NO : Repair the wiring harness. Check that the A/C works
2 1
6 5 4 3 normally.

C-214

14 13 12 11 10 9 8 7 6 5 4 3 2 1

28 27 26 25 24 23 22 21 20 19 18 17 16 15

AC402066AJ

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-73

STEP 4. Measure the resistance at heater control


connector C-16.
CONNECTOR: C-16
(1) Disconnect heater control connector C-16, and measure at
the wiring harness side.

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

(2) Measure the resistance between terminal 12 and ground.


CONNECTOR C-16 • The measured value should be 2 ohms or less.
(HARNESS SIDE)
Q: Does the measured resistance value correspond with
this range?
8 7 6 5 4 3 2 1 YES : Replace the heater control, and check that the A/C
1615 14 13 12 11 10 9 works normally.
NO : Go to Step 5.

AC201115AC

STEP 5. Check heater control connector C-16 for loose,


corroded or damaged terminals, or terminals pushed back
in the connector.
CONNECTOR: C-16
Q: Is heater control connector in good condition?
YES : Go to Step 6.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
HARNESS SIDE that the A/C works normally.
C-16(B)
CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

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55-74 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 6. Check the wiring harness between heater control


connector C-16 (terminal 12) and the ground.
CONNECTOR: C-16

HARNESS SIDE C-16(B)


CONNECTOR
C-16
8 7 6 5 4 3 2 1
16 15 14 13 121110 9

AC211265 AC

HARNESS SIDE NOTE: Also check joint connector (3) connectors C-06 for
CONNECTOR: C-06
CONNECTOR loose, corroded, or damaged terminals, or terminals pushed
C-06 C-06 back in the connector. If joint connector (3) connectors C-06 is
damaged, repair or replace the connector as described in
11 10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12
GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between heater control connector
C-16 (terminal 12) and the ground in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
AC211266 AR Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-75

INSPECTION PROCEDURE 10: Condenser Fan does not Operate.

Condenser Fan Motor Circuit

IGNITION
BATTERY SWITCH (IG2)

JUNCTION
BLOCK
RELAY
BOX

JOINT
CONNECTOR (2)

CONDENSER CONDENSER
FAN CONTROL FAN CONTROL
RELAY (HIGH) RELAY (LOW)

CONDENSER
FAN MOTOR

ENGINE
CONTROL
MODUKE

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55-76 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTOR: A-06X, A-07X CONNECTOR: A-29

A-07X

A-06X
A-29 (B)

AC311061AD AC311066AC

CONNECTORS: A-34, A-35 CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)

C-211

A-34 (B) C-210

A-35 (GR)
AC311059 AD AC402065 AB

CONNECTORS: C-101, C-129

C-101 (L)

C-129

AC311068 AB

TROUBLESHOOTING HINTS
.

TECHNICAL DESCRIPTION (COMMENT)


If the condenser fan does not operate, the condenser • Malfunction of the heater control
fan relay circuit system or the condenser fan motor • The wiring harness or connectors may have
may be defective.. loose, corroded, or damaged terminals, or termi-
nals pushed back in the connector
.

DIAGNOSIS
Required Special Tools:
• MB991223: Harness Set
• MB992006: Extra Fine Probe

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-77

STEP 1. Measure the voltage at condenser fan motor


connector A-34.
CONNECTOR: A-34 (1) Disconnect condenser fan motor connector A-34 and
measure the voltage at the harness side.

HARNESS SIDE

A-34 (B)

AC311059 AC

CONNECTOR: C-121 (2) Disconnect engine-ECU connector C-121, and earth


HARNESS SIDE terminal 30.
8 7 6 5 JAE 4 3 2 1 (3) Turn the ignition switch to the "ON" position.
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

CONNECTOR: C-121
(HARNESS SIDE)

AC504964 AD

(4) Measure the voltage between terminal 1 and ground.


CONNECTOR A-34 • The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 12.
NO : Go to Step 2.

AC209365LA

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55-78 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 2. Measure the voltage at condenser fan control


relay (high) connector A-07X.
CONNECTOR: A-07X (1) Disconnect condenser fan control relay (high) connector
A-07X, and measure the voltage at the junction block side.
(2) Turn the ignition switch to the "ON" position.

RELAY BOX SIDE

AC311061AB

(3) Measure the voltage between terminal 2 and ground.


CONNECTOR A-07X
(RELAY BOX SIDE)
• The measured value should be approximately 12 volts
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 5.
NO : Go to Step 3.

AC209365LC

STEP 3. Check condenser fan control relay (high)


connector A-07X for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: A-07X Q: Is condenser fan control relay (high) connector A-07X in
good condition?
YES : Go to Step 4.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
that the A/C works normally.
RELAY BOX SIDE

AC311061AB

STEP 4. Check the wiring harness between condenser fan


control relay (high) connector A-07X (terminal 2) and the
ignition switch (IG2).
CONNECTOR: A-07X

RELAY BOX SIDE

AC311061AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-79
CONNECTOR: C-101, C-129
NOTE: Also check junction block connectors C-211, C-210,
intermediate connector C-129 and joint connector C-101 for
C-101 (L) loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If junction block connectors C-211,
C-210, intermediate connector C-129 or joint connector C-101
is damaged, repair or replace the connector as described in
C-129 GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between condenser fan control
relay (high) connector A-07X (terminal 2) and the
ignition switch (IG2) in good condition?
YES : It can be assumed that this malfunction is intermittent.
HARNESS SIDE Refer to GROUP 00, How to Cope with intermittent
C-101 Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

HARNESS SIDE
C-129

AC311065AB

CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)
C-211

C-210

HARNESS SIDE

C-210 C-211
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3

AC402066 AB

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55-80 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 5. Measure the voltage at condenser fan control


relay (high) connector A-07X.
CONNECTOR: A-07X (1) Disconnect condenser fan control relay (high) connector
A-07X, and measure the voltage at the junction block side.

RELAY BOX SIDE

AC311061AB

(2) Measure the voltage between terminal 4 and ground.


• The measured value should be approximately 12 volts
CONNECTOR A-07X
(battery positive voltage).
(RELAY BOX SIDE)
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 8.
NO : Go to Step 6.

AC209365LD

STEP 6. Check condenser fan control relay (high)


connector A-07X for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: A-07X Q: Is condenser fan control relay (high) connector A-07X in
good condition?
YES : Go to Step 7.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
that the A/C works normally.
RELAY BOX SIDE

AC311061AB

STEP 7. Check the wiring harness between condenser fan


control relay (high) connector A-07X (terminal 4) and the
battery.
CONNECTOR: A-07X Q: Is the wiring harness between condenser fan control
relay (high) connector A-07X (terminal 4) and the battery
in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
RELAY BOX SIDE NO : Repair the wiring harness. Check that the A/C works
normally.

AC311061AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-81

STEP 8. Check condenser fan control relay (high)


connector A-07X and condenser fan motor connector A-34
for loose, corroded or damaged terminals, or terminals
pushed back in the connector.
CONNECTOR: A-07X Q: Is condenser fan control relay (high) connector A-07X
and condenser fan motor connector A-34 in good
condition?
YES : Go to Step 9.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
RELAY BOX SIDE that the A/C works normally.

AC311061AB

CONNECTOR: A-34

HARNESS SIDE

A-34 (B)

AC311059 AC

STEP 9. Check the wiring harness between condenser fan


control relay (high) connector A-07X (terminal 1) and
condenser fan motor connector A-34 (terminal 1).
CONNECTOR: A-07X Q: Is the wiring harness between condenser fan control
relay (high) connector A-07X (terminal 1) and condenser
fan motor A-34 connector (terminal 1) in good
condition?
YES : Go to Step 10.
NO : Repair the wiring harness. Check that the A/C works
RELAY BOX SIDE normally.

AC311061AB

CONNECTOR: A-34

HARNESS SIDE

A-34 (B)

AC311059 AC

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55-82 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 10. Check condenser fan control relay (high)


connector A-07X and engine control module connector
C-121 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: A-07X Q: Is condenser fan control relay (high) connector A-07X
and engine control module connector C-121 in good
condition?
YES : Go to Step 11.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
RELAY BOX SIDE that the A/C works normally.

AC311061AB

CONNECTOR: C-121
HARNESS SIDE
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

STEP 11. Check the wiring harness between condenser fan


control relay (high) connector A-07X (terminal 3) and
engine control module connector C-121 (terminal 30).
CONNECTOR: A-07X

RELAY BOX SIDE

AC311061AB

CONNECTOR: C-121
HARNESS SIDE
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-83
CONNECTOR: A-29 NOTE: Also check intermediate connector A-29 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector A-29 is damaged, repair or
replace the connector as described in GROUP 00E, Harness
Connector Inspection P.00E-2.
A-29 (B) Q: Is the wiring harness between condenser fan control
relay (high) connector A-07X (terminal 3) and engine
control module connector C-121 (terminal 30) in good
condition?
AC311066AB YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

TSB Revision
55-84 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 12. Measure the voltage at condenser fan motor


connector A-34.
CONNECTOR: A-34 (1) Disconnect condenser fan motor connector A-34 and
measure the voltage at the harness side.

HARNESS SIDE

A-34 (B)

AC311059 AC

CONNECTOR: C-121 (2) Disconnect engine-ECU connector C-121, and earth


HARNESS SIDE terminal 31.
8 7 6 5 JAE 4 3 2 1 (3) Turn the ignition switch to the "ON" position.
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

CONNECTOR: C-121
(HARNESS SIDE)

AC504964 AE

(4) Measure the voltage between terminal 2 and ground.


CONNECTOR A-34 • The measured value should be approximately 12 volts
(HARNESS SIDE) (battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 23.
NO : Go to Step 13.

AC209365 LE

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-85

STEP 13. Measure the voltage at condenser fan control


relay (low) connector A-06X.
CONNECTOR: A-06X (1) Disconnect condenser fan control relay (low) connector
A-06X, and measure the voltage at the junction block side.
(2) Turn the ignition switch to the "ON" position.

RELAY BOX SIDE

AC311061AC

(3) Measure the voltage between terminal 2 and ground.


CONNECTOR A-06X
(RELAY BOX SIDE)
• The measured value should be approximately 12 volts
(battery positive voltage).
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 16.
NO : Go to Step 14.

AC209365LF

STEP 14. Check condenser fan control relay (low)


connector A-06X for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: A-06X Q: Is condenser fan control relay (low) connector A-06X in
good condition?
YES : Go to Step 15.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
that the A/C works normally.
RELAY BOX SIDE

AC311061AC

STEP 15. Check the wiring harness between condenser fan


control relay (low) connector A-06X (terminal 2) and the
ignition switch (IG2).
CONNECTOR: A-06X

RELAY BOX SIDE

AC311061AC

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55-86 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTOR: C-101, C-129


NOTE: Also check junction block connectors C-211, C-210,
intermediate connector C-129 and joint connector C-101 for
C-101 (L) loose, corroded, or damaged terminals, or terminals pushed
back in the connector. If junction block connectors C-211,
C-210, intermediate connector C-129 or joint connector C-101
is damaged, repair or replace the connector as described in
C-129 GROUP 00E, Harness Connector Inspection P.00E-2.
Q: Is the wiring harness between condenser fan control
relay (low) connector A-06X (terminal 2) and the ignition
switch (IG2) in good condition?
YES : It can be assumed that this malfunction is intermittent.
HARNESS SIDE Refer to GROUP 00, How to Cope with intermittent
C-101 Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

HARNESS SIDE
C-129

AC311065AB

CONNECTORS: C-210, C-211


JUNCTION BLOCK (FRONT VIEW)
C-211

C-210

HARNESS SIDE

C-210 C-211
6 5 4 3 2 1 2 1
14 13 12 11 10 9 8 7 6 5 4 3

AC402066 AB

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-87

STEP 16. Measure the voltage at condenser fan control


relay (low) connector A-06X.
CONNECTOR: A-06X (1) Disconnect condenser fan control relay (low) connector
A-06X, and measure the voltage at the junction block side.

RELAY BOX SIDE

AC311061AC

(2) Measure the voltage between terminal 4 and ground.


• The measured value should be approximately 12 volts
CONNECTOR A-06X
(battery positive voltage).
(RELAY BOX SIDE)
Q: Is the measured voltage approximately 12 volts?
YES : Go to Step 19.
NO : Go to Step 17.

AC209365LG

STEP 17. Check condenser fan control relay (low)


connector A-06X for loose, corroded or damaged
terminals, or terminals pushed back in the connector.
CONNECTOR: A-06X Q: Is condenser fan control relay (low) connector A-06X in
good condition?
YES : Go to Step 18.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
that the A/C works normally.
RELAY BOX SIDE

AC311061AC

STEP 18. Check the wiring harness between condenser fan


control relay (low) connector A-06X (terminal 4) and the
battery.
CONNECTOR: A-06X Q: Is the wiring harness between condenser fan control
relay (low) connector A-06X (terminal 4) and the battery
in good condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
RELAY BOX SIDE NO : Repair the wiring harness. Check that the A/C works
normally.

AC311061AC

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55-88 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

STEP 19. Check condenser fan control relay (low)


connector A-06X and condenser fan motor connector A-34
for loose, corroded or damaged terminals, or terminals
pushed back in the connector.
CONNECTOR: A-06X Q: Is condenser fan control relay (low) connector A-06X
and condenser fan motor connector A-34 in good
condition?
YES : Go to Step 20.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
RELAY BOX SIDE that the A/C works normally.

AC311061AC

CONNECTOR: A-34

HARNESS SIDE

A-34 (B)

AC311059 AC

STEP 20. Check the wiring harness between condenser fan


control relay (high) connector A-06X (terminal 1) and
condenser fan motor connector A-34 (terminal 1).
CONNECTOR: A-06X Q: Is the wiring harness between condenser fan control
relay (high) connector A-06X (terminal 1) and condenser
fan motor A-34 connector (terminal 1) in good
condition?
YES : Go to Step 21.
NO : Repair the wiring harness. Check that the A/C works
RELAY BOX SIDE normally.

AC311061AC

CONNECTOR: A-34

HARNESS SIDE

A-34 (B)

AC311059 AC

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-89

STEP 21. Check condenser fan control relay (low)


connector A-06X and engine control module connector
C-121 for loose, corroded or damaged terminals, or
terminals pushed back in the connector.
CONNECTOR: A-06X Q: Is condenser fan control relay (low) connector A-06X
and engine control module connector C-121 in good
condition?
YES : Go to Step 22.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2.Check
RELAY BOX SIDE that the A/C works normally.

AC311061AC

CONNECTOR: C-121
HARNESS SIDE
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

STEP 22. Check the wiring harness between condenser fan


control relay (low) connector A-06X (terminal 3) and engine
control module connector C-121 (terminal 31).
CONNECTOR: A-06X

RELAY BOX SIDE

AC311061AC

CONNECTOR: C-121
HARNESS SIDE
8 7 6 5 JAE 4 3 2 1
23 2221 20 19 18 17 16 15 14 13 12 11 10 9
3534 33 32 31 30 29 2827 26 25 24

C-121 (GR)

AC505028AF

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55-90 HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS

CONNECTOR: A-29 NOTE: Also check intermediate connector A-29 for loose, cor-
roded, or damaged terminals, or terminals pushed back in the
connector. If intermediate connector A-29 is damaged, repair or
replace the connector as described in GROUP 00E, Harness
Connector Inspection P.00E-2.
A-29 (B) Q: Is the wiring harness between condenser fan control
relay (low) connector A-06X (terminal 3) and engine
control module connector C-121 (terminal 31) in good
condition?
AC311066AB YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.

STEP 23. Measure the resistance at condenser fan motor


connector A-35.
CONNECTOR: A-35 (1) Disconnect heater condenser fan motor connector A-35,
and measure at the wiring harness side.

HARNESS SIDE

A-35 (GR)
AC311059AC

(2) Measure the resistance between terminal 2 and ground.


CONNECTOR A-35 • The measured value should be 2 ohms or less.
(HARNESS SIDE)
Q: Does the measured resistance value correspond with
this range?
YES : Replace the engine control module, and check that
the A/C works normally.
NO : Go to Step 24.

AC402166AB

STEP 24. Check condenser fan motor connector A-35 for


loose, corroded or damaged terminals, or terminals
pushed back in the connector.
CONNECTOR: A-35 Q: Is condenser fan motor connector A-35 connector in
good condition?
YES : Go to Step 25.
NO : Repair or replace the connector. Refer to GROUP
00E, Harness Connector Inspection P.00E-2. Check
HARNESS SIDE that the A/C works normally.

A-35 (GR)
AC311059AC

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HEATER, AIR CONDITIONING AND VENTILATION
MANUAL A/C DIAGNOSIS
55-91

STEP 25. Check the wiring condenser fan motor connector


A-35 (terminal 2) and the ground.
CONNECTOR: A-35 Q: Is the wiring harness between condenser fan motor
connector A-35 (terminal 2) and the ground in good
condition?
YES : It can be assumed that this malfunction is intermittent.
Refer to GROUP 00, How to Cope with intermittent
HARNESS SIDE Malfunctions P.00-13.
NO : Repair the wiring harness. Check that the A/C works
normally.
A-35 (GR)
AC311059AC

CHECK AT ECU TERMINAL


M1552010300624

1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16

AC100607A

TERMINAL CHECK ITEM CHECKING REQUIREMENT NORMAL CONDITION


NO.
1 Rear window defogger relay Rear window defogger switch: 0V
ON
Rear window defogger switch: Battery positive voltage
OFF
2 Outside/inside air selection When the damper is moved to 0V
damper motor (outside air) the inside air recirculation
position
When the damper is moved to Battery positive voltage
the outside air inside air intake
position
3 Outside/inside air selection When the damper is moved to Battery positive voltage
damper motor (inside air) the inside air recirculation
position
When the damper is moved to 0V
the outside air inside air intake
position
4 Output to the ECM (A/C1) A/C stopped 0V
A/C switch: ON, blower switch: Battery positive voltage
ON
5 Output to the ECM (A/C2) When the A/C is under low load Battery positive voltage
When the A/C is under high 0V
load
6 Power supply to the A/C Lighting switch: ON Battery positive voltage
illumination
7 - - -
8 Blower switch (low) blower switch: 1 Battery positive voltage

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55-92 HEATER, AIR CONDITIONING AND VENTILATION
SPECIAL TOOLS

TERMINAL CHECK ITEM CHECKING REQUIREMENT NORMAL CONDITION


NO.
9 - - -
10 Power supply to the ignition Ignition switch: ON Battery positive voltage
switch (IG2)
11 Ground to the A/C illumination Always 0V
12 Ground Always 0V
13 Air thermo sensor (outlet side) Sensor probe temperature 2.2 V
25° C (77° F) 1.5k Ω
14 Air thermo sensor (inlet side) Sensor probe temperature 2.2 V
25° C (77° F) 1.5k Ω
15 - - -
16 Ground to the air thermo sensor Always 0V

SPECIAL TOOLS
M1552000600538

TOOL TOOL NUMBER SUPERSESSION APPLICATION


AND NAME
MB991367 MB991367-01 Armature mounting nut of
Special spanner compressor removal and
installation

B991367

MB991386 MIT217213 Armature mounting nut of


Pin compressor removal and
installation

MB991223 General service tools Making voltage and resistance


A
A: MB991219 measurement during
B: MB991220 troubleshooting
C: MB991221 A: Connector pin contact
D: MB991222 pressure inspection
B Harness set B: Power circuit inspection
A: Test harness C: Power circuit inspection
B: LED harness D: Commercial tester
C: LED harness connection
adaptor
C
D: Probe

D
DO NOT USE
MB991223 AZ

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HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE
55-93
TOOL TOOL NUMBER SUPERSESSION APPLICATION
AND NAME
MB992006 General service tool Making voltage and resistance
Extra fine probe measurement during
troubleshooting

MB992006

ON-VEHICLE SERVICE
REFRIGERANT LEVEL TEST
M1552008400312
Use the refrigerant recovery station to remove all of the refrig-
erant, and then calculate the amount of the refrigerant and
charge it.

A/C COMPRESSOR CLUTCH TEST


M1552019900010
1. Disconnect the A/C compressor clutch connector.
A/C COMPRESSOR CLUTCH CONNECTOR 2. Connect positive battery voltage directly to the connector for
the A/C compressor clutch.
3. If the A/C compressor clutch is normal, there will be "click." If
the pullet and armature do not make contact ("click"), there
is a malfunction.

AC005671AC

RECEIVER DRIER TEST


M1552008600242
Operate the unit and check the piping temperature by touching
the receiver drier outlet and inlet.
If there is a difference in the temperatures, the receiver drier is
restricted.
Replace the receiver drier.

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55-94 HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE

PRESSURE SWITCH CHECK


M1552010400308
1. Remove the dual pressure switch connector and connect
DUAL PRESSURE SWITCH the high/low pressure side terminals located on the harness
side as shown in the illustration.
2. Install a gauge manifold to the high-pressure side service
valve of the refrigerant line. (Refer to P.55-118.)
3. When the high/low pressure sides of the dual pressure
switch are at operation pressure (ON) the resistance should
less than two ohms between the terminals. If open circuit,
replace the switch.
ITEM SWITCH POSITION
OFF to ON ON to OFF
196 ± 20 2,940 ± 180
(28.4 ± 2.9) (426.7 ± 26.1)
Low-pressure side 221 ± 20 196 ± 20
kPa (psi) (32.1 ± 2.9) (28.4 ± 2.9)
ON
High-pressure side 2,350 ± 200 2,940 ± 180
OFF kPa (psi) (341.4 ± 29.0) (426.7 ± 26.1)
221 ± 20 2,350 ± 200
(32.1 ± 2.9) (341.4 ± 29.0)
kPa (psi)
AC211431AB

COMPRESSOR DRIVE BELT ADJUSTMENT


M1552001000283
Refer to GROUP 00, Maintenance Service −Drive Belts
P.00-41.

CHARGING
M1552001200317
Use the refrigerant recovery station to charge the refrigerant.
.

METHOD BY USING REFRIGERANT RECOVERY


AND RECYCLING UNIT
Using the refrigerant recovery and recycling unit, refill the
refrigerant.
NOTE: Refer to that Refrigerant Recovery and Recycling Unit
Instruction Manual for operation of the unit.
.

DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas
from the system.
NOTE: Refer to that Refrigerant Recovery and Recycling Unit
Instruction Manual for operation of the unit.
.

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HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE
55-95
REFILLING OF OIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor lubrication and
cause a compressor failure. Too much oil will increase dis-
charge air temperature.
When a compressor is installed at the factory, it contains 140
cm3 (4.7 floz) of refrigerant oil. While the A/C system is in oper-
ation, the oil is carried through the entire system by the refriger-
ant. Some of this oil will be trapped and retained in various
parts of the system.
When the following system components are changed, it is nec-
essary to add oil to the system to replace the oil being removed
with the component.
Compressor oil: SUN PAG 56
Quantity:
• Evaporator: 60 cm3 (2.0 floz)
• Condenser: 15 cm3 (0.5 floz)
• Suction hose: 10 cm3 (0.3 floz)

PERFORMANCE TEST
M1552001400300
1. The vehicle to be tested should be parked out of direct
sunlight.
2. Close the high and low-pressure valve of the gauge
manifold.
LOW-PRESSURE HIGH-PRESSURE
VALVE VALVE 3. Connect the charging hose (blue) to the low-pressure valve
and connect the charging hose (red) to the high-pressure
valve of the gauge manifold.
4. Install the quick joint (for low-pressure) to the charging hose
(blue), and connect the quick joint (for high-pressure) to the
charging hose (red).
GAUGE MANIFOLD
CHARGING CAUTION
HOSE (RED) • To connect the quick joint, press section A firmly
CHARGING against the service valve until a click is heard.
HOSE (BLUE) • When connecting, run your hand along the hose while
A
pressing to ensure that there are no bends in the hose.
ADAPTOR
VALVE SLEEVE NOTE: The high-pressure service valve is on the liquid pipe A
(FOR and the low-pressure service valve is on the suction hose.
ADAPTOR
LOW-PRES-
VALVE
5. Connect the quick joint (for low-pressure) to the
SURE) HIGH- low-pressure service valve and connect the quick joint (for
LOW- (FOR HIGH-
PRESSURE
SERVICE
PRESSURE
SERVICE PRESSURE) high-pressure) to the high-pressure service valve.
VALVE VALVE 6. Start the engine.
AC001388 AB
7. Set the A/C controls as follows:
• A/C switch: A/C −ON position
• Mode selection: FACE position
• Temperature control: MAXIMUM COOLING position
• Air selection: RECIRCULATION position
• Blower switch: "4" (HI) position
8. Adjust engine speed to idle speed with A/C clutch engaged.
9. Engine should be warmed up with doors and windows open.

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55-96 HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE

THERMOMETER 10.Insert a thermometer in the center air outlet and operate the
engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before the clutch
disengages.
11.Note the discharge air temperature.

AC211479 AB

PERFORMANCE TEMPERATURE CHART


GARAGE AMBIENT TEMPERATURE ° C (° F) 20 (68) 25 (77) 30 (86) 35 (95)
Discharge air temperature ° C (° F) 8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
(46 − 52) (54 − 61) (63 − 70) (73 − 82)
Compressor high pressure kPa (psi) 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
(107 − 122) (138 − 152) (168 − 189) (197 − 225)
Compressor low pressure kPa (psi) 150 − 190 190 − 240 240 − 300 300 − 375
(21.8 − 27.6) (27.6 − 34.8) (34.8 − 43.5) (43.5 − 54.4)

REFRIGERANT LEAK REPAIR PROCEDURE


M1552001500244

LOST CHARGE HANDLING TUBING AND FITTINGS


If the system has lost all charge due to a leak: Kinks in the refrigerant tubing or sharp bends in the
1. Evacuate the system. (Refer to P.55-94.) refrigerant hose lines will greatly reduce the capacity
2. Charge the system with approximately 0.453 kg (1 of the entire system. High pressures are produced in
pound) of refrigerant. the system when it is operating. Extreme care must
be exercised to make sure that all connections are
3. Check for leaks.
pressure tight. Dirt and moisture can enter the sys-
4. Discharge the system. tem when it is opened for repair or replacement of
5. Repair leaks. lines or components. The following precautions must
CAUTION be observed. The system must be completely dis-
Replacement filter-drier units must be sealed charged before opening any fitting of connection in
while in storage. The drier used in these units will the refrigeration system. Open fittings with caution
saturate water quickly upon exposure to the even after the system has been discharged. If any
atmosphere. When installing a drier, have all pressure is noticed as a fitting is loosened, allow
tools and supplies ready for quick assembly to trapped pressure to bleed off very slowly.
avoid keeping the system open any longer than Never attempt to rebend formed lines to fit. Use the
necessary. correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
6. Replace receiver drier. of all bends at least 10 times the diameter of the
7. Evacuate and charge system. hose.
Sharper bends will reduce the flow of refrigerant. The
LOW CHARGE flexible hose lines should be routed so that they are
If the system has not lost all of its refrigerant charge; at least 80 mm (3.1 inches) from the exhaust mani-
locate and repair all leaks. If it is necessary to fold. It is good practice to inspect all flexible hose
increase the system pressure to find the leak lines at least once a year to make sure they are in
(because of an especially low charge) add refriger- good condition and properly routed.
ant. If it is possible to repair the leak without dis- On standard plumbing fittings with O-rings, these
charging the refrigerant system, use the procedure O-rings are not reusable.
for correcting low refrigerant level.

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HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE
55-97
COMPRESSOR NOISE CHECK
M1552008700238
You must first know the conditions when the noise ADJUSTMENT
occurs. These conditions are: weather, vehicle 1. Select a quiet area for testing. Duplicate
speed, in gear or neutral, engine temperature or any conditions as much as possible. Switch
other special conditions. compressor on and off several times to clearly
Noises that develop during A/C operation can often identify compressor noise. To duplicate high
be misleading. For example: what sounds like a ambient conditions (high head pressure), restrict
failed front bearing or connecting rod, may be air flow through condenser. Install manifold gauge
caused by loose bolts, nuts, mounting brackets, or a set to make sure discharge pressure doesn't
loose clutch assembly. Verify accessory drive belt exceed 2,070 kPa (300.2 psi).
tension (power steering or generator).
2. Tighten all compressor mounting bolts, clutch
Improper accessory drive belt tension can cause a
mounting bolt, and compressor drive belt. Check
misleading noise when the compressor is engaged
to assure clutch coil is tight (no rotation or
and little or no noise when the compressor is disen-
wobble).
gaged.
Drive belts are speed-sensitive. That is, at different 3. Check refrigerant hoses for rubbing or
engine speeds, and depending upon belt tension, interference that can cause unusual noises.
belts can develop unusual noises that are often mis- 4. Check refrigerant charge. (Refer to P.55-94.)
taken for mechanical problems within the compres- 5. Recheck compressor noise as in Step 1.
sor. 6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.

POWER RELAY CHECK


M1552008800417

BLOWER RELAY CONTINUITY CHECK


BLOWER RELAY
BATTERY TESTER SPECIFIED
VOLTAGE CONNECTION CONDITION
Not applied 4−5 Open circuit
• Connect 4−5 Less than 2 ohms
terminal 1 to the
positive battery
terminal
• Connect
terminal 3 to the
negative battery
terminal

1 2 3 5
4 4

5 1 3

AC211366AB

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55-98 HEATER, AIR CONDITIONING AND VENTILATION
ON-VEHICLE SERVICE

A/C COMPRESSOR CLUTCH RELAY,


CONDENSER FAN RELAY (LO) AND (HI)
CONTINUITY CHECK
A/C COMPRESSOR RELAY
BATTERY TESTER SPECIFIED
VOLTAGE CONNECTION CONDITION
Not applied 1−4 Open circuit
• Connect 1−4 Less than 2 ohms
terminal 2 to the
positive battery
terminal
CONDENSER FAN • Connect
CONTROL RELAY (HI) terminal 3 to the
CONDENSER FAN negative battery
CONTROL RELAY (LO)
terminal
TRIANGLE MARK

1 2 1
X 4
3 4
2 3

FRONT OF
VEHICLE AC211359AH

IDLE-UP OPERATION CHECK


M1552001600304
1. Before inspection and adjustment, set vehicle in the
following condition:
• Engine coolant temperature: 80 − 90 ° C (176.0 − 194.0 ° F)
• Lights, electric cooling fan and accessories: Set to OFF
• Transmission: Neutral
• Steering wheel: Straightforward
2. Check whether or not the idle speed is the standard value.
Refer to GROUP 13A, On-vehicle Service −Basic Idle Speed
Adjustment P.13A-864.
Standard value: 850 ± 100 r/min
3. When the A/C is running after turning the A/C switch to ON,
and the blower switch to the 3(MH) or 4(HI) position, check
to be sure that the idle speed is at the standard value.
Standard value: 850 ± 100 r/min
NOTE: The engine control module determines whether the
A/C load is low or high according to the output signal from
the automatic compressor controller.
NOTE: It is not necessary to make an adjustment, because
the idling speed is automatically adjusted by the ISC sys-
tem. If, however, a deviation from the standard value occurs
for some reason, check the ISC system.
NOTE: Check 4 minutes after idling begins.

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HEATER, AIR CONDITIONING AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55-99
CLEAN AIR FILTER REPLACEMENT
PROCEDURE
M1552020100063
1. Remove the glove box (Refer to group 52A, instrument
panel P.52A-3.)
2. Remove the two screws as shown, and replace the clean air
filter.
3. Remove the clean air filter.
4. Install the glove box.

CLEAN AIR FILTER


AC309643AB

HEATER CONTROL ASSEMBLY AND A/C SWITCH


REMOVAL AND INSTALLATION
M1552002400392

Pre-removal and Post-installation Operation


• Under Cover Removal and Installation (Refer to GROUP
52A, Instrument Panel P.52A-3.)
• Foot Duct (LH) Removal and Installation (Refer to
P.55-120.)

6
1
2

3 B

B
4

NOTE 7
(1) CLIP LOCATIONS
(2) CLAW LOCATIONS
AC203835AF

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55-100 HEATER, AIR CONDITIONING AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH

SECTION A – A CLIP SECTION B – B


CLAW

INSTRUMENT PANEL
INSTRUMENT
PANEL AC505174 AB

REMOVAL STEPS REMOVAL STEPS (Continued)


>>B<< 1. AIR MIX DOOR CABLE 6. CENTER PANEL
CONNECTION • RADIO AND TAPE PLAYER
>>A<< 2. MODE SELECTION DAMPER (REFER TO GROUP 54A − AUDIO
CABLE CONNECTION SYSTEM - RADIO AND TAPE
3. TEMPERATURE ADJUSTMENT PLAYER, CD PLAYER AND CD
KNOB AUTO CHANGER P.54A-167.)
4. AIR VOLUME ADJUSTMENT 7. HEATER CONTROL PANEL
KNOB ASSEMBLY
5. BLOW VENT SWITCHING KNOB

INSTALLATION SERVICE POINTS


.

>>A<< MODE SELECTION DAMPER CABLE


CONNECTION
MODE 1. Set the heater control assembly’s mode selection knob to
SELECTION the DEF position.
DAMPER LEVER
MODE 2. Set the heater unit’s mode selection damper lever to the
LOCATOR DEF position (turn the damper relay to the left until it stops)
and install the cable.
3. Set the mode locator to the heater unit case and secure with
a clip.

MOLD LOCATOR
DEF POSITION AC211480AC

>>B<< AIR MIX DOOR CABLE CONNECTION


1. Turn the heater control assembly’s temperature adjustment
AIR MIX DOOR LEVER knob all the way to the HOT side.
MODE LOCATOR
2. Set the heater unit’s air mix door lever to the MAX HOT
position (turn the damper lever as the left illustration) and
attach the cable.
3. Set the mode locator to the heater unit case and secure with
a clip.
MAX COOL
POSITION
MAX HOT POSITION AC211483AC

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HEATER, AIR CONDITIONING AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH
55-101
INSPECTION
M1551006300394

BLOWER SWITCH CONTINUITY CHECK

SWITCH TESTER CONNECTION SPECIFIED


POSITION CONDITION
0 (OFF) 1 − 2, 2 − 4, 2 − 5, 2 − 6 Open circuit
1 (LO) 1−2 Less than 2 ohms
1 2 3
4 5 6 2 (ML) 2−4 Less than 2 ohms
3 (MH) 2−5 Less than 2 ohms
4 (HI) 2−6 Less than 2 ohms
AC100615AB

DISASSEMBLY AND ASSEMBLY


M1552014200210

2 3
4

1
7

5
AC100614 AB
6
DISASSEMBLY STEPS DISASSEMBLY STEPS
1. SWITCH PANEL <<A>> 6. MODE SELECTION DAMPER
2. REAR WINDOW DEFOGGER CABLE
SWITCH 7. BLOWER SWITCH ASSEMBLY
3. A/C SWITCH 8. HEATER CONTROL PANEL
4. OUTSIDE/INSIDE AIR (heater control)
SELECTION SWITCH
<<A>> 5. AIR MIX DOOR CABLE

TSB Revision
55-102 HEATER, AIR CONDITIONING AND VENTILATION
HEATER CONTROL ASSEMBLY AND A/C SWITCH

DISASSEMBLY SERVICE POINT


.

<<A>> MODE SELECTION DAMPER CABLE AND


AIR MIX DOOR CABLE REMOVAL
Insert a flat-tipped screwdriver into the clip through the inside of
the control base and pry out the clip claw to disconnect the
cables.

(-) flat-tipped
screwdriver

Clip
claw AC100619AB

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-103
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND
EVAPORATOR UNIT
REMOVAL AND INSTALLATION
M1552011600576

WARNING
When removing and installing the heater unit, do not let it bump against the SRS-ECU or the
components.
Pre-removal and Post-installation Operation
• Refrigerant draining and Refilling (Refer to P.55-94.)
• Engine coolant Draining and Refilling (Refer to GROUP
00, Engine Coolant P.00-48.)
• Instrument Panel Assembly Removal and Installation
(Refer to GROUP 52A, Instrument Panel Assembly
P.52A-3.)
• Steering Column Shaft Assembly Removal and Installa-
tion (Refer to GROUP 37, Steering Shaft Assembly
P.37-26.)
• Front Seat Removal and Installation (Refer to GROUP
52A, Front Seat Assembly P.52A-20.)
• Front Floor Console Assembly Removal and Installation
(Refer to GROUP 52A, Front Floor Console P.52A-7.)
• Floor Carpet Removal and Installation

-PIPE COUPLING
6

12 ± 2 N·m
107 ± 17 in-lb
4
3, 4 5N 8
3
A/C COMPRESSOR OIL:
SUN PAG 56 5N

AC211505AF

REMOVAL STEPS REMOVAL STEPS (Continued)


1. FRONT DECK CROSSMEMBER <<A>> 3. FLEXIBLE SUCTION HOSE
2. HEATER HOSE CONNECTION CONNECTION
<<A>> 4. LIQUID PIPE B CONNECTION

TSB Revision
55-104 HEATER, AIR CONDITIONING AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT

REMOVAL STEPS (Continued)


5. O-RING
6. CENTER DUCT
7. HEATER UNIT
8. INTAKE DUCT
9. BLOWER ASSEMBLY

REMOVAL SERVICE POINT


.

<<A>> FLEXIBLE SUCTION HOSE AND LIQUID


PIPE B DISCONNECTION
CAUTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to hose and nipples.
To prevent the entry of dust or other foreign material, plug the
dismantled hose and the nipples of the expansion valves.
HEATER UNIT DISASSEMBLY AND ASSEMBLY
M1551005400161

2
1

10

3
N 7
5
9 7N
6
11 7N

AC211527 AB

DISASSEMBLY STEPS DISASSEMBLY STEPS


1. FOOT DUCT (RH) 6. JOINT
2. FOOT DUCT (LH) 7. O-RING
3. HEATER CORE 8. EVAPORATOR
4. EVAPORATOR COVER 9. AIR THERMO SENSOR CLIP
5. EXPANSION VALVE

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
HEATER UNIT, HEATER CORE, BLOWER ASSEMBLY AND EVAPORATOR UNIT
55-105
DISASSEMBLY STEPS
10. AIR THERMO SENSOR
11. HEATER CASE

BLOWER ASSEMBLY DISASSEMBLY AND ASSEMBLY


M1551005500221

2 3

7
6 6

4
5
AC309642AB

DISASSEMBLY STEPS DISASSEMBLY STEPS


1. JOINT DUCT 5. BLOWER MOTOR
2. RESISTOR 6. BLOWER CASE
3. OUTSIDE/INSIDE AIR 7. CLEAN AIR FILTER
SELECTION DAMPER CONTROL
MOTOR
4. HOSE

TSB Revision
55-106 HEATER, AIR CONDITIONING AND VENTILATION
BLOWER MOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

BLOWER MOTOR, RESISTOR AND OUTSIDE/INSIDE


AIR SELECTION DAMPER CONTROL MOTOR
REMOVAL AND INSTALLATION
M1551002800289

2 3

AC211053AB

BLOWER MOTOR REMOVAL OUTSIDE/INSIDE AIR


STEPS SELECTION DAMPER CONTROL
<<A>> 1. BLOWER MOTOR MOTOR REMOVAL STEPS
RESISTOR REMOVAL STEPS • GLOVE BOX (OUTER AND
• GLOVE BOX (OUTER AND INNER) (REFER TO GROUP 52A,
INNER) (REFER TO GROUP 52A, INSTRUMENT PANEL P.52A-3.)
INSTRUMENT PANEL P.52A-3.) • ECM
• ECM 3. OUTSIDE/INSIDE AIR
2. RESISTOR SELECTION DAMPER CONTROL
MOTOR

REMOVAL SERVICE POINT


.

<<A>> BLOWER MOTOR REMOVAL


NOTE: A normal plate-type ratchet driver is recommended.

AC100628 AB

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HEATER, AIR CONDITIONING AND VENTILATION
BLOWER MOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR
55-107
INSPECTION
M1551006300242

RESISTOR CHECK
Use an ohmmeter to measure the resistance between the ter-
minals. Check that the measured value is at the standard
value.
1 2 Standard value:
3 4
MEASUREMENT TERMINAL STANDARD VALUE Ω
Between terminals 2 and 4 (LO) 2.54
Between terminals 1 and 2 (ML) 1.24
AC211516 Between terminals 2 and 3 (MH) 0.6

BLOWER FAN AND MOTOR CHECK


When battery voltage is applied between the terminals, check
that the motor operates. Also, check that there is no abnormal
noise.

AC100626 AB

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55-108 HEATER, AIR CONDITIONING AND VENTILATION
BLOWER MOTOR, RESISTOR AND OUTSIDE/INSIDE AIR SELECTION DAMPER CONTROL MOTOR

OUTSIDE/INSIDE AIR SELECTION DAMPER


CONTROL MOTOR CHECK
CAUTION
Cut off the battery voltage when the damper is in the inside
or outside air position.

LEVER POSITION BATTERY LEVER


CONNECTION OPERATION
At the inside • Connect The lever moves
INSIDE AIR
position terminal 7 to the from the inside
positive battery position to the
terminal outside position
• Connect
OUTSIDE AIR
terminal 6 to the
negative battery
AC100625AD
terminal
At the outside • Connect The lever moves
position terminal 7 to the from the outside
positive battery position to the
terminal inside position
• Connect
terminal 4 to the
negative battery
terminal

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HEATER, AIR CONDITIONING AND VENTILATION
EVAPORATOR ASSEMBLY
55-109
EVAPORATOR ASSEMBLY
REMOVAL AND INSTALLATION
M1552003600300

PIPE COUPLING

1, 2, 5, 9 6N
A/C COMPRESSOR OIL : 10 2 12 ± 2 N·m
SUN PAG 56 11 107 ± 17 in-lb
N 6

1
N 6
6N 4 3
5
7

9
8

AC211054AC

REMOVAL STEPS REMOVAL STEPS (Continued)


• REFRIGERANT DRAINING AND 3. EXPANSION VALVE COVER
REFILLING (REFER TO P.55-94.) 4. EXPANSION VALVE
• GLOVE BOX (REFER TO GROUP 5. JOINT
52A, INSTRUMENT PANEL 6. O-RING
P.52A-3.) 7. JOINT DUCT
• ECM 8. EVAPORATOR COVER
<<A>> <<B>> >>A<< 9. EVAPORATOR
1. FLEXIBLE SUCTION HOSE
CONNECTION 10. AIR THERMO SENSOR CLIP
<<A>> 2. LIQUID PIPE B CONNECTION 11. AIR THERMO SENSOR

REMOVAL SERVICE POINT


.

<<A>> FLEXIBLE SUCTION HOSE, LIQUID PIPE B


DISCONNECTION
CAUTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to hose and nipples.
To prevent the entry of dust or other foreign material, plug the
dismantled hose and the nipples of the expansion valves.
.

TSB Revision
55-110 HEATER, AIR CONDITIONING AND VENTILATION
EVAPORATOR ASSEMBLY

<<B>> EVAPORATOR REMOVAL


CAUTION
Do not cut the upper side of the pad.
1. When removing the evaporator, cut and fold back the
dashboard pad as in the diagram. (The thickness of the pad
DASHBOARD PAD interferes with the removal of the evaporator.)
2. Remove the evaporator.

BLOWER UNIT
AC100629AC

INSTALLATION SERVICE POINTS


.

>>A<< EVAPORATOR INSTALLATION


After installing the evaporator, glue the cut dashboard panel
pad with an adhesive agent.

INSPECTION
M1552014301458

AIR THERMO SENSOR INSPECTION


.

INLET SIDE
Measure the resistance between connector terminals 1 and 3
under at least two different temperatures. The resistance val-
ues should generally match those in the graph.
NOTE: The temperature at the check should not exceed the
range in the graph.
OUTLET SIDE
.

OUTLET SIDE
Measure the resistance between connector terminals 4 and 5
INLET SIDE under at least two different temperatures. The resistance val-
ues should generally match those in the graph.
RESISTANCE
(kΩ) 25 NOTE: The temperature at the check should not exceed the
20
range in the graph.

15

10

5
0
-10 0 10 20 30 40
(14) (32) (50) (68) (86) (104)
TEMPERATURE ˚C (˚F)
AC100770AL

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HEATER, AIR CONDITIONING AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-111
COMPRESSOR ASSEMBLY AND TENSION PULLEY
REMOVAL AND INSTALLATION
M1552004100342

Pre-removal Operation Post-installation Operation


• Refrigerant Discharging (Refer to P.55-94.) • Drive Belt Tension Adjustment (Refer to GROUP 00,
Maintenance Service − Drive Belt P.00-41.)
• Refrigerant Charging (Refer to P.55-94.)

-PIPE COUPLING

6
5

3N
1, 2 3N
A/C COMPRESSOR OIL: 2
SUN PAG 56

25 ± 4 N·m
1 18 ± 3 ft-lb

4
AC310704AF

REMOVAL STEPS REMOVAL STEPS (Continued)


<<A>> 1. FLEXIBLE SUCTION HOSE 3. O RING
CONNECTION <<B>> 4. DRIVE BELT
<<A>> 2. FLEXIBLE DISCHARGE HOSE <<C>> >>A<< 5. A/C COMPRESSOR
CONNECTION 6. A/C COMPRESSOR BRACKET

REMOVAL SERVICE POINTS


.

<<A>> FLEXIBLE SUCTION HOSE AND FLEXIBLE


DISCHARGE HOSE DISCONNECTION
CAUTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign material, plug the
dismantled hoses and compressor nipples.
.

<<B>> DRIVE BELT REMOVAL


The following operations will be needed due to the serpentine
drive system with the drive belt auto-tensioner.

TSB Revision
55-112 HEATER, AIR CONDITIONING AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY

1. Securely insert the spindle handle or ratchet handle with a


AUTO-TENSIONER 12.7mm (1/2-inch) insertion angle into the jig hole of the
auto-tensioner, and turn the auto-tensioner
counterclockwise until it hits the stopper.
CAUTION
To reuse the drive belt, draw an arrow indicating the rotat-
HOLE B
ing direction (to the right) on the back of the belt using
chalk, etc.

HOLE A AC107640AC

2. Align hole A with hole B, insert an L-shaped hexagon


AUTO-TENSIONER wrench, etc. to fix and then remove the drive belt.
.

<<C>> A/C COMPRESSOR REMOVAL


Take care not to spill any compressor oil when removing the
compressor.

L-SHAPED
HEXAGON
WRENCH AC107641AB

INSTALLATION SERVICE POINT


.

>>A<< A/C COMPRESSOR INSTALLATION


If a new compressor is installed, first adjust the amount of oil
according to the procedures described below, and then install
the compressor.
1. Measure the amount [X cm3 (X floz)] of oil within the
removed compressor.
2. Drain (from the new compressor) the amount [Y cm3 (Y
floz)] of oil calculated according to the following formula, and
then install the new compressor.
New compressor oil amount=130 cm3 (4.7floz)
130 cm3 − X cm3 = Y cm3 (4.7 floz − X floz = Y floz)
NOTE: Y cm3 (Y floz) indicates the amount of oil in the
refrigerant line, the condenser, the evaporator, etc.
NOTE: When replacing the following parts at the same time
as the compressor, subtract the rated oil amount of the each
part from Y cm3 (Y floz), and discharge from the new com-
pressor.
Quantity:
• Evaporator: 60 cm3 (2.0 floz)
• Condenser: 15 cm3 (0.5 floz)
• Suction hose: 10 cm3 (0.3 floz)
• Receiver: 10 cm3 (0.3 floz)

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-113
INSPECTION
M1552014301306

COMPRESSOR MGNETIC CLUTCH OPERATION


CHECK
A/C COMPRESSOR Connect the compressor connector terminal to the battery posi-
CLUTCH tive (+) terminal and ground the battery’s negative (-) terminal
CONNECTOR to the compressor unit. At that time, the A/C compressor clutch
should make a definite operating sound.

AC005671AG

DISASSEMBLY AND ASSEMBLY


M1552004600541

3 N 2

10
9
8
7
5 6 1
N 4

16 ± 1 N·m
AC100630 AD
12 ± 1 ft-lb
COOLING TEMPERATURE A/C COMPRESSOR CLUTCH
SWITCH DISASSEMBLY STEPS DISASSEMBLY (Continued)
1. SNAP RING >>B<< 7. SNAP RING
2. COOLING TEMPERATURE 8. ROTOR
SWITCH 9. SNAP RING
3. O-RING >>A<< 10. FIELD CORE
A/C COMPRESSOR CLUTCH Required Special Tools:
DISASSEMBLY • MB991367: Special Spanner
>>D<< • AIR GAP ADJUSTMENT
• MB991386: Pin
<<A>> >>C<< 4. SELF-LOCKING NUT
5. ARMATURE
6. SHIM

TSB Revision
55-114 HEATER, AIR CONDITIONING AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY

DISASSEMBLY SERVICE POINT


.

<<A>> SELF-LOCKING NUT REMOVAL

MB991386

MB991367

AC100633AB

ASSEMBLY SERVICE POINTS


.

>>A<< FIELD CORE ATTACHMENT


Line up the pin hole on the compressor unit with the field core
FIELD CORE projection and attach.
PROJECTION

COMPRESSOR
UNIT PIN HOLE
AC100634AB

>>B<< SNAP RING INSTALLATION


Using snap ring pliers, fit the snap ring so that the snap ring’s
SNAP RING CLUTCH COIL
ROTOR tapered part is on the outside.
.

>>C<< SELF-LOCKING NUT INSTALLATION


Using a special tool, as when removing the nut, secure the
armature and tighten the self-locking nut.

TAPERED PART

AC001412 AB

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
COMPRESSOR ASSEMBLY AND TENSION PULLEY
55-115
>>D<< AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the stan-
FEELER dard value.
GAUGE
Standard value: 0.3 − 0.5 mm (0.012 − 0.020 inch)
NOTE: If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the number
of shims.

AC100637AG

INSPECTION
M1552014300574

REFRIGERANT TEMPRATURE SWITCH


CAUTION
Do not heat more than necessary.
1. Dip the metal part of the refrigerant temperature switch into
engine oil and increase the oil temperature using a gas
burner or similar.

THERMOMETER

ENGINE OIL

AC203843 AB

2. When the oil temperature reaches the standard value, check


120˚C 150˚C that voltage is supplied between the terminals.
(248˚F) (302˚F)
Standard value:
LESS THAN 2Ω ITEM TEMPERATURE
NO CONTINUITY
Less than 2 ohms Slightly below 150° C (302° F)
No continuity 150° C (302° F) or more
OIL TEMPERATURE

NOTE: When the oil temperature is 150° C (302° F) or more


AC100810 AF
and there is no continuity, the resistance will not be 2Ω or
lower until the oil temperature reduces to 120° C (248° F) or
less.

TSB Revision
55-116 HEATER, AIR CONDITIONING AND VENTILATION
CONDENSER AND CONDENSER FAN MOTOR

CONDENSER AND CONDENSER FAN MOTOR


REMOVAL AND INSTALLATION
M1552006700641

Pre-removal and Post-installation Operation


• Refrigerant Draining and Refilling (Refer to P.55-94.)
• Front Bumper Removal and Installation (Refer to GROUP
51 P.51-2.)

4.9 ± 0.9 N·m


43 ± 8 in-lb 12 ± 2 N·m
-PIPE COUPLING
107 ± 7 in-lb
6

5
N 10

5, 6 10 N
A/C COMPRESSOR OIL:
SUN PAG 56

2 7
3
4 1 N 10
9 8 AC211410AF

FAN SHROUD ASSEMBLY CONDENSER REMOVAL STEPS


REMOVAL STEPS <<B>> 5. FLEXIBLE DISCHARGE HOSE
<<A>> 1. FAN SHROUD ASSEMBLY CONNECTION
2. FAN <<B>> 6. LIQUID PIPE A CONNECTION
3. FAN MOTOR >>A<< 7. CONDENSER
4. FAN SHROUD 8. CLAMP
9. RECEIVER
10. O-RING

REMOVAL SERVICE POINT


.

<<A>> FAN SHROUD ASSEMBLY REMOVAL


1. Remove the intercooler mounting bolts/nuts and pull the
intercooler forward.
2. Move the fan shroud assembly upward for removal.
.

<<B>> FLEXIBLE DISCHARGE HOSE / LIQUID


PIPE A DISCONNECTION
CAUTION
As the compressor oil and receiver are highly moisture
AC211409AB absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of dust or other foreign material, plug the
dismantled hose and condenser assembly nipples.

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
CONDENSER AND CONDENSER FAN MOTOR
55-117
INSTALLATION SERVICE POINT
.

>>A<< CONDENSER INSTALLATION


When replacing the condenser, refill it with a specified amount
of compressor oil and install it to the vehicle.
Compressor oil: SUN PAG 56
Quantity: 15 cm3 (0.5 floz)

INSPECTION
M1552014300585

CONDENSER FAN MOTOR CHECK


A-34
BATTERY CONNECTION CONDENSER FAN
1 2 MOTOR
OPERATION
• Connect connector A-34 terminal 2 Condenser fan
to the positive battery terminal motor LO operation
1 2 • Connect connector A-35 terminal 2
to the negative battery terminal
A-35
• Connect connector A-34 terminal 1 Condenser fan
AC211409AB
to the positive battery terminal motor HI operation
• Connect connector A-35 terminal 2
to the negative battery terminal

TSB Revision
55-118 HEATER, AIR CONDITIONING AND VENTILATION
REFRIGERANT LINE

REFRIGERANT LINE
REMOVAL AND INSTALLATION
M1552006400606

Pre-removal and Post-installation Operation


• Refrigerant Draining and Refilling (Refer to P.55-94.)
• Air Cleaner Removal and Installation (Refer to GROUP 15
Air Cleaner P.15-7.)

-Pipe coupling

7N
2 13 ± 1 N·m
7N
6
HIGH-PRESSURE 7 N 115 ± 9 in-lb 1,2,3,4,5,6 7N
SIDE SERVICE VALVE
A/C COMPRESSOR OIL: SUN PAG 56
12 ± 2 N·m
107 ± 17 in-lb

1 LOW-PRESSURE SIDE
SERVICE VALVE
6
7N
4.9 ± 0.9 N·m
43 ± 8 in-lb 7N

12 ± 2 N·m
107 ± 17 in-lb

4
5

12 ± 2 N·m
107 ± 17 in-lb

7N 7N

3
25 ± 4 N·m
18 ± 3 ft-lb AC210882AD

REMOVAL STEPS REMOVAL STEPS (Continued)


<<A>> 1. LIQUID PIPE A <<A>> 5. SUCTION PIPE
2. DUAL PRESSURE SWITCH <<A>> 6. LIQUID PIPE B
<<A>> 3. FLEXIBLE DISCHARGE HOSE 7. O-RING
<<A>> >>A<< 4. FLEXIBLE SUCTION HOSE

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
REFRIGERANT LINE
55-119
REMOVAL SERVICE POINT
.

<<A>> LIQUID PIPE A, FLEXIBLE DISCHARGE


HOSE, FLEXIBLE SUCTION HOSE, SUCTION
PIPE, LIQUID PIPE B, DISCONNECTION
CAUTION
As the compressor oil and receiver are highly moisture
absorbent, use a non-porous material to plug the hose and
nipples.
To prevent the entry of other foreign material, plug the con-
denser, compressor, and expansion valve nipples.

INSTALLATION SERVICE POINT


.

>>A<< FLEXIBLE SUCTION HOSE INSTALLATION


When replacing the suction hose, refill them with a specified
amount of compressor oil, and then install them.
Compressor oil: SUN PAG 56
Quantity: 10 cm3 (0.3 floz)

TSB Revision
55-120 HEATER, AIR CONDITIONING AND VENTILATION
VENTILATORS

VENTILATORS
REMOVAL AND INSTALLATION
M1553001600437

SECTION A – A

CLIP
4
5
INSTRUMENT
PANEL
1 3
7

6
2
A
1
A
7
8

AC311038AD

AIR OUTLET REMOVAL STEPS DEFROSTER NOZZLE AND


1. CENTER AIR OUTLET PANEL DISTRIBUTION DUCT REMOVAL
2. CENTER AIR OUTLET STEPS (Continued)
DEFROSTER NOZZLE AND 4. SIDE DEFROSTER DUCT (LH)
DISTRIBUTION DUCT REMOVAL 5. DEFROSTER NOZZLE
STEPS 6. DISTRIBUTION DUCT
• INSTRUMENT PANEL ASSEMBLY 7. SIDE AIR OUTLET
(REFER TO GROUP 52A 8. FOOT DUCT (LH)
INSTRUMENT PANELP.52A-3.) 9. FOOT DUCT (RH)
3. SIDE DEFROSTER DUCT (RH)

TSB Revision
HEATER, AIR CONDITIONING AND VENTILATION
SPECIFICATIONS
55-121

SECTION A – A SECTION B – B A
A
8 A
CLAW A

CLAW B
8 B
AC211528AE

REAR VENTILATION DUCT


REMOVAL STEPS
8. REAR VENTILATION DUCT

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATION
M1552012100303

ITEM SPECIFICATION
Liquid pipe A mounting nut (condenser side) 4.9 ± 0.9 N⋅ m (43 ± 8 in-lb)
Flexible discharge hose mounting nut (condenser side) 12 ± 2 N⋅ m (107 ± 17 in-lb)
Flexible discharge hose mounting bolt (compressor side) 25 ± 4 N⋅ m (18 ± 3 ft-lb)
Flexible suction hose mounting bolt (compressor side) 25 ± 4 N⋅ m (18 ± 3 ft-lb)
Flexible suction hose mounting nut (suction pipe connection) 12 ± 2 N⋅ m (107 ± 17 in-lb)
Suction pipe mounting bolt (heater unit side) 12 ± 2 N⋅ m (107 ± 17 in-lb)
Liquid pipe A mounting nut (liquid pipe B connection) 13 ± 1 N⋅ m (115 ± 9 in-lb)
Compressor cluch mounting nut 16 ± 1 N⋅ m (12 ± 1 ft-lb)

TSB Revision
55-122 HEATER, AIR CONDITIONING AND VENTILATION
SPECIFICATIONS

GENERAL SPECIFICATION
M1552000200206

ITEM MANUAL A/C


Heater/cooler unit Full-air mix type providing stratified cool and
warm air flows
Heater control Dial type
A/C switch Push-button type
Compressor MSC90C (Scroll type)
Dual pressure High-pressure ON to OFF 2,940 ± 180 (426.7 ± 26.1)
switch kPa (psi) switch OFF to ON 2,350 ± 200 (341.4 ± 29.0)
Low-pressure ON to OFF 196 ± 20 (28.4 ± 2.9)
switch OFF to ON 221 ± 20 (32.1 ± 2.9)
Refrigerant Type R134a (HFC-134a)
Amount g (oz) 480 − 520 (16.93 − 18.34)

SERVICE SPECIFICATIONS
M1552000300418

ITEM STANDARD VALUE


Idle speed r/min 850 ± 100*1
Idle-up speed r/min 850 ± 100*1
Resistor (for blower motor) Ω LO 2.54
ML 1.24
MH 0.6
Air gap (A/C compressor clutch) mm (in) 0.3 − 0.5 (0.012 − 0.020)
Refrigerant temperature switch Less than 2 ohms Slightly below 150° C (302° F)*2
No continuity 150° C (302° F) or more
NOTE: *1 The r/min marked by an asterisk should be NOTE: *2 When the oil temperature is 150° C
checked 4 minutes after idling begins. (302° F) or more and there is no continuity, the resis-
tance will not be 2Ω or lower until the oil temperature
reduces to 120° C (248° F) or less.
LUBRICANT
M1552000400255

ITEM SPECIFIED LUBRICANT QUANTITY


Each connection of refrigerant line SUN PAG 56 As required
Compressor refrigerant unit lubricant cm3 (floz) SUN PAG 56 120 − 140 (4.2 − 4.9)

TSB Revision

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