Air conditioning system

A¿¿N1-M
PRECAUTIONS FOR SERVICING R134a AIR
CONDITIONINGS
1. USE OF NEW REFRIGERANT R134a
The very different characteristics of refrigerants
R134a and R12 have determined the design of their
respective air conditioning systems. Under no circum-
stances allow R12 to enter an R134a system, or vice
versa, because serious damage could occur.
GENERAL DESCRIPTION
NEW AIR CONDITIONING SYSTEM WITH
R134a
Refrigerant R12(CFC12), previously used in automo-
bile air conditioning systems is believed to contribute
towards the depletion the earth’s ozone layer. The
ozone layer help to protect us against the harmful
ultraviolet rays of the sun.
2. USE OF PROPER COMPRESSOR OIL
Compressor oil used in conventional R12 air condi-
tioning systems cannot be used in R134a air condi-
tioning systems.
Always use genuine Toyota R134a air conditioning oil
ND - OIL 9, made expressly for use with R134a.
If even a small amount of the wrong oil is changed, it
will result in clouding of the refrigerant.
A large amount will cause the compressor to seize up.
A newly developed refrigerant, R134a (HFC 134a),
does not the destroy the ozone layer.
-AIR CONDITIONING SYSTEM GENERAL DESCRIPTION
AC-2

4. TIGHTEN CONNECTING PARTS SECURELY
Securely tighten the connecting parts to prevent leak-
ing of refrigerant gas.
• Apply a few drops of compressor oil to O-ring
fittings for easy tightening and to prevent leaking
of refrigerant gas.
CAUTION: Apply only ND-OIL 9 compressor oil
• Tighten the nuts using 2 wrenches to avoid twist-
ing the tube.
• Tighten the O-ring fittings or the bolted type
fittings to the specified torque.
5. INSERT PLUG IMMEDIATELY IN DISCONNECTED
PARTS
Insert a plug immediately in the disconnected parts to
prevent the ingress of moisture and dust.
6. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL
IMMEDIATELY BEFORE INSTALLATION
3. USE OF PROPER O-RINGS AND SEALS
O-rings and seals used for conventional R12 air
conditioning systems cannot be used for R134a air
conditioning systems.
Always use genuine Toyota R134a system O-rings
and seals for R134a air conditioning systems.
If O-rings and/or seals for R12 air conditioning sys-
tems are used by mistake in the connections of an R
134a air conditioning system, the O-ring and seals
will foam and swell resulting in leakage of refrigerant.
7. WHEN DISCONNECTING THE PLUG, TAKE CARE
SO THAT OIL WILL NOT AGAIN
AC-3

3. USE VACUUM PUMP ADAPTER
By connecting a vacuum pump adapter, the vacuum
pump can be used for both R134a and R12 air conditioning
systems.
The vacuum pump adaptor has an internal magnetic
valve.
When evacuation is completed and the vacuum pump
switch is turned off, the magnetic valve opens allow.
ing the introduction of atmospheric air into the manifold
gauges to prevent the back flow of oil from the
vacuum pump into the gauge hose.
CAUTION:
Be sure to turn off the manifold gauge valve immediately
after evacuating the system. Then you may switch off
the vacuum pump. If this order is reversed, the line wilI
be temporarily open to atmosphere.
SERVICE TOOLS FOR R134a AIR
CONDITIONING
When servicing R134a air conditioning systems
always use the R134a dedicated manifold gauges, gas
leak detector and vacuum pump adaptor.
1. USE MANIFOLD GAUGES FOR R134a AIR CONDI-
TIONING
Always use R134a dedicated manifold gauges to pre-
vent R12 and R12 compressor oil contaminating the
R134a system.
2. USE R134a GAS LEAK DETECTOR
Similarly, always use an R134a dedicated leak detec-
tor. The R12 leak detector is not sufficiently sensitive.
AC-4

3. BE CAREFUL THAT LIQUID REFRIGERANT DOES
NOT GET IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin:
(a) Wash the area with lots of cool water.
CAUTION: Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) GO immediately to a physician or hospital for profes-
sional treatment.
HANDLING PRECAUTIONS FOR
REFRIGERANT CONTAINER
1. NEVER HEAT CONTAINER OR EXPOSE IT TO
NAKED FLAME
2. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
HANDLING PRECAUTIONS FOR
REFRIGERANT
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
CHARGING AND LEAK-CHECK METHODS
Evacuate the refrigeration system according to the
following procedures.
Fill refrigerant in gas state until
gauge pressure reads 1 kg/cm2
Abnormal indication of
manifold gauges
Check and correct
pipe joints
Refrigerant
Charge
Refrigerant
Charge
Start
Evacuation
Stop
Evacuation
Leave for 5 min.
Gas Leak
Check
Airtight
Check
10 min.
AC-5

CAUTION:
• Be sure to connect both the high and low pressure
quick-connectors onto the A/C system when eva-
cuating. If only one side is connected, the system
would be open to atmosphere through the other
connector, making it impossible to maintain
vacuum.
• Be sure to turn off the manifold gauge valve imme-
diately after evacuating the system. Then you may
switch off the vacuum pump.
PRECAUTIONS WHEN CHARGING
REFRIGERANT
1. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT CYCLE
If there is not enough refrigerant in the refrigerant
system, oil lubrication will be insufficient and com-
pressor burnout may occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILST COMPRESSOR IS OPERATING
If the high pressure valve is opened, refrigerant flows
in the reverse direction and could cause the charging
cylinder to rupture, so open and close the low pres-
sure valve only.
3. BE CAREFUL NOT TO OVERCHARGE WITH RE-
FRIGERANT IN SYSTEM
If refrigerant is overcharged, it causes problems such
as insufficient cooling, poor fuel economy, engine
overheating etc.
ELECTRICAL PARTS
Before removing and inspecting the electrical parts,
set the ignition switch to the LOCK position and
disconnect the negative (-) terminal cable from bat-
tery.
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the ”LOCK”
position and the negative (-) terminal cable is discon-
nected from the battery.
AC-6

SUPPLEMENTAL RESTRAINT SYSTEM
(SRS)
Failure to carry out service operations in the correct
sequence could cause the airbag system to deploy,
possibly leading to a serious accident.
During removal or installation of the parts and the
yellow wire harness and connector for the airbag is
necessary, refer to the precautionary notices in the RS
section before performing the operation.
AC-7

DESCRIPTION
PARTS LOCATION
-AIR CONDITIONING SYSTEM DESCRIPTION
AC-8

WIRING DIAGRAM
USA
AC-9

Canada
AC-10

DAMPERS POSITION
AC-1 1

PREPARATION
SST (SPECIAL SERVICE TOOLS)
(07117-88070) Refrigerant Charging Hose
(07117-78050) Refrigerant Charging Gauge
(07117-58080) Quick Coupler
(07117-58090) Quick Coupler
(07117-58070) T-Joint
(07117-58060) Refrigerant Drain Service Valve
Suction (Blue)
Suction (diam. 13 mm)
Discharge (Red)
Utility (Green)
Discharge (diam. 16 mm)
07110-58060 Air Conditioner Service Tool Set
07116-38360 Gas Leak Detector Assembly
07112-66040 Magnetic Clutch Remover
07112-76060 Magnetic Clutch Stopper
07114-84020 Snap Ring Pliers
-AIR CONDITIONING SYSTEM PREPARATION
AC-12

RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set
LUBRICANT
When replacing compressor
When replacing evaporator
When replacing condenser
When replacing receiver
40 cc (1.4 fl.oz.)
40 cc (1.4 fl.oz.)
120 cc (4.1 fl.oz.)
10 cc (2.9 fl.oz.)
Compressor oil
Classification
ND-OIL 8
CapacityItem
-AIR CONDITIONING SYSTEM PREPARATION
AC-13

USE OF MANIFOLD GAUGE SET
MANIFOLD GAUGE SET INSTALLATION
1. CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts by hand.
CAUTION: Do not connect the wrong hoses.
2. CONNECT QUICK CONNECTORS TO CHARGING
HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD
GAUGE SET
4. REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINE
MANIFOLD GAUGE SET REMOVAL
1. CLOSE BOTH HAND VALVES OF MANIFOLD
GAUGE SET
2. DISCONNECT QUICK CONNECTORS. FROM SER-
VICE VALVES ON REFRIGERANT LINE
HINT: Slide the sleeve of the quick connector upward
to unlock the connector and remove it from the ser-
vice valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIG-
ERANT LINE
5. CONNECT QUICK CONNECTORS TO SERVICE
VALVES
HINT: Push the quick connector onto the service
valve, then slide the sleeve of the quick connector
downward to lock it.
-AIR CONDITIONING SYSTEM USE OF MANIFOLD GAUGE SET
AC-14

TROUBLESHOOTING
You will find the troubles easier using the table well shown below. In this table, each number
shows the priority of causes in troubles. Check each part in order. If necessary, replace these
parts.
Cool air comes out only at high
engine rpm
No engine idle up when A/C
switch on
InspectA/Ccontrolleveradjustment
Inspectcoolingsystemforrefrigerant
Compressor operates immediately
Inspectenginecoolantvolume
Cool air comes out immediately
Inspectvolumeofrefrigerant
No air temperature control
No condenser fan operation
Blowerspeedcontrolswitch
CondenserfanrelayNo.2
Condenserfanfuse
CondenserfanrelayNo.3
Inspectdrivebelttension
Inspectoutletaircontrol
No compressor operation
No warm air comes out
Radiatorfanmainrelay
No cool air cones out
Part Name
No blower operation
Condenserfanmotor
Insufficient cooling
Heatermainrelay
Blowerresistor
Blowermotor
AC-54
AC-55
AC-54
AC-55
See Page
Trouble
AC-61
AC-23
AC-47
AC-51
AC-52
AC-22
AC-46
AC-64
-AIR CONDITIONING SYSTEM TROUBLESHOOTING
AC-15

Engine coolant temperature switch
Wiring and wiring connections
Vacuum switching valve (VSV)
Inspect refrigeration control
Inspect refrigerant lines
Magnetic clutch relay
High pressure switch
Dual pressure switch
Expansion valve
Magnetic clutch
Heater radiator
A/C amplifier
A/C switch
Compressor
Thermistor
Condenser
Evaporator
AC-49
AC-66
A/C fuse
Receiver
AC-60
AC-60
AC-53
AC-63
AC-41
AC-48
AC-34
AC-44
AC-42
AC-57
AC-34
-AIRCONDITIONINGSYSTEMTROUBLESHOOTING
AC-16

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET
This is a method in which the trouble is located by using a manifold gauge set.
(See ”USE OF MANIFOLD GAUGE SET” on page AC-14 )
Read the manifold gauge pressure when the following conditions are established:
(a) Temperature at the air inlet with the switch set at RECIRC is 30 - 35_C (86 - 95°F)
(b) Engine running at 1,500 rpm
(c) Blower speed control switch set at high
(d) Temperature control set at max. cool
HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature
conditions.
1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM
Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm2)
AC-17

(1) Check for gas leak-
age with leak detector
and repair if necessary
(2) Charge refrigerant to
proper amount
(3) If pressure indicated
value is near 0 when
connected to gauge,
create the vacuum
after inspecting and
repairing the location
of the leak
S Drier in oversaturated
state
↓
S Moisture in refrigeration
system freezes at expan-
sion valve orifice and
blocks circulation of re-
frigerant
S Moisture entered in re-
frigeration system
freezes at expansion
valve orifice and tempo-
rarily stops cycle, but
normal state is restored
after a time when the ice
melts
(1) Replace receiver/drier
(2) Remove moisture in
cycle through repeat-
edly evacuating air
(3) Charge new refrigerant
to proper amount
S Pressure low on both
low and high pressure
sides
S Bubbles seen in sight
glass continuously
S Insufficient cooling
performance
S During operation, pres-
sure on low pressure
side sometimes
becomes a vacuum
and sometimes normal
2. MOISTURE PRESENT IN REFRIGERATION SYSTEM
S Insufficient refrigerant
in system
↓
S Refrigerant leaking
Condition: Periodically cools and then fails to cool
S Gas leakage at some
place in refrigeration
system
3. INSUFFICIENT REFRIGERANT
Symptom seen in
refrigeration system
Condition: Insufficient cooling
Symptom seen in
Probable cause
Probable cause Diagnosis
Diagnosis
Remedy
Remedy
AC-18

(1) Check heat sensing
tube, expansion valve
and EPR
(2) Clean out dirt in expan-
sion valve by blowing
with air
If not able to remove
dirt, replace expansion
valve
(3) Replace receiver
(4) Evacuate air and
charge new refrigerant
to proper amount.
For gas leakage from
heat sensing tube, re-
place expansion valve.
S Refrigerant flow ob-
structed by moisture or
dirt in refrigeration sys-
tem
structed by gas leakage
from expansion valve
heat sensing tube
S Vacuum indicated on
low pressure side, very
low pressure indicated
on high pressure side
S Frost or dew seen on
piping before and after
receiver/drier or expan-
sion valve
5. REFRIGERANT DOES NOT CIRCULATE
Condition: Does not cool (Cools from time to time in some cases)
S Pressure low on both
low and high pressure
sides
S Frost on tubes from
receiver to unit
4. POOR CIRCULATION OF REFRIGERANT
structed by dirt in re-
ceiver
S Refrigerant does not cir-
culate
Symptom seen in
Symptom seen in
Probable cause
S Replace receiverS Receiver clogged
Probable cause
Diagnosis
Diagnosis
Remedy
Remedy
AC-19

6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER
(1) Clean condenser
(2) Check fan motor oper-
ation
(3) !f (1) and (2) are in nor-
mal state, check
amount of refrigerant
Charge proper amount
of refrigerant
NOTE: These gauge indications are shown when the re-
frigeration system has been opened and the refrig-
erant charged without vacuum purging.
S Excessive refrigerant in
cycle → refrigerant over-
charged
S Condenser cooling insuf-
ficient → condenser fins
clogged or fan motor
faulty
S Pressure too high on
both low and high
pressure sides
S No air bubbles seen
through the sight glass
even when the engine
rpm is lowered.
both low and high
pressure sides
S The low pressure piping
is hot to the touch
S Bubbles seen insight
glass
S Unable to develop suffi-
cient performance due to
excessive refrigerant in
system
S Insufficient cooling of
condenser
(1) Check compressor oil
to see if dirty or insuffi-
cient
(2) Evacuate air and
charge new refrigerant
S Air present in refrigera-
tion system
↓
S Insufficient vacuum
purging
7. AIR PRESENT IN REFRIGERATION SYSTEM
Condition: Does not cool down sufficiently
Condition: Does not cool sufficiently
S Air entered in refrigera-
tion system
Symptom seen in
Symptom seen in
Probable cause
Probable cause
Diagnosis
Diagnosis
Remedy
Remedy
AC-20

8. EXPANSION VALVE IMPROPERLY
MOUNTED/HEAT SENSING TUBE DEFECTIVE
(OPENS TOO WIDE)
both low and high
pressure sides
S Frost or large amount
of dew on piping on low
pressure side
(1) Check heat sensing
tube installed condition
(2) If (1) is normal, check
expansion valve
Replace if defective
S Excessive refrigerant in
low pressure piping
↓
S Expansion valve opened
too wide
S Compression defective
↓
Valve leaking or broken,
sliding parts
low pressure side
S Pressure too low on
high pressure side
S Trouble in expansion
valve or heat sensing
tube not installed cor-
rectly
9. DEFECTIVE COMPRESSION COMPRESSOR
S Internal leak in compres-
sor
S Repair or replace com-
pressor
Symptom seen in
Symptom seen in
Condition: Does not cooI
^
Diagnosis
Probable cause
Probable cause
Diagnosis Remedy
Remedy
AC-21

REFRIGERANT VOLUME
REFRIGERANT VOLUME INSPECTION
1. RUN ENGINE AT APPROX. 1,500 RPM
2. SET TEMPERATURE CONTROL AT MAX. COOL
3. SET BLOWER SWITCH AT ’HI’
4. SET AIR INLET CONTROL AT ’RECIRC’
5. TURN A/C SWITCH ON
6. FULLY OPEN DOORS
7. INSPECT AMOUNT OF REFRIGERANT
Observe the sight glass on the liquid tube.
REFRIGERANT CHARGE VOLUME
Specified amount:
700 ±50 g (24.69 ± 1.76 oz.)
* Bubbles in the sight glass with ambient tempera-
tures higher can be considered normal if cooling is
sufficient.
(1) Check for gas leakage with gas leak
tester and repair if necessary
(2) Add refrigerant until bubbles disap-
pear
(1) Check for gas leakage with gas leak
tester and repair if necessary
(2) Add refrigerant until bubbles disap-
pear
(1) Recover refrigerant
(2) Evacuate air and charge proper
amount of purified refrigerant
Immediately after air conditioning is
turned off, refrigerant in sight glass
stays clear
When air conditioning is turned off, re-
frigerant foams and then stays clear
No temperature difference between
compressor inlet and outlet
Temperature between compressor inlet
and outlet is noticeably different
No bubbles present in sight glass
Bubbles present in sight glass
None, sufficient or too much
Empty or nearly empty
Amount of refrigerant
Refer to items 3 and 4
Refer to items 5 and 6Correct or too much
Insufficient*
Symptom
Too much
Remedy
Correct
Item
-AIR CONDITIONING SYSTEM REFRIGERANT VOLUME
AC-22

2. INSPECT DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge: Nippondenso BTG-20 (95506-
00020) or Borroughs No. BT-33-73F
Drive belt tension:
New belt 160 ± 25 lbf
Used belt 100 ± 20 lbf
HINT:
• ”New belt” refers to a belt which has been used
less than 5 minutes on a running engine.
• ”Used belt” refers to a belt which has been used
on a running engine for 5 minutes or more.
• After installing the drive belt, check that it fits
properly in the ribbed grooves.
DRIVE BELT TENSION
DRIVE BELT TENSION INSPECTION
1. MAKE SURE THAT DRIVE BELT IS INSTALLED
CORRECTLY
Check that the drive belt fits properly in the ribbed
groves.
-AIR CONDITIONING SYSTEM DRIVE BELT TENSION
AC-23

IDLE-UP SPEED
IDLE UP SPEED INSPECTION
1. WARM UP ENGINE
2. SET VEHICLE IN FOLLOWING CONDITION
• Blower switch high position
• A/C switch on
• Magnetic clutch on
3. INSPECT IDLE UP SPEED
Standard:
950 ± 50 RPM
IDLE-UP SPEED ADJUSTMENT
ADJUST IDLE-UP SPEED
Adjust idle-up speed with the idle adjusting screw of
the VSV.
-AIR CONDITIONING SYSTEM IDLE-UP SPEED
AC-24

REFRIGERANT LINES
LOCATIONS
-AIR CONDITIONING SYSTEM REFRIGERANT LINES
AC-25

REFRIGERANT LINES REPLACEMENT
1. RECOVER REFRIGERANT IN REFRIGERATION
SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fittings immediately to keep mois-
ture or dirt out of the system.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE: Connections should not be torque tighter than
the specified torque.
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND
CHARGE WITH REFRIGERANT
Specified amount:
700 ± 50 g (24.69 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refriger-
ant.
6. INSPECT AIR CONDITIONING OPERATION
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR
LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak tester, check for leakage of refriger-
ant.
-AIR CONDITIONING SYSTEM REFRIGERANT LINES
AC-26

COOLING UNIT
COOLING UNIT REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
the time the ignition switch is turned to the ’LOCK’
2. RECOVER REFRIGERANT FROM REFRIGERATION
SYSTEM
3. DISCONNECT SUCTION TUBE FROM COOLING
UNIT OUTLET FITTING
4. DISCONNECT LIQUID TUBE FROM COOLING UNIT
INLET FITTING
ture out of the system.
5. REMOVE INSTRUMENT LOWER FINISH PANEL
(See page BO-46 )
6. DISCONNECT CONNECTOR FROM WIRE HARNESS
7. REMOVE EARTH WIRE
8. REMOVE A/C AMPLIFIER
(a) Disconnect the connector from the A/C amplifier.
(b) Remove the 3 screws and the A/C amplifier.
9. REMOVE COOLING UNIT
Remove the 3 screws, nuts and the cooling unit.
-AIR CONDITIONING SYSTEM COOLING UNIT
AC-27

1. REMOVE UPPER AND LOWER CASE
(a) Disconnect and remove the wire harness.
(b) Remove the 2 clips and the 4 screws.
(c) Remove the upper and the lower case.
(d) Remove the A/C main relay from the upper case.
(e) Remove the blower resistor from the lower case.
COOLING UNIT DISASSEMBLY
AC-28

2. INSTALL THERMISTOR
3. INSTALL UPPER AND LOWER CASE TO EVAPORA-
TOR
(a) Install the blower resistor to the lower case.
(b) Install the A/C main relay to the upper case.
(c) Install the upper and lower case to the evaporator.
(d) Install the 2 clips and 4 tapping screws.
(e) Connect the connectors of wire harness.
COOLING UNIT ASSEMBLY
1. CONNECT EXPANSION VALVE, SUCTION AND
LIQUID TUBES TO EVAPORATOR
Torque the bolts.
Torque: 5.4 N-m (55 kgf-cm. 48 in.-Ibf)
3. REMOVE EXPANSION VALVE, SUCTION AND
LIQUID TUBES FROM EVAPORATOR
2. REMOVE THERMISTOR FROM EVAPORATOR
AC-29

6. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf)
7. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 32 N-m (330 kgf-cm, 24 ft-Ibf)
8. IF EVAPORATOR WAS REPLACED, ADD COMPRES-
SOR OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.)
Compressor oil:
ND-OIL 9
9. CONNECT NEGATIVE (-) CABLE TO BATTERY
10. EVACUATE AIR FROM REFRIGERATION SYSTEM
11. CHARGE SYSTEM WITH REFRIGERANT AND IN-
SPECT FOR LEAKAGE OF REFRIGERANT
Specified amount:
700 ± 50 g (24.69 ± 1.76 oz.)
COOLING UNIT INSTALLATION
1. INSTALL COOLING UNIT
Install the cooling unit with the 3 nuts and 4 screws.
2. INSTALL A/C AMPLIFIER
(a) Install the A/C amplifier to the cooling unit with the 2
screws.
(b) Connect the connector to the A/C amplifier.
3. INSTALL EARTH WIRE TO BODY
4. CONNECT CONNECTOR TO WIRE HARNESS OF VE-
HICLE SIDE
5. INSTALL INSTRUMENT LOWER FINISH PANEL
AC-30

BLOWER UNIT
BLOWER UNIT REMOVAL
(See page AC-25 )
2. REMOVE BLOWER UNIT
(a) Disconnect the connector from the blower motor.
(b) Disconnect the air inlet damper control cable from the
blower motor.
(e) Remove the nut, 2 screws and the blower unit.
BLOWER UNIT INSTALLATION
1. INSTALL BLOWER UNIT
(a) Install the blower unit with the nut and 2 screws.
(b) Connect the air inlet damper control cable to the
blower unit.
HINT: For installing the control cable, refer to ”Adjust-
ment of A/C Control Cables”.
(c) Connect the connector to the blower motor.
2. INSTALL COOLING UNIT
(See page AC-30 )
-AIR CONDITIONING SYSTEM BLOWER UNIT
AC-31

4. DISCONNECT WATER HOSES FROM HEATER RA-
DIATOR PIPES
(a) Grip the claws of the hose clip with pliers and slide the
clip along the hose to a place where it dose not clamp
the hose to the pipe.
(b) Disconnect the water hoses.
5. REMOVE PIPE GROMMETS
6. REMOVE A/C CONTROL ASSEMBLY
(See page AC-64 )
HEATER UNIT
HEATER UNIT REMOVAL
1. REMOVE SAFETY PAD
See ”Instrument Panel” on BO section.
(See page AC-25 )
3. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all the coolant.
8. REMOVE INSTRUMENT PANEL REINFORCEMENT
NO. 1 BRACE
Remove the 2 nuts, 2 bolts and the No. 1 brace.
9. REMOVE INSTRUMENT PANEL REINFORCEMENT
NO. 2 BRACE
Remove the 2 nuts, a bolts and the No. 2 brace.
7. REMOVE HEATER TO REGISTER CENTER DUCT
Remove the 3 screws and the duct.
10. REMOVE HEATER UNIT
Remove the screw, nut and the heater unit.
-AIR CONDITIONING SYSTEM HEATER UNIT
AC-32

HEATER UNIT INSTALLATION
Install by following the removal procedure in reverse
order.
HINT:
• Push the water hose onto the heater radiator pipe
as far as the ridge on the pipe.
• Install the hose clip in a position, as shown to the
left.
-AIR CONDITIONING SYSTEM HEATER UNIT
AC-33

COMPRESSOR
Magnetic Clutch:
INSPECT MAGNETIC CLUTCH FOR FOLLOWING
(a) Inspect the pressure plate and the rotor for signs of
oil.
(b) Check the clutch bearings for noise and grease leak-
age.
(c) Connect the positive (+) lead from the battery to the
terminal on the magnetic clutch connector and the
negative (-) lead to the body ground.
(d) Check that the magnetic clutch is energized.
If the magnetic clutch is not energized, replace the
magnetic clutch.
Compressor:
1. INSTALL MANIFOLD GAUGE SET
3. INSPECT COMPRESSOR FOR FOLLOWING
(a) High pressure gauge reading is not lower and low
pressure gauge reading is not higher than normal.
(b) Check that the metallic sound.
(c) Check that the leakage from shaft seal.
-AIR CONDITIONING SYSTEM COMPRESSOR
AC-34

1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10
MINUTES
2. STOP ENGINE
TERY
SYSTEM
5. REMOVE UNDER COVER
6. DISCONNECT CONNECTOR FROM MAGNETIC
CLUTCH
7. DISCONNECT 2 HOSES FROM COMPRESSOR SER-
VICE VALVE
Cap the open fitting immediately to keep moisture and
dust out of the system.
COMPRESSOR REMOVAL
AC-35

8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the com-
pressor.
1. REMOVE PRESSURE PLATE
(a) Using a socket and SST, remove the shaft nut.
SST 07112-76060
(b) Install SST to the pressure plate.
SST 07112 - 66040
MAGNETIC CLUTCH DISASSEMBLY
AC-36

3. REMOVE STATOR
(a) Using a screwdriver and disconnect the stator lead
wires from the compressor housing.
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE: Be careful not to damage the pulley when tapp-
ing on the rotor.
(c) Using SST and the socket, remove the pressure plate.
SST 07112-76060, 07112-66040
2. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114-84020
(d) Remove the shims from the shaft.
AC-37

MAGNETIC CLUTCH ASSEMBLY
1. INSTALL STATOR
(a) Install the stator on the compressor.
(b) Using SST, install a new snap ring.
SST 07114-84020
(c) Connect the stator lead wires to the compressor hous-
ing.
NOTICE: The snap ring should be installed so that its
beveled side faces up.
(b) Using SST, remove the snap ring.
SST 07114-84020
(c) Remove the stator.
AC-38

3. INSTALL PRESSURE PLATE
(a) Adjust the clearance between the pressure plate and
rotor by putting shims on the compressor shaft.
Standard clearance:
0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
If the clearance is not within tolerance, change the
number of shims to obtain the standard clearance.
2. INSTALL ROTOR
(a) Install the rotor on the compressor shaft.
(b) Using SST, install a new snap ring.
SST 07114-84020
(b) Using SST and torque wrench, install the shaft nut.
SST 07112-76060
Torque: 14 N-m (140 kgf-cm, 10 ft-lbf)
NOTICE: The snap ring should be installed so that its
beveled side faces up.
AC-39

COMPRESSOR INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING
BOLTS
2. INSTALL DRIVE BELT
See Drive Belt Tension Adjustment on page AC-23 .
3. CONNECT 2 HOSES TO COMPRESSOR SERVICE
VALVES
Torque:
Discharge line
10 N-m (100 kgf-cm, 8 ft-lbf)
Suction line
10 N-m (100 kgf-cm. 8 ft-lbf)
4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS
7. CHARGE SYSTEM WITH REFRIGERANT AND IN.
Specified amount:
700 ±50 g (24.69 ± 1.76 oz.)
4. INSPECT CLEARANCE OF MAGNETIC CLUTCH
(a) Set the dial-gauge to the pressure plate of the mag-
netic clutch.
(b) Connect the magnetic clutch lead wire to the positive
(+) terminal of the battery.
(c) Check the clearance between the pressure plate and
rotor, when connect the negative (-) terminal of the
battery.
Standard clearance:
0.5 ± 0.15 mm (0.020 ± 0.0059 in.)
If the clearance is not within standard clearance
adjust the clearance using shims to obtain the stand-
ard clearance.
AC-40

RECEIVER REMOVAL
SYSTEM
2. DISCONNECT (-) NEGATIVE CABLE FROM BAT-
TERY
the time the ignition switch is turned to the ’LOCK’ position
and the negative (-) terminal cable is discon-
3. REMOVE FRONT GRILLE
4. DISCONNECT 2 LIQUID TUBES FROM RECEIVER
5. REMOVE RECEIVER FROM RECEIVER HOLDER
RECEIVER INSTALLATION
1. INSTALL RECEIVER IN RECEIVER HOLDER
HINT: Do not remove the blind plugs until ready for
connection.
2. CONNECT 2 LIQUID TUBES TO RECEIVER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
3. INSTALL FRONT GRILLE
5. IF RECEIVER WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
Add 20 cc (0.71 fl.oz.)
Compressor oil:
ND-OIL 9
Specified amount:
700 ± 50 g (24.69 ± 1.76 oz.)
RECEIVER
INSPECT SIGHT GLASS, FUSIBLE PLUG AND FIT-
TINGS FOR LEAKAGE
Use a gas leak tester. Repair as necessary.
-AIR CONDITIONING SYSTEM RECEIVER
AC-41

3. REMOVE FOLLOWING PARTS
• Front grille
• Horn
• Hood lock
• Center brace
• Condenser fan
4. DISCONNECT LIQUID TUBE AND DISCHARGE
HOSE FROM CONDENSER FITTING
5. REMOVE RECEIVER WITH RECEIVER BRACKET
FROM CONDENSER
6. REMOVE RADIATOR SUPPORT BRACKETS
7. REMOVE CONDENSER
(a) Remove the 2 condenser mounting bolts.
(b) Remove the 2 condenser brackets.
CONDENSER
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, wash them with water and dry
with compressed air.
NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver
or pliers.
2. INSPECT CONDENSER FITTINGS FOR LEAKAGE
Repair as necessary.
CONDENSER REMOVAL
SYSTEM
TERY
-AIR CONDITIONING SYSTEM CONDENSER
AC-42

2. INSTALL RADIATOR SUPPORT
3. INSTALL RECEIVER WITH RECEIVER BRACKET TO
CONDENSER
4. CONNECT LIQUID TUBE TO RECEIVER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
5. CONNECT LIQUID TUBE AND DISCHARGE HOSE
TO CONDENSER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
6. INSTALL FOLLOWING PARTS
• Condenser fan
• Center brace
• Hood lock
• Horn
• Front grille
8. IF CONDENSER WAS REPLACED, ADD COMPRES-
SOR OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.)
Compressor oil:
ND-OIL 9
9. EVACUATE AIR FROM AIR CONDITIONING
SYSTEM
Specified amount:
700 ± 50 g (24.69 ± 1.76 oz.)
CONDENSER INSTALLATION
1. INSTALL CONDENSER
Install the condenser with the 2 condenser brackets
and the 2 mounting bolts.
(c) Pull the condenser out.
AC-43

EVAPORATOR INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed
air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
REMOVAL AND INSTALLATION OF
EVAPORATOR
See item of cooling unit.
AC-44

HEATER RADIATOR
HEATER RADIATOR REMOVAL
1. REMOVE HEATER UNIT
(See page AC-32 )
2. REMOVE HEATER RADIATOR
(a) Remove the 2 screws and the 2 plates.
(b) Pull the heater radiator out.
HEATER RADIATOR INSPECTION
INSPECT FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed
air.
HEATER RADIATOR INSTALLATION
1. INSTALL HEATER RADIATOR
(a) Insert the heater radiator to the heater unit.
(b) Install the 2 plates with the 2 screws.
2. INSTALL HEATER UNIT
(See page AC-33 )
-AIR CONDITIONING SYSTEM HEATER RADIATOR
AC-45

BLOWER MOTOR
MOTOR REMOVAL
TERY
MOTOR INSTALLATION
1. INSTALL BLOWER MOTOR
(a) Install the blower motor with the 3 screws.
(b) Connect the connector to blower motor.
2. INSTALL A/C AMPLIFIER
Install A/C amplifier with the 3 screws.
MOTOR INSPECTION
INSPECT BLOWER MOTOR OPERATION
Connect the positive (+) lead from the battery to
terminal 1 and the negative (-) lead to terminal 2,
then check that the motor operation is smooth.
3. REMOVE BLOWER MOTOR
(a) Disconnect the connector from the blower motor.
(b) Remove the 3 screws and the blower motor.
2. REMOVE A/C AMPLIFIER
Remove the 3 screws and the A/C amplifier with the
connector connected.
-AIR CONDITIONING SYSTEM BLOWER MOTOR
AC-46

CONDENSER FAN REMOVAL
TERY
2. REMOVE FOLLOWING COMPONENTS
• Front grille
• Hood lock
• Center brace
3. REMOVE CONDENSER FAN
(a) Disconnect the connector from fan motor.
(b) Remove the 2 bolts and the condenser fan.
CONDENSER FAN INSTALLATION
1. INSTALL CONDENSER FAN
(a) Install the condenser fan with the 2 bolts.
(b) Connect the connector to the fan motor.
2. INSTALL FOLLOWING PARTS
• Center brace
• Hood lock
• Front grille
CONDENSER FAN
INSPECT CONDENSER FAN MOTOR
(a) Using the wire harness, apply battery positive voltage
to the connector.
(b) Confirm smooth rotation of the motor within the spe-
cified current flow.
Standard current:
9.5 ±1.5 A
If current is not as specified, replace the motor.
-AIR CONDITIONING SYSTEM CONDENSER FAN
AC-47

EXPANSION VALVE
1. CHECK QUANTITY OF GAS DURING REFRIGERA-
TION CYCLE
3. RUN ENGINE
Run the engine at 2,000 RPM for at least 5 minutes.
Then check that the high pressure reading is 1,275 -
1,471 kPa (13 - 15 kgf/cm2, 185 - 213 psi).
4. CHECK EXPANSION VALVE
If the expansion valve is faulty, the low pressure
reading will drop to 0 kPa (0 kgf/cm2, 0 psi), otherwise
it is OK.
HINT: When the low pressure drops to 0 kPa (0 kgf/
cm2, 0 psi), feel the receiver’s IN and OUT sides for no
temperature difference.
EXPANSION VALVE REMOVAL AND
INSTALLATION
-AIR CONDITIONING SYSTEM EXPANSION VALVE
AC-48

2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY
BLOWING AIR INTO PIPES
(a) Connect the VSV terminals to the battery terminals as
illustrated.
(b) Blow into pipe ”A” and check that air comes out of
pipe ”B”.
(c) Disconnect the battery.
(d) Blow into pipe ”A” and check that air does not come
out pipe ’B’.
If a problem is found, replace the VSV.
3. CHECK FOR SHORT CIRCUIT
Using an ohmmeter, check that there is no continuity
between each terminal and the VSV body.
If there is continuity, replace the VSV.
VSV INSPECTION
1. DISCONNECT VACUUM HOSES AND CONNECTOR
FROM VSV
VACUUM SWITCHING VALVE (VSV)
VACUUM HOSE CIRCUIT
-AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV)
AC-49

4. CHECK FOR OPEN CIRCUIT
Using an ohmmeter, the resistance between the 2
terminals.
Resistance:
30 - 34 W at 20 C (68 F)
If the resistance is not within specification, replace
the VSV.
-AIR CONDITIONING SYSTEM VACUUM SWITCHING VALVE (VSV)
AC-50

BLOWER RESISTOR
BLOWER RESISTOR REMOVAL
TERY
2. REMOVE BLOWER RESISTOR
(a) Disconnect the connector from the blower resistor.
(b) Remove the 2 screws and the blower resistor.
BLOWER RESISTOR INSTALLATION
1. INSTALL BLOWER RESISTOR
(a) Install the blower resistor with the 2 screws.
(b) Connect the connector to the blower resistor.
BLOWER RESISTOR INSPECTION
INSPECT BLOWER RESISTOR
Continuity
If continuity is not as specified, replace the blower
resistor.
Condition
Terminal
Constant
-AIR CONDITIONING SYSTEM BLOWER RESISTOR
AC-51

HEATER MAIN RELAY
RELAY REMOVAL
TERY
(See page BO-46 )
3. DISCONNECT HEATER MAIN RELAY FROM A/C
RELAY BLOCK
RELAY INSTALLATION
1. CONNECT HEATER MAIN RELAY TO A/C RELAY
BLOCK
RELAY INSPECTION
INSPECT HEATER MAIN RELAY
Continuity
If continuity is not as specified, replace the relay.
Tester connection to
terminal number
Apply B + between
terminals 1 and 3.
Specified value
1-3
2-4
Continuity
Continuity
Condition
Constant
4-5
-AIR CONDITIONING SYSTEM HEATER MAIN RELAY
AC-52

MAGNETIC CLUTCH RELAY
RELAY REMOVAL
TERY
(See page BO-46 )
3. REMOVE MAGNETIC CLUTCH RELAY
Remove a screw and disconnect the relay from the
connector.
RELAY INSTALLATION
1. INSTALL MAGNETIC CLUTCH RELAY
Connect the relay to the connector and install it to the
cooling unit with the screw.
RELAY INSPECTION
INSPECT MAGNETIC CLUTCH RELAY
Continuity
terminal number
Apply B+ between
terminals 1 and 3.
Specified value
Continuity
Continuity
Condition
Constant 1-3
2-4
-AIR CONDITIONING SYSTEM MAGNETIC CLUTCH RELAY
AC-53

CONDENSER FAN RELAY NO.2 AND
NO.3 (USA)
RELAYS REMOVAL
TERY
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 FROM RELAY BLOCK NO. 2
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO. 2
Check the relay the same way as for the heater main
relay.
2. INSPECT CONDENSER FAN RELAY NO. 3
Check the relay the same way as for the magnetic
clutch relay.
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 TO RELAY BLOCK NO. 2
-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N0.3 (USA)
AC-54

CONDENSER FAN RELAY NO.2 AND
NO.3 (Canada)
RELAYS REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 FROM RELAY BLOCK NO. 5
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO.2
Continuity
2. INSPECT CONDENSER FAN RELAY NO.3
Continuity
terminal number
terminal number
Apply B + between
terminals 1 and 2.
Apply B+ between
terminals 1 and 2.
Specified value
Specified value
1-2
3-4
Continuity
Continuity
Continuity
Continuity
Condition
Condition
Constant
Constant
1-2
3-5
3-5
-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY NO.2 AND NO.3 (Canada)
AC-55

RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 TO RELAY BLOCK NO.5
-AIR CONDITIONING SYSTEM CONDENSER FAN RELAY N0.2 AND N 0.3(Canada)
AC-56

THERMISTOR INSPECTION
INSPECT THERMISTOR RESISTANCE
(a) Measure the resistance between terminals at 25 C
(77 F).
Resistance:
1,500 W at 25°C (77°F)
(b) Place the thermistor in cold water. While varying the
temperature of the water, measure the resistance at
the connector and at the same time, measure the
temperature of the water with a thermometer.
(c) Compare the 2 readings on the chart.
If the resistance valve is not as specified, replace the
thermistor.
THERMISTOR
THERMISTOR REMOVAL AND
INSTALLATION
-AIR CONDITIONING SYSTEM THERMISTOR
AC-57

REVOLUTION DETECTING SENSOR
(w Power Steering)
SENSOR INSPECTION
MEASURE SENSOR RESISTANCE
Measure the resistance between terminals 3 and 4.
Standard resistance:
240 ± 80 at 20°C (68°F)
If resistance value is not as specified, replace the
sensor.
SENSOR REMOVAL
1. REMOVE COMPRESSOR
(See page AC-35 )
2. REMOVE REVOLUTION DETECTING SENSOR
(a) Remove the bolt.
(b) Remove the revolution detecting sensor.
SENSOR INSTALLATION
1. INSTALL REVOLUTION DETECTING SENSOR
Using a torque wrench, tighten the bolt.
Torque: 11 N .m (110 kgf-cm, 8 ft-lbf)
2. INSTALL COMPRESSOR
(See page AC-40 )
-AIR CONDITIONING SYSTEM REVOLUTION DETECTING SENSOR (w Power Steering)
AC-58

REFRIGERANT TEMPERATURE
SWITCH
SWITCH REMOVAL AND INSTALLATION
See ”Discharge Valve Removal or Installation” on page
AC-35 or 40.
SWITCH INSPECTION
INSPECT REFRIGERANT TEMPERATURE SWITCH
Check refrigerant temperature switch operation.
If operation is not as specified, replace the switch.
HINT: After inspection, throughly clean the switch
before assembly.
Oil Temperature
120°C (248°F)
180°C (356°F)
Specified Value
No continuity
Continuity
-AIR CONDITIONING SYSTEM REFRIGERANT TEMPERATURE SWITCH
AC-59

SWITCHES REMOVAL
SYSTEM
TERY
3. REMOVE TRIPLE PRESSURE SWITCH FROM
LIQUID TUBE
Disconnect the connector and remove the triple pres-
sure switch.
SWITCHES INSTALLATION
1. INSTALL TRIPLE PRESSURE SWITCH TO LIQUID
TUBE
Tighten the triple pressure switch then connect the
connector to it.
Specified amount:
700 ± 50 g (24.69 ± 1.76 oz.)
4. INSPECT TRIPLE PRESSURE SWITCH
(Magnetic Clutch Control)
(a) Connect the positive (+) lead from the ohmmeter to
terminal 1 and negative (-) lead to terminal 2.
(b) Check continuity between terminals when refrigerant
pressure is changed, as shown.
If operation is not as specified, replace the pressure
switch.
TRIPLE PRESSURE SWITCH
1. DISCONNECT CONNECTOR FROM TRIPLE PRES-
SURE SWITCH
-AIR CONDITIONING SYSTEM TRIPLE PRESSURE SWITCH
AC-60

BLOWER SPEED CONTROL SWITCH
SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) GABLE FROM BAT-
TERY
2. REMOVE A/C CONTROL PANEL
(See page BO-47 )
3. REMOVE AUDIO AND ASH TRAY
(See page BO-46 )
4. REMOVE BLOWER SPEED CONTROL SWITCH
(a) Remove the illumination light from the A/C control
assembly.
(b) Using a screwdriver, pry loose the clip and push out
the blower speed control switch to rear of the A/C
control assembly.
(c) Disconnect the connector from the blower speed con-
trol switch.
SWITCH INSPECTION
INSPECT BLOWER SPEED CONTROL SWITCH
Continuity
If continuity is not as specified, replace the blower
speed control switch.
Switch position
IlluminationTerminal
OFF
-AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH
AC-61

SWITCH INSTALLATION
1. INSTALL BLOWER SPEED CONTROL SWITCH
(a) Connect the connector to the blower speed control
switch.
(b) Install the illumination light to the A/C control assem-
bly.
(c) Install the blower speed control switch to the A/C
control assembly.
2. INSTALL AUDIO AND ASH TRAY
3. INSTALL A/C CONTROL PANEL
-AIR CONDITIONING SYSTEM BLOWER SPEED CONTROL SWITCH
AC-62

AIR CONDITIONING SWITCH
SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE PROM BAT-
TERY
2. REMOVE A/C SWITCH
Using a screwdriver, pry loose the clips and remove
the A/C switch.
HINT: Tape the screwdriver tip before use.
SWITCH INSTALLATION
1. INSTALL A/C SWITCH
Push in the A/C switch to the A/C control assembly.
If continuity is not as specified, check the bulb or
replace the switch.
SWITCH INSPECTION
INSPECT A/C SWITCH
Continuity
terminal number
Illumination circuit
A/C Switch OFF
A/C Switch ON
Specified value
4-5
4-6
No continuity
Continuity
Continuity
Condition
1-3
-AIR CONDITIONING SYSTEM AIR CONDITIONING SWITCH
AC-63

AIR CONDITIONING CONTROL
ASSEMBLY
INSPECT A/C CONTROL LEVERS OPERATION
Move the control levers left and right and check for
stiffness and binding through the full range of the
levers.
3. ADJUST AIR MIX DAMPER CONTROL CABLE
Set the air mix damper on ”COOL” position, install the
control cable and lock the clamp.
1. ADJUST AIR INLET DAMPER CONTROL CABLE
Set the air inlet damper on ”RECIRC” position, install
the control cable and lock clamp.
2. ADJUST MODE DAMPER CONTROL CABLE
Set the air inlet damper on ”FACE” position, install the
control cable and lock the clamp.
A/C CONTROL CABLES ADJUSTMENT
-AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY
AC-64

A/C CONTROL ASSEMBLY
INSTALLATION
1. INSTALL A/C CONTROL ASSEMBLY
(a) Install the blower switch to the A/C control assembly.
(b) Wire the control cables, as shown the illustration.
(c) Connect the control cables to the heater unit and
blower unit.
HINT: For installing the control cables, refer to ”Ad-
justment of A/C Control Cables”.
2. INSTALL SAFETY PAD
A/C CONTROL ASSEMBLY REMOVAL
1. REMOVE SAFETY PAD
See ”Instrument Panel” on BO section.
2. REMOVE A/C CONTROL ASSEMBLY
(a) Disconnect the control cables from the heater unit
and the blower unit.
(b) Remove the blower switch and remove the A/C con-
trol assembly.
-AIR CONDITIONING SYSTEM AIR CONDITIONING CONTROL ASSEMBLY
AC-65

AMPLIFIER INSPECTION
INSPECT A/C AMPLIFIER CONNECTOR ON WIRE
HARNESS SIDE
Test conditions:
• Ignition switch ON
• Temperature control lever to MAX COOL
• Blower switch ON
w/o Power Steering
AIR CONDITIONING AMPLIFIER
AMPLIFIER REMOVAL
REMOVE A/C AMPLIFIER
(a) Disconnect the connector from the amplifier.
(b) Remove the 3 screws and the amplifier.
terminal number
terminal number
terminal number
terminal number
Approx. 1.5 kW at 25°C (77°F)
w/ Power Steering
Specified value (Resistance)
Specified value (Continuity)
Specified value (Voltage)
Specified value (Voltage)
Battery positive voltage
Approx. 10 to 14 V
Approx. 10 to 14 V
Blower switch OFF
Blower switch OFF
Blower switch ON
Blower switch ON
A/C switch OFF
A/C switch OFF
Stop the engine
Start the engine
Stop the engine
Start the engine
A/C switch ON
A/C switch ON
Approx. 240W
12 - Ground
8 - Ground
8 - Ground
8 - Ground
8 - Ground
1 - Ground
1 - Ground
7 - Ground
7 - Ground
7 - Ground
1 - Ground
1 - Ground
7 - Ground
No voltage
No voltage
No voltage
No voltage
No voltage
No voltage
Continuity
Continuity
Condition
Condition
Condition
Condition
Constant
Constant
Constant
Constant
9-13
2- 13
5 -7
-AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER
AC-66

If continuity is not as specified, replace the A/C ampli-
fier.
terminal number
terminal number
Specified value (Continuity)
Specified value (Resistance)
12 - Ground Continuity
Continuity
Condition
Condition
Constant
Constant
Constant2 - 12
5-7
Approx. 1.5 kW at 25°C (77°F)
-AIR CONDITIONING SYSTEM AIR CONDITIONING AMPLIFIER
AC-67

SERVICE SPECIFICATIONS
SERVICE DATA
TORQUE SPECIFICATIONS
0.5 ± 0.15 mm (0.02 ± 0.0059 in.)
Compressor x Compressor bracket
Refrigerant charge volume 700 ± 50 g (24.69 ± 1.76 oz.)
Compressor x Discharge hose
Compressor x Suction hose
Cooling unit x Suction tube
Cooling unit x Liquid tube
Magnetic clutch clearance
Condenser x Liquid tube
Receiver x Liquid tube
Drive belt tension
1,450 ± 50 RPMIdle-up speed
Part tightened
160 ± 25 lbf
100 ± 20 lbf
48 in.-lbf
Used belt
48 in.-lbf
New belt
kgf-cm ft-lbf
250
330
140
100
100
N-m
5.5
5.5
-AIR CONDITIONING SYSTEM SERVICE SPECIFICATIONS
AC-68

Air conditioning system

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