Air Conditioning: Overview Lexus IS II

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1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. Apply clean petroleum jelly to the skin. Go immediately to a hospital or see a physician for professional treatment.
4. NEVER HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME
5. BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the compressor may be damaged. Necessary care should be taken to avoid this.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valve is opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc.
9. NOTICE FOR INITIALIZATION When disconnecting the negative (-) battery terminal, initialize the following systems after the terminal is reconnected. POWER WINDOW CONTROL SYSTEM REFERENCE System Name See procedure Power Window Control System (See «INITIALIZATION»(ref-235541-S32349848442006062400000) )
10. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT CAUTION: Doing so may damage the inside of the compressor because the compressor parts always move regardless of whether the A/C system is turned on or off.
11. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) This vehicle is equipped with an SRS (Supplemental Restraint System) such as the driver, front passenger, side, and curtain shield air bags. Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices (See «PRECAUTION»(ref-235542-S10058841152006062400000) ).
12. GENERAL PRECAUTION While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur.

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TRANSMITTER RECEIVER SIGNAL REFERENCE

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1. GENERAL The air conditioning system has the following controls: SYSTEM DESCRIPTION Control Outline Neural Network Control This control is capable of effecting complex control by artificially simulating the information processing method of the nervous system of living organisms in order to establish a complex input / output relationship that is similar to a human brain. Automatic Recirculation Control (1) Automatically changes the air inlet mode to the fresh air or recirculation air mode according to the level of harmful elements in the outside air, cabin temperature, and outside temperature. Micro Dust and Pollen Filter Mode Control Activated by the micro dust and pollen filter mode switch operation. Switches the air vent to the FACE mode. Sends air which has passed through the clean air filter to the area around the upper part of the bodies of the driver and front passenger. Outlet Air Temp. Control Based on the temperature set at the temperature control switch, the neural network control calculates the outlet air temperature based on the input signals from various sensors. This air is filtered by the clean air filter in order to remove pollen. The temperature setting for the driver and front passenger is controlled independently in order to provide a separate vehicle interior temperature for the right and left side of the vehicle. Thus, air conditioning that accommodates the occupants' preferences has been realized. Blower Control Controls the blower motor in accordance with the airflow volume that has been calculated by the neural network control based on the input signals from various sensors. Air Outlet Control Automatically switches the air outlets in accordance with the outlet mode that has been calculated by the neural network control based on the input signals from various sensors. In accordance with the engine coolant temperature, outside air temperature, amount of sunlight, required blower, outlet temperature, and vehicle speed conditions, this control automatically switches the blower outlet to the FOOT / DEF mode to prevent the windows from becoming fogged when the outside air temperature is low. Air Inlet Control Automatically controls the air inlet control damper to achieve the calculated outlet air temperature that is required. Drives the servo motor (for air inlet) according to the operation of the air inlet control switch and moves the dampers to the FRESH or RECIRC position. Compressor Control This control turns OFF the magnetic clutch of the A/C compressor when the blower motor is turned OFF at the time the engine coolant temperature is below a predetermined value, an abnormal refrigerant pressure has been detected, or the discharge temperature of the evaporator is below a predetermined value (evaporator too cold). A/C amplifier turns the compressor off if the engine coolant temperature becomes abnormally hot (115 °c (239 °F) or above) when driving under a high load. Glow Plug Control The A/C amplifier and ECM operate two glow plugs in engine coolant to reduce the period of increased fuel consumption due to a cold engine, and to improve heater performance. Rear Window Defogger Control Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger button is pressed. Switches them off if the button is pressed while they are operating. Outside Temperature Indication Control Based on the signals from the ambient temperature sensor, this control calculates the outside temperature, which is then corrected in A/C amplifier, and shown in the multi-display. Self-Diagnosis A DTC (Diagnostic Trouble Code) is stored in the memory when the A/C amplifier detects a problem with the air conditioning system. (1) Models with a 2GR-FSE engine
2. NEURAL NETWORK CONTROL In previous automatic air conditioning systems, the A/C amplifier determined the required outlet air temperature and blower air volume in accordance with the calculation formula that has been obtained based on information received from the sensors. However, because the senses of a person are rather complex, a given temperature is sensed differently, depending on the environment in which the person is situated. For example, a given amount of solar radiation can feel comfortably warm in a cold climate, or extremely uncomfortable in a hot climate. Therefore, as a technique for effecting a higher level of control, a neural network has been adopted in the automatic air conditioning system. With this technique, the data that has been collected under varying environmental conditions is stored in the A/C amplifier. The A/C amplifier can then effect control to provide enhanced air conditioning comfort. The neural network control consists of neurons in the input layer, intermediate layer, and output layer. The input layer neurons process the input data of the outside temperature, the amount of sunlight, and the room temperature based on the outputs of the switches and sensors, and output them to the intermediate layer neurons. Based on this data, the intermediate layer neurons adjust the strength of the links among the neurons. The sum of these is then calculated by the output layer neurons in the form of the required outlet temperature, solar correction, target airflow volume, and outlet mode control volume. Accordingly, the A/C amplifier controls the servo motors and blower motor in accordance with the control volumes that have been calculated by the neural network control.
3. AUTOMATIC RECIRCULATION CONTROL When the automatic recirculation control is operating, the A/C amplifier automatically changes the air inlet mode to the fresh air or recirculate air mode based on signals from the smog ventilation sensor, ambient temperature, and room temperature sensors when the AUTO air inlet mode is selected. The A/C amplifier detects harmful elements (CO, HC, and NOx) based on smog ventilation sensor signals and automatically switches the air inlet mode to the recirculate air mode to prevent such harmful elements from entering the cabin. The A/C amplifier detects cabin temperature based on a room temperature sensor signal and automatically switches the air inlet mode to the recirculate air mode to prevent the cabin temperature from becoming too high. The A/C amplifier detects the outside temperature based on an ambient temperature sensor signal and automatically switches the air inlet mode to the fresh air mode to prevent the windshield from fogging up.
4. MICRO DUST AND POLLEN FILTER MODE CONTROL When the micro dust and pollen filter switch is pressed, the micro dust and pollen filter mode control is activated. Then, the air vent is switched to the FACE mode and recirculated pollen free air flows in the area around the upper part of the bodies of the driver and front passenger. When the micro dust and pollen filter switch signal is input to the A/C amplifier, the A/C amplifier controls the A/C compressor, air inlet control servo motor, air outlet control servo motor and blower motor as shown in the timing chart below. This control usually operates for approximately 3 minutes. However, when the outside temperature is low, it will operate for approximately 1 minute. After this control stops operating, the A/C amplifier controls the air conditioning system using the AUTO mode.
5. GLOW PLUG CONTROL In the glow plug control, the A/C amplifier and ECM operate two glow plugs to reduce the period of increased fuel consumption due to a cold engine and to improve heater performance. The A/C amplifier and ECM control this function. The A/C amplifier and ECM determine the number of glow plugs to operate based on the engine coolant temperature, outside temperature, and A/C Max. Hot state. The A/C amplifier then transmits request signals to the ECM. Based on the request signals from the A/C amplifier and a voltage generation rate signal from the generator, the ECM transmits a glow plug operation permission signal to the A/C amplifier.
6. MODE POSITION AND DAMPER OPERATION Mode Position and Damper Operation Functions of Main Dampers: DAMPER CONTROL OPERATION Control Damper Operation Position Damper Position Operation Air Inlet Control Damper FRESH A Allows fresh air to enter. RECIRC B Causes internal air to recirculate. Air Mix Control Damper MAX COLD to MAX HOT Temperature Setting C - D - E (C' - D' - E') Varies the mixture ratio of the hot air and the cold air in order to regulate the temperature continuously between HOT and COLD. Air Outlet Control Damper F, V, L, W, S Defrosts the windshield through the center defroster, side defroster, side register, and rear center register. G, K, L, P, Q Defrosts the windshield through the center defroster, side defroster, side register, and rear center register, while and also allows air to be blown out from the front and rear foot well register ducts. H, K, L, P, Q Air blows out of the foot well register duct and side register. In addition, a small amount of air will blow out from the center defroster and side defroster. I, T, N, U, R Air blows out of the front and rear center registers, side register and front and rear foot well register ducts. I, J, M, O, S Air blows out of the front and rear center registers and side register.
7. AIR OUTLETS AND AIRFLOW VOLUME Air Outlets and Airflow Volume
8. EVAPORATOR TEMPERATURE SENSOR The evaporator temperature sensor detects the temperature of the cool air immediately past the evaporator in the form of resistance changes, and outputs it to the A/C amplifier.
9. BLOWER MOTOR The blower motor has a built-in blower controller, and is controlled using duty control performed by the A/C amplifier.
10. BUS CONNECTOR A BUS connector is used in the wire harness connection that connects the servo motor from the A/C amplifier. The BUS connector has a built-in communication/driver IC which communicates with each servo motor connector, actuates the servo motor, and has a position detection function. This enables bus communication for the servo motor wire harness, for a more lightweight construction and a reduced number of wires.
11. SERVO MOTOR The pulse pattern type servo motor consists of a printed circuit board and a servo motor. The printed circuit board has three contact points, and can transmit two ON-OFF signals to the A/C ECU based on the difference of the pulse phases. The BUS connector can detect the damper position and movement direction with this signal.
12. LOCK SENSOR The lock sensor sends an A/C pulley speed signal to the ECM. The ECM compares this signal with an engine speed signal sent from the crankshaft position sensor. If the ECM determines that the A/C pulley has locked, the ECM turns the magnetic clutch off.
13. ROOM TEMPERATURE SENSOR The room temperature sensor detects the cabin temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C amplifier.
14. AMBIENT TEMPERATURE SENSOR The ambient temperature sensor detects the outside temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C amplifier.
15. SOLAR SENSOR The solar sensor consists of a photo diode, two amplifier circuits for the solar sensor, and frequency converter circuit for the light control sensor. A solar sensor detects (in the form of changes in the current that flows through the built-in photo diode) the changes in the amount of sunlight from the LH and RH sides (2 directions) and outputs these sunlight strength signals to the A/C amplifier.
16. A/C PRESSURE SENSOR The A/C pressure sensor detects the refrigerant pressure and outputs it to the A/C amplifier in the form of voltage changes.
17. SMOG VENTILATION SENSOR (for 2GR-FSE engine) The smog ventilation sensor detects harmful elements such as CO, HC, and Nox, which are present in the air outside of the vehicle. The sensor outputs it to the A/C amplifier. The sensitivity of the smog ventilation sensor can be adjusted. Adjustment can be done using the heater control panel or multi-display.

DESCRIPTION

This sensor detects the cabin temperature that is used as the basis for temperature control and sends a signal to the A/C amplifier.

DTC DETECTION CONDITION

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1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / min.: -6.5°C (20.3°F), max.: 57.25°C (135.05°F) Actual cabin temperature is displayed - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOM TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. INSPECT AIR CONDITIONING AMPLIFIER Remove the A/C amplifier with the connectors still connected. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-16 (TR) - J58-19 (SG-1) Engine switch on (IG) at 25°C (77°F) 1.8 to 2.2 V J58-16 (TR) - J58-19 (SG-1) Engine switch on (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOM TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT A/C ROOM TEMPERATURE SENSOR Remove the A/C room temperature sensor. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J38-1 - J38-2 10°C (50°F) 3.00 to 3.73 kohms J38-1 - J38-2 15°C (59°F) 2.45 to 2.88 kohms J38-1 - J38-2 20°C (68°F) 1.95 to 2.30 kohms J38-1 - J38-2 25°C (77°F) 1.60 to 1.80 kohms J38-1 - J38-2 30°C (86°F) 1.28 to 1.47 kohms J38-1 - J38-2 35°C (95°F) 1.00 to 1.22 kohms J38-1 - J38-2 40°C (104°F) 0.80 to 1.00 kohms J38-1 - J38-2 45°C (113°F) 0.65 to 0.85 kohms J38-1 - J38-2 50°C (122°F) 0.50 to 0.70 kohms J38-1 - J38-2 55°C (131°F) 0.44 to 0.60 kohms J38-1 - J38-2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Hold the sensor only by its connector. Touching the sensor may change the resistance value. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG: REPLACE A/C ROOM TEMPERATURE SENSOR OK: Go to next step
4. CHECK HARNESS AND CONNECTOR (A/C ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) Disconnect the connectors from the A/C room temperature sensor and A/C amplifier. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-16 (TR) - J38-1 Always Below 1 ohms J58-19 (SG-1) - J38-2 Always Below 1 ohms J58-16 (TR) - Body ground Always 10 kohms or higher J58-19 (SG-1) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

The ambient temperature sensor is installed in front of the condenser to detect the ambient temperature which is used to control the air conditioner "AUTO" mode. This sensor connected to the ECM and detects fluctuations in the ambient temperature. This data is used for controlling the cabin temperature. The sensor sends a signal to the A/C amplifier via the ECM. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases.

The ECM applies voltage (5 V) to the ambient temperature sensor and reads voltage changes as the resistance of the ambient temperature sensor changes. The ECM sends the signal to the A/C amplifier via CAN and body multiplex communication.

DTC DETECTION CONDITION

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1. CHECK MULTIPLEX COMMUNICATION SYSTEM Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result RESULT REFERENCE Result Proceed to MPX DTC is not output A MPX DTC is output B B : GO TO «MULTIPLEX COMMUNICATION SYSTEM»(ref-235578-S20958542052006062400000) A : Go to next step
2. CHECK CAN COMMUNICATION SYSTEM Use the intelligent tester to check if the CAN Communication System is functioning normally. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B : GO TO «CAN COMMUNICATION SYSTEM»(ref-235565-S22980917632006062400000) A : Go to next step
3. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS (Ambient temperature sensor) Ambient temperature sensor / Min: -23.3°C (-9.94°F), Max: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in circuit: -23.3°C (-9.94°F) Short in circuit: 65.95°C (150.71°F) OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
4. INSPECT AMBIENT TEMPERATURE SENSOR Remove the ambient temperature sensor. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B5-1 - B5-2 10°C (50°F) 3.00 to 3.73 kohms B5-1 - B5-2 15°C (59°F) 2.45 to 2.88 kohms B5-1 - B5-2 20°C (68°F) 1.95 to 2.30 kohms B5-1 - B5-2 25°C (77°F) 1.60 to 1.80 kohms B5-1 - B5-2 30°C (86°F) 1.28 to 1.47 kohms B5-1 - B5-2 35°C (95°F) 1.00 to 1.22 kohms B5-1 - B5-2 40°C (104°F) 0.80 to 1.00 kohms B5-1 - B5-2 45°C (113°F) 0.65 to 0.85 kohms B5-1 - B5-2 50°C (122°F) 0.50 to 0.70 kohms B5-1 - B5-2 55°C (131°F) 0.44 to 0.60 kohms B5-1 - B5-2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG: REPLACE AMBIENT TEMPERATURE SENSOR OK: Go to next step
5. CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - ECM) Disconnect the ambient temperature sensor connector. Disconnect the ECM connectors. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B5-1 - A5-18 (TAM) Always Below 1 ohms B5-2 - E5-30 (E3) Always Below 1 ohms A5-18 (TAM) - Body ground Always 10 kohms or higher E5-30 (E3) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE ECM

The evaporator temperature sensor (A/C thermistor) is installed on the evaporator in the air conditioner unit. It detects the temperature of the cooled air that has passed through the evaporator and its signal is used to control the air conditioning. It sends a signal to the A/C amplifier. The resistance of the evaporator temperature sensor (A/C thermistor) changes in accordance with the temperature of the cooled air that has passed through the evaporator. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases.

The A/C amplifier applies voltage (5 V) to the evaporator temperature sensor (A/C thermistor) and reads voltage changes as the resistance of the evaporator temperature sensor (A/C thermistor) changes. This sensor is used to prevent the evaporator from freezing.

DTC DETECTION CONDITION

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1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP TEMP (Evaporator temperature sensor) Evaporator temperature sensor / Min.: -29.7°C (-21.46°F), Max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in circuit: -29.7°C (-21.46°F) Short in circuit: 59.55°C (139.19°F) OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. INSPECT AIR CONDITIONING HARNESS Remove the air conditioning harness (evaporator temperature sensor). Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition e1-5 - e1-6 -10°C (14°F) 7.30 to 9.10 kohms e1-5 - e1-6 -5°C (23°F) 5.65 to 6.95 kohms e1-5 - e1-6 0°C (32°F) 4.40 to 5.35 kohms e1-5 - e1-6 5°C (41°F) 3.40 to 4.15 kohms e1-5 - e1-6 10°C (50°F) 2.70 to 3.25 kohms e1-5 - e1-6 15°C (59°F) 2.14 to 2.58 kohms e1-5 - e1-6 20°C (68°F) 1.71 to 2.05 kohms e1-5 - e1-6 25°C (77°F) 1.38 to 1.64 kohms e1-5 - e1-6 30°C (86°F) 1.11 to 1.32 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG: REPLACE AIR CONDITIONING HARNESS OK: REPLACE AIR CONDITIONING AMPLIFIER

The smog ventilation sensor, which is installed on the front of the condenser, is used for automatic air inlet control. This sensor detects CO and HC in the emission gas and transmits signals to the A/C amplifier.

DTC DETECTION CONDITION

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1. INSPECT FUSE (LH-IG) Remove the LH-IG fuse from the cowl side junction block LH. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition LH-IG fuse Always Below 1 ohms NG: REPLACE FUSE (LH-IG) OK: Go to next step
2. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Allow exhaust gas (HC, CO) to travel to the sensing portion of the smog ventilation sensor. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measure Item / Display (Range) Normal Condition Diagnostic Note EMISS GAS SENS (Emission gas sensor) Emission gas / Min.: 0 V, Max.: 255 V Smog ventilation sensor value increases as gas amount increases - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - BODY GROUND) Disconnect the smog ventilation sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B11-6 (E) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
4. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - BATTERY) Disconnect the smog ventilation sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition B11-3 (IG) - Body ground Engine switch on (IG) 10 to 14 V Engine switch off Below 1 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
5. INSPECT SMOG VENTILATION SENSOR Remove the smog ventilation sensor. Apply battery voltage between terminals 3 (IG) and 6 (E). Allow exhaust gas (HC, CO) to travel to the sensing portion of the smog ventilation sensor, and measure the resistance between terminals 1 (SG) and 2 (DGS). OK: When the sensor is exposed to the exhaust gas, the resistance increases. HINT: The resistance before blowing exhaust gas is 10 kohms to 40 kohms. NG: REPLACE SMOG VENTILATION SENSOR OK: Go to next step
6. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - A/C AMPLIFIER) Disconnect the smog ventilation sensor. Disconnect the A/C amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B11-1 (SG) - J58-39 (SG-6) Always Below 1 ohms B11-2 (DGS) - J58-34 (DGS) Always Below 1 ohms J58-39 (SG-6) - Body ground Always 10 kohms or higher J58-34 (DGS) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

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The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the air conditioning in AUTO mode. The output voltage from the solar sensor varies according to the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The A/C amplifier detects voltage output from the solar sensor.

DTC DETECTION CONDITION

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HINT

1. If DTC B1244 is output at the same time, troubleshoot DTC B1244 first.
2. If the check is performed in a dark place, DTC B1421/21 or B1424/24 (solar sensor circuit abnormal) may be output.

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1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Expose the sensing portion of the solar sensor to light. HINT: Use an incandescence light for inspection. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measure Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P (Solar sensor (P side)) Passenger side solar sensor / Min.: 0, Max.: 255 Passenger side solar sensor value increases as brightness increases - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK WIRE HARNESS (SOLAR SENSOR) Disconnect the solar sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition K1-6 (CLTB) - K1-3 (CLTE) Engine switch off Below 1 V K1-6 (CLTB) - K1-3 (CLTE) Engine switch on (IG) 10 to 14 V OK: Go to step 4 NG: Go to next step
3. CHECK WIRE HARNESS (MAIN BODY ECU RH - SOLAR SENSOR) Disconnect the main body ECU RH connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J74-6 (CLTB) - K1-6 (CLTB) Always Below 1 ohms J74-4 (CLTE) - K1-3 (CLTE) Always Below 1 ohms J74-6 (CLTB) - Body ground Always 10 kohms or higher J74-4 (CLTE) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE MAIN BODY ECU RH
4. CHECK SOLAR SENSOR Remove the solar sensor with its connector still connected. Apply battery voltage between terminals 6 (CLTB) and 3 (CLTE) of the solar sensor. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition K1-2 (TSR) - K1-3 (CLTE) Sensor is subjected to electric light 0.8 to 4.3 V K1-2 (TSR) - K1-3 (CLTE) Sensor is covered with a cloth Below 0.8 V NOTE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 2 and positive (+) lead to terminal 1 of the solar sensor. While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. HINT: Use an incandescent light for inspection. Bring it within about 30 cm (11.8 in.) of the solar sensor. As the inspection light is moved away from the sensor, the voltage increases. NG: REPLACE SOLAR SENSOR OK: Go to next step
5. CHECK WIRE HARNESS (SOLAR SENSOR - A/C AMPLIFIER) Disconnect the solar sensor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-14 (TSP) -K1-2 (TSR) Always Below 1 ohms J58-14 (TSP) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

This sensor sends 1 pulse per engine revolution to the ECM.

If the ratio between engine and compressor speed deviates 20% or more compared to normal operation, the ECM turns the cooler compressor off and the indicator blinks at approximately 1 second intervals. The ECM informs the A/C amplifier of the operation condition of the cooler compressor through multiplex communication (CAN and BEAN).

DTC DETECTION CONDITION

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. CHECK MULTIPLEX COMMUNICATION SYSTEM Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result RESULT REFERENCE Result Proceed to MPX DTC is not output A MPX DTC is output B B : GO TO «MULTIPLEX COMMUNICATION SYSTEM»(ref-235578-S20958542052006062400000) A : Go to next step
2. CHECK CAN COMMUNICATION SYSTEM Use the intelligent tester to check if the CAN Communication System is functioning normally. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B : GO TO «CAN COMMUNICATION SYSTEM»(ref-235565-S22980917632006062400000) A : Go to next step
3. INSPECT ECM Remove the ECM with its connectors still connected. Measure the waveform of the connector. Standard TESTER SPECIFICATION CONNECTION Tester Connection Condition Specified Condition E3-10 (LCKI) - Body ground Engine switch on (IG) AUTO switch ON A/C switch ON Magnetic clutch ON Pulse generation ITEM CONTENTS Item Contents Tool setting 200 mV/DIV., 10 ms/DIV. Vehicle condition Engine switch on (IG) AUTO switch ON A/C switch ON Magnetic clutch ON Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE ECM A : Go to next step
4. INSPECT A/C COMPRESSOR (LOCK SENSOR) Disconnect the A/C compressor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E8-2 (SSR+) - E8-5 (SSR-) 160 to 320 ohms NG: REPLACE A/C COMPRESSOR (LOCK SENSOR) OK: Go to next step
5. CHECK WIRE HARNESS (ECM - A/C COMPRESSOR) Disconnect the A/C compressor connector. Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E3-10 (LCKI) - E8-2 (SSR+) Always Below 1 ohms E3-10 (LCKI) - Body ground Always 10 kohms or higher E8-5 (SSR-) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE ECM

This DTC is output when refrigerant pressure is extremely low (0.19 MPa (2.0 kgf/cm 2 , 28 psi) or less) or extremely high (3.14 MPa (32.0 kgf/cm 2 , 455 psi) or more). The pressure sensor, which is installed on the pipe of the high pressure side to detect refrigerant pressure, outputs a refrigerant pressure signal to the A/C amplifier. The A/C amplifier converts this signal to pressure according to the sensor characteristics to control the compressor.

HINT

Be sure to check the refrigerant volume first when this DTC is output because this DTC can also be output if there is no refrigerant in the system.

DTC DETECTION CONDITION

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. CHECK REFRIGERANT Check the sight glass of the cooler unit refrigerant liquid pipe. Prepare the vehicle according to the chart below. ITEM CONDITION Item Condition Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed HI A/C ON Compare the sight glass to the following chart. SIGHT GLASS REFERENCE Item Symptom Amount of Refrigerant Corrective Actions 1 Bubbles visible Insufficient (1) Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 2 No bubbles visible Empty, insufficient, or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty Check for gas leakage with gas leak detector and repair if necessary Evacuate A/C system and recharge with proper amount of refrigerant 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned OFF, refrigerant clears Excessive Recover refrigerant Evacuate A/C system and recharge with proper amount of refrigerant 6 Immediately after air conditioning is turned OFF, refrigerant foams and then becomes clear Proper - (1) Bubbles in the sight glass with the vehicle interior temperature above 35°C (95°F) can be considered normal if cooling is sufficient. NG: CHARGE REFRIGERANT OK: Go to next step
2. CHECK WIRE HARNESS (PRESSURE SENSOR - A/C AMPLIFIER) Disconnect the pressure sensor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B7-2 (PR) - J58-13 (PRE) Always Below 1 ohms B7-3 (+) - J58-26 (S5-2) Always Below 1 ohms B7-1 (-) - J58-38 (SG-2) Always Below 1 ohms J58-13 (PRE) - Body ground Always 10 kohms or higher J58-26 (S5-2) - Body ground Always 10 kohms or higher J58-38 (SG-2) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
3. INSPECT PRESSURE SENSOR Install the manifold gauge set (See «ON-VEHICLE INSPECTION»(ref-235579-S02659531892006062400000) ). Connect the three 1.5 V dry cell battery's positive (+) lead to terminal 3 and the negative (-) lead to terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2 and the negative (-) lead to terminal 1. Measure the voltage. OK: The voltage changes according to refrigerant pressure, as shown in the graph. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the DTC) B OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) C B : REPLACE AIR CONDITIONING AMPLIFIER C : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE A : REPLACE PRESSURE SENSOR

Scheme 49

The solar sensor, which is installed on the upper side of the instrument panel, detects sunlight and controls the air conditioning in AUTO mode. The output voltage from the solar sensor varies according to the amount of sunlight. When the sunlight increases, the output voltage increases. As the sunlight decreases, the output voltage decreases. The A/C amplifier detects output voltage from the solar sensor.

DTC DETECTION CONDITION

Scheme 50

HINT

1. If DTC B1244 is output at the same time, troubleshoot DTC B1244 first.
2. If the check is performed in a dark place, DTC B1421/21 or B1424/24 (solar sensor circuit abnormal) may be output.

Scheme 51

Scheme 52

Scheme 53

Scheme 54

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Expose the sensing portion of the solar sensor to light. HINT: Use an incandescence light for inspection. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measure Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-D (Solar sensor (D side)) Driver side solar sensor / Min.: 0, Max.: 255 Driver side solar sensor value increases as brightness increases - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK WIRE HARNESS (SOLAR SENSOR) Disconnect the solar sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition K1-6 (CLTB) - K1-3 (CLTE) Engine switch on (IG) 10 to 14 V K1-6 (CLTB) - K1-3 (CLTE) Engine switch off Below 1 V OK: Go to step 4 NG: Go to next step
3. CHECK WIRE HARNESS (SOLAR SENSOR - MAIN BODY ECU RH) Disconnect the main body ECU RH connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J74-6 (CLTB) - K1-6 (CLTB) Always Below 1 ohms J74-4 (CLTE) - K1-3 (CLTE) Always Below 1 ohms J74-6 (CLTB) - Body ground Always 10 kohms or higher J74-4 (CLTE) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE MAIN BODY ECU RH
4. CHECK SOLAR SENSOR Remove the solar sensor with its connector still connected. Apply battery voltage between terminals 6 (CLTB) and 3 (CLTE) of the solar sensor. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition K1-1 (TSL) - K1-3 (CLTE) Sensor is subjected to electric light 0.8 to 4.3 V K1-1 (TSL) - K1-3 (CLTE) Sensor is covered with a cloth Below 0.8 V NOTE: The connection procedure for using a digital tester such as a TOYOTA electrical tester is shown above. When using an analog tester, connect the negative (-) lead to terminal 2 and positive (+) lead to terminal 1 of the solar sensor. While using the battery during inspection, do not bring the positive and negative tester probes too close to each other as a short circuit may occur. HINT: Use an incandescent light for inspection. Bring it about 30 cm (11.8 in.) from the solar sensor. As the inspection light is moved away from the sensor, the voltage increases. NG: REPLACE SOLAR SENSOR OK: Go to next step
5. CHECK WIRE HARNESS (SOLAR SENSOR - A/C AMPLIFIER) Disconnect the solar sensor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-35 (TSD) - K1-1 (TSL) Always Below 1 ohms J58-35 (TSD) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

The air mix damper servo sends pulse signals to inform the air conditioner amplifier of the damper position. The air conditioner amplifier activates the motor (normal, reverse) based on the signals to move the air mix damper (passenger seat) to any position, which adjusts the amount of air passing the heater core after passing the evaporator to control the blowing temperature.

HINT

Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked.

DTC DETECTION CONDITION

Scheme 55

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Operate the front passenger side temperature adjustment switch. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-P (Air mix servomotor target pulse (P side)) Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX. COLD: 105 (pulse) MAX. HOT: 6 (pulse) - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. Check for DTCs. Result RESULT REFERENCE Result Proceed to DTC B1441/41 is output A DTC B1441/41 is not output B B : END A : REPLACE AIR CONDITIONING HARNESS

The damper servo (air inlet control) sends pulse signals to inform the air conditioner amplifier of the damper position. The air conditioner amplifier activates the motor (normal, reverse) based on the signals to move the air inlet mode selection air inlet control damper to any position, which controls the intake air settings (FRESH, FRESH / RECIRCULATION, and RECIRCULATION).

HINT

Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked.

DTC DETECTION CONDITION

Scheme 56

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Operate the R/F (Recirculation/Fresh) switch. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP PLS (Air inlet damper target pulse) Air inlet damper target pulse / Min.: 0, Max.: 255 RECIRCULATION: 31 (pulse) FRESH: 7 (pulse) - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. REPLACE AIR INLET CONTROL SERVO MOTOR HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. Check for DTCs. Result RESULT REFERENCE Result Proceed to DTC B1442/42 is output A DTC B1442/42 is not output B B : END A : REPLACE AIR CONDITIONING HARNESS

The mode damper servo sends pulse signals to inform the air conditioner amplifier of the damper position. The air conditioner amplifier activates the motor (normal, reverse) based on the signals to move the mode damper to any position, which controls the air outlet switching.

HINT

Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked.

DTC DETECTION CONDITION

Scheme 57

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Operate the MODE switch. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR OUT PULSE-D (Air outlet servomotor target pulse (D side)) Driver side air outlet servo motor target pulse / Min.: 0, Max.: 255 FACE: 9 to 17 (pulse) B/L: 32 to 38 (pulse) FOOT: 45 to 70 (pulse) FOOT/DEF: 84 (pulse) DEF: 97 (pulse) - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. REPLACE AIR OUTLET CONTROL SERVO MOTOR HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. Check for DTCs. Result RESULT REFERENCE Result Proceed to DTC B1443/43 is output A DTC B1443/43 is not output B B : END A : REPLACE AIR CONDITIONING HARNESS

The damper servo (cool air by-pass) sends pulse signals to inform the air conditioner amplifier of the damper position. The air conditioner amplifier activates the motor (normal, reverse) based on the signals to move the damper to any position. As a result, when the A/C is operating, the temperature of the air blowing toward the passenger's head area is controlled.

HINT

Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked.

DTC DETECTION CONDITION

Scheme 58

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Expose the sensing portion of the solar sensor to light. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/B DAMP PLS (Cool air bypass pulse) Passenger side cool air by-pass pulse / Min.: 0, Max.: 255 CLOSE: 50 (pulse) OPEN: 8 (pulse) - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPAIR AIR CONDITIONING AMPLIFIER A : Go to next step
2. REPLACE COOL AIR BY-PASS CONTROL SERVO MOTOR HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. Check for DTCs. Result RESULT REFERENCE Result Proceed to DTC B1445/45 is output A DTC B1445/45 is not output B B : END A : REPAIR AIR CONDITIONING HARNESS

The air mix damper servo sends pulse signals to inform the air conditioner amplifier of the damper position. The air conditioner amplifier activates the motor (normal, reverse) based on the signals to move the air mix damper (driver seat) to any position. As a result, the amount of air passing through the heater core after passing through the evaporator is adjusted, and the temperature of the air blowing toward the driver seat side is controlled.

HINT

Confirm that no mechanical problem is present because this diagnostic code can be output when either a damper link or damper is mechanically locked.

DTC DETECTION CONDITION

Scheme 59

1. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Operate the driver side temperature adjustment switch. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-D (Air mix servomotor target pulse (D side)) Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 MAX COLD: 5 (pulse) MAX HOT: 104 (pulse) - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be inspected while it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. Check for DTCs. Result RESULT REFERENCE Result Proceed to DTC B1446/46 is output A DTC B1446/46 is not output B B : END A : REPLACE AIR CONDITIONING HARNESS

In this circuit, the compressor receives a refrigerant compression demand signal from the air conditioning amplifier.

Based on this signal, the compressor changes the amount of compressor output.

DTC DETECTION CONDITION

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. INSPECT A/C COMPRESSOR Disconnect the A/C compressor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-3 (SOL+) - E8-6 (SOL-) 20°C (68°F) 10 to 11 ohms NG: REPLACE A/C COMPRESSOR OK: Go to next step
2. CHECK WIRE HARNESS (A/C COMPRESSOR - BODY GROUND) Disconnect the A/C compressor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-6 (SOL-) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
3. CHECK WIRE HARNESS (A/C COMPRESSOR - A/C AMPLIFIER) Disconnect the A/C compressor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-5 (SOL+) - E8-3 (SOL+) Always Below 1 ohms J58-5 (SOL+) - Body ground Always 10 kohms or higher Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : REPAIR OR REPLACE HARNESS OR CONNECTOR

The smog ventilation sensor detects NOx in the emission gas and transmits signals to the A/C amplifier. Based on the signals, the A/C amplifier performs automatic air inlet control (FRESH, FRESH / RECIRCULATION, or RECIRCULATION mode).

DTC DETECTION CONDITION

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

1. INSPECT FUSE (LH-IG) Remove the LH-IG fuse from the cowl side junction block LH. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition LH-IG fuse Always Below 1 ohms NG: REPLACE FUSE (LH-IG) OK: Go to next step
2. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Allow exhaust gas (NOx) to travel to the sensing portion of the smog ventilation sensor. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Measure Item / Display (Range) Normal Condition Diagnostic Note NOX GAS SENS (Emission gas Nox sensor) Emission gas NOx sensor / Min.: 0, Max.: 255 Smog ventilation sensor value increases as gas amount increases - OK: The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (When troubleshooting according to the PROBLEM SYMPTOMS TABLE) B OK (When troubleshooting according to the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - BODY GROUND) Disconnect the smog ventilation sensor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B11-6 (E) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
4. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - BATTERY) Disconnect the smog ventilation sensor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition B11-3 (IG) - Body ground Engine switch on (IG) 10 to 14 V Engine switch off Below 1 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
5. INSPECT SMOG VENTILATION SENSOR Remove the smog ventilation sensor. Apply battery voltage between terminals 3 (IG) and 6 (E). Allow exhaust gas (NOx) to travel to the sensing portion of the smog ventilation sensor, and measure the resistance between terminals 1 (SG) and 4 (DGS1). OK: When the sensor is exposed to the exhaust gas, the resistance increases. HINT: The resistance before blowing exhaust gas is 10 kohms to 40 kohms. NG: REPLACE SMOG VENTILATION SENSOR OK: Go to next step
6. CHECK WIRE HARNESS (SMOG VENTILATION SENSOR - A/C AMPLIFIER) Disconnect the exhaust gas sensor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition B11-1 (SG) - J58-39 (SG-6) Always Below 1 ohms B11-4 (DGS1) - J58-33 (DGS1) Always Below 1 ohms J58-39 (SG-6) - Body ground Always 10 kohms or higher J58-33 (DGS1) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

The air conditioning harness connects the air conditioning amplifier and each servo. The air conditioning amplifier supplies power and sends operation instructions to each servo through the air conditioning harness. Each servo sends the damper position information to the air conditioning amplifier.

DTC DETECTION CONDITION

Scheme 69

Scheme 70

Scheme 71

Scheme 72

1. CHECK HARNESS AND CONNECTOR Remove the A/C amplifier. Disconnect the connector from the A/C amplifier. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-20 (GND) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER Reconnect the connector to the A/C amplifier. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition e1-2 (BUS G) - J58-20 (GND) Always Below 1 ohms NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step
3. CHECK AIR CONDITIONING AMPLIFIER Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition e1-4 (B BUS) - e1-2 (BUS G) Engine switch off Below 1 V e1-4 (B BUS) - e1-2 (BUS G) Engine switch on (IG) 10 to 14 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: REPLACE AIR CONDITIONING HARNESS

DTC DETECTION CONDITION

HINT

Refer to MULTIPLEX COMMUNICATION SYSTEM .

Scheme 73

The blower motor is operated by signals from the A/C amplifier. The blower motor speed is controlled using various duty ratios.

Duty Ratio

The duty ratio is the ratio of the blower motor ON time (A) to the total of the blower motor ON and OFF time (A + B).

The blower motor controller controls the blower motor speed.

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. PERFORM ACTIVE TEST BY INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Select the item below in the ACTIVE TEST and then check that the relay operates. ACTIVE TEST / AIR CONDITIONER: ITEM NORMAL CONDITION REFERENCE Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR (Blower motor) Blower motor / Min.: Level 01, Max.: Level 31 - Result RESULT REFERENCE Result Proceed to OK A NG (blower motor does not operate) B NG (blower motor operates but does not change speed) C B : Go to step 2 C : Go to step 6 A : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
2. INSPECT FUSE Remove the HEATER fuse from the engine room R/B and J/B No. 1. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition HEATER fuse Always Below 1 ohms NG: REPLACE FUSE (HEATER) OK: Go to next step
3. CHECK WIRE HARNESS (BLOWER MOTOR - BODY GROUND) Disconnect the blower motor connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A34-1 (GND) (1) - Body ground Always Below 1 ohms b1-1 (GND) (2) - Body ground Always Below 1 ohms HINT: (1) 4GR-FSE (2) 2GR-FSE NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
4. CHECK WIRE HARNESS (BLOWER MOTOR - BATTERY) Disconnect the blower motor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition A34-3 (+B) (1) - Body ground Always 10 to 14 V b1-3 (+B) (2) - Body ground Always 10 to 14 V HINT: (1) 4GR-FSE (2) 2GR-FSE NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
5. INSPECT BLOWER MOTOR Disconnect the A/C amplifier connector. Connect the blower motor connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition A34-2 (SI) (1) - Body ground Engine switch on (IG) 4.5 to 5.5 V b1-2 (SI) (2) - Body ground Engine switch on (IG) 4.5 to 5.5 V HINT: (1) 4GR-FSE (2) 2GR-FSE NG: REPLACE BLOWER MOTOR OK: Go to next step
6. CHECK WIRE HARNESS (A/C AMPLIFIER - BODY GROUND) Disconnect the A/C amplifier connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition J58-11 (BLW) - Body ground Engine switch on (IG) 4.5 to 5.5 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go To Next Step
7. INSPECT AIR CONDITIONING AMPLIFIER Remove the A/C amplifier with its connectors still connected. Turn the engine switch on (IG) . Turn the blower switch ON (Lo). Measure the waveform between terminal J58-11 (BLW) of the A/C amplifier and body ground. OK: Waveform is as shown in the illustration. HINT: Waveform varies with the blower level. ITEM CONTENTS REFERENCE Item Contents Tool setting 1 V/DIV., 500 $$s/DIV. Vehicle condition Engine switch on (IG) Blower switch ON (Lo) NG: REPLACE AIR CONDITIONING AMPLIFIER OK: REPLACE BLOWER MOTOR

The A/C amplifier sends a magnetic clutch ON command signal to the ECM through the BEAN line and CAN line. Then the ECM turns the A/C COMP relay on to turn the magnetic clutch on.

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1. CHECK MULTIPLEX COMMUNICATION SYSTEM Use the intelligent tester to check if the Multiplex Communication System (MPX) is functioning normally. Result RESULT REFERENCE Result Proceed to MPX DTC is not output A MPX DTC is output B B : GO TO «MULTIPLEX COMMUNICATION SYSTEM»(ref-235578-S20958542052006062400000) A : Go to next step
2. CHECK CAN COMMUNICATION SYSTEM Use the intelligent tester to check if the CAN Communication System is functioning normally. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B : GO TO «CAN COMMUNICATION SYSTEM»(ref-235565-S22980917632006062400000) A : Go to next step
3. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Turn the A/C switch on and off. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / ECM: ITEM NORMAL CONDITION REFERENCE Item Measure Item Normal Condition Diagnostic Note A/C SIG (A/C Signal) A/C signal / ON or OFF ON: A/C ON OFF: A/C OFF - OK: The display is as specified in the normal condition column. NG: Go to step 12 OK: Go To Next Step
4. READ VALUE OF INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Change the blower fan speed to LO using the blower switch. Turn the A/C switch on and off. Select the item below in the DATA LIST, and read the display on the intelligent tester. DATA LIST / ECM: ITEM NORMAL CONDITION REFERENCE Item Measure Item Normal Condition Diagnostic Note A/C MAG CLUTCH (A/C magnetic clutch relay) A/C magnetic clutch relay / OFF, ON ON: A/C magnetic clutch ON OFF: A/C magnetic clutch OFF - OK: The display is as specified in the normal condition. NG: REPLACE ECM OK: Go to next step
5. PERFORM ACTIVE TEST BY INTELLIGENT TESTER Connect the intelligent tester to the DLC3. Turn the engine switch on (IG) and turn the intelligent tester main switch on. Select the item below in the ACTIVE TEST and read the display on the intelligent tester. ACTIVE TEST / ECM: ACTIVE TEST DETAILS Item Test Details / Display (Range) Diagnostic Note A/C MAG CLUTCH Magnetic Clutch Relay / OFF, ON - OK: The magnetic clutch operates normally. OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG: Go to next step
6. INSPECT FUSE (A/C COMP) Remove the A/C COMP fuse from the engine room R/B and J/B No. 2. Measure the resistance of the fuse. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition A/C COMP fuse Always Below 1 ohms NG: REPLACE FUSE (A/C COMP) OK: Go to next step
7. INSPECT RELAY (A/C COMP) Remove the A/C COMP relay from the engine room R/B and J/B No. 2. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition 3 -- 5 10 kohms or higher 3 -- 5 Below 1 ohms (when battery voltage is applied to terminals 1 and 2) NG: REPLACE RELAY (A/C COMP) OK: Go To Next Step
8. INSPECT A/C COMPRESSOR Disconnect the A/C compressor connector. Disconnect the magnetic clutch connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-1 (MG+) - A-1 Always Below 1 ohms E8-1 (MG+) - Body ground Always 10 kohms or higher NG: REPLACE A/C COMPRESSOR OK: Go to next step
9. INSPECT MAGNETIC CLUTCH Measure the resistance of the connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A-1 - Body ground Always 3.4 to 3.8 ohms When connector terminal A1 is connected to the positive (+) battery terminal, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock. NG: REPLACE MAGNETIC CLUTCH OK: Go to next step
10. CHECK WIRE HARNESS (ENGINE ROOM R/B AND J/B NO. 2 - A/C COMPRESSOR) Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Specified Condition Relay block A/C COMP relay terminal 5 - Body ground 10 to 14 V Relay block A/C COMP relay terminal 1 - Body ground 10 to 14 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go to next step
11. CHECK WIRE HARNESS (ENGINE ROOM R/B AND J/B NO. 2 - ECM) Disconnect the ECM connector. Measure the resistance according to the value(s) in the table below. Standard resistance 4GR-FSE RESISTANCE SPECIFICATION Tester Connection Specified Condition Relay block A/C COMP relay terminal 2 - A6-13 (ACMG) Below 1 ohms A6-13 (ACMG) - Body ground 10 kohms or higher 2GR-FSE RESISTANCE SPECIFICATION Tester Connection Specified Condition Relay block A/C COMP relay terminal 2 - A6-11 (ACMG) Below 1 ohms A6-11 (ACMG) - Body ground 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPAIR OR REPLACE HARNESS OR CONNECTOR (A/C COMPRESSOR - ENGINE ROOM R/B AND J/B NO. 2)
12. REPLACE AIR CONDITIONING AMPLIFIER Replace the A/C amplifier with a normal one and check that the condition returns to normal. OK: Same problem does not occur. OK: END NG: REPLACE ECM

The GLW RLY turns on when it receives a signal from the A/C amplifier. As a result, power is supplied to the heater glow plug.

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1. INSPECT FUSE (LH-IG, GLW PLG1, GLW PLG2) Remove the LH-IG fuse from the cowl side J/B LH. Remove the GLW PLG1 and GLW PLG2 fuses from the engine room R/B and J/B No. 1. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition LH-IG fuse Always Below 1 ohms GLW PLG1 fuse Always Below 1 ohms GLW PLG2 fuse Always Below 1 ohms NG: REPLACE FUSE OK: Go To Next Step
2. INSPECT RELAY (GLW RLY1, GLW RLY2) Remove the GLW RLY1 and GLW RLY2 relays from the engine room R/B and J/B No. 1. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 3 -- 5 Always 10 kohms or higher 3 -- 5 When battery voltage is applied to terminals 1 and 2 Below 1 ohms NG: REPLACE RELAY OK: Go To Next Step
3. CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - BATTERY) Disconnect the connector from the A/C amplifier. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection (Symbols) Condition Specified Condition J58-4 (HTR2) - Body ground Engine switch on (IG) 10 to 14 V J58-23 (HTR1) - Body ground Engine switch on (IG) 10 to 14 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go To Next Step
4. INSPECT AIR CONDITIONING AMPLIFIER Reconnect the connector to the A/C amplifier. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition J58-4 (HTR2) - Body ground Engine switch on (IG) 10 to 14 V J58-4 (HTR2) - Body ground Engine switch on (IG) While the PTC operating conditions are met (engine is running at 850 rpm or more, ambient temperature is 0°C (32°F) or less, engine coolant temperature is 69°C (156°F) or less, and A/C switch setting is MAX HOT), turn the blower switch to the LO setting. Below 1 V J58-23 (HTR1) - Body ground Engine switch on (IG) 10 to 14 V D47-2 - Body ground Engine switch on (IG) While the PTC operating conditions are met (engine is running at 850 rpm or more, ambient temperature is 0°C (32°F) or less, engine coolant temperature is 69°C (156°F) or less, and A/C switch setting is MAX HOT), turn the blower switch to the LO setting. Below 1 V NG: REPLACE AIR CONDITIONING AMPLIFIER OK: Go to next step
5. INSPECT HEATER BLOWER WIRE Remove the grommets and nuts of the water by-pass glow plugs. Turn the engine switch on (IG). Perform ACTIVE TEST by referring to the table below. AIR CONDITIONER: AIR CONDITIONER Item Test Details / Display (Range) Diagnostic Note HEATER 1 (Electric Heater 1) Electric Heater 1 / OFF, ON - HEATER 2 (Electric Heater 2) Electric Heater 2 / OFF, ON - Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition 1 - Body ground Perform ACTIVE TEST / HEATER 1 (Electric Heater 1): ON 10 to 14 V 2 - Body ground Perform ACTIVE TEST / HEATER 2 (Electric Heater 2): ON 10 to 14 V NG: REPAIR OR REPLACE HEATER BLOWER WIRE OK: Go To Next Step
6. INSPECT WATER BY-PASS GLOW PLUG Remove the water by-pass glow plug. Measure the resistance according to the value(s) in the table below. Standard resistance: Below 1 ohms NG: REPLACE WATER BY-PASS GLOW PLUG OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE

The low pressure sensor reduces the capacity of the compressor when the compressor is operating at high speed. This sensor monitors the pressure on the low pressure side at terminal CUT+ and sends a signal to terminal PSW of the A/C amplifier, which increases the accuracy of compressor control.

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1. CHECK REFRIGERANT PRESSURE Check the sight glass of the cooler unit refrigerant liquid pipe. Prepare the vehicle according to the chart below. ITEM CONDITION Item Condition Vehicle Doors Fully open Temperature Setting MAX COLD Blower Speed HI A/C ON Compare the sight glass to the following chart. SYMPTOM CHART Item Symptom Amount of Refrigerant Corrective Actions 1 Bubbles visible Insufficient (1) Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 2 No bubbles visible Empty, insufficient, or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty Check for gas leakage with gas leak detector and repair if necessary Evacuate A/C system and recharge with proper amount of refrigerant 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned OFF, refrigerant clears Excessive Recover refrigerant Evacuate A/C system and recharge with proper amount of refrigerant 6 Immediately after air conditioning is turned OFF, refrigerant foams and then becomes clear Proper - (1) Bubbles in the sight glass with the vehicle interior temperature above 35°C (95°F) can be considered normal if cooling is sufficient. NG: CHARGE REFRIGERANT OK: Go to next step
2. CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - LOW PRESSURE SENSOR) Disconnect the pressure sensor connector. Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. RESISTANCE SPECIFICATION Tester Connection (Symbols) Condition Specified Condition J58-18 (SG-3) - A56-1 (-S) Always Below 1 ohms J58-27 (S5-3) - A56-3 (+S) Always Below 1 ohms J58-32 (PSW) - A56-2 (CUT+) Always Below 1 ohms J58-18 (SG-3) - Body ground Always 10 kohms or higher J58-27 (S5-3) - Body ground Always 10 kohms or higher J58-32 (PSW) - Body ground Always 10 kohms or higher NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go To Next Step
3. INSPECT LOW PRESSURE SENSOR Install the manifold gauge set (See «ON-VEHICLE INSPECTION»(ref-235579-S02659531892006062400000) ). Connect the three 1.5 V dry cell batterie's positive (+) lead to terminal 3 and the negative (-) lead to terminal 1. Then connect the voltmeter's positive (+) lead to terminal 2 and the negative (-) lead to terminal 1. Measure the voltage. OK: The voltage changes according to refrigerant pressure, as shown in the graph. NG: REPLACE LOW PRESSURE SENSOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE

The main power source is supplied to the A/C amplifier when the engine switch on (IG).

The power source is used for operating the A/C amplifier and servo motor, etc.

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HINT

Start the engine before inspection. Check the IG1 relay or battery if the engine does not start.

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1. INSPECT FUSE (ECU-IG LH) Remove the ECU-IG LH fuse from the cowl side junction block LH. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition ECU-IG LH fuse Always Below 1 ohms NG: REPLACE FUSE (ECU-IG LH) OK: Go To Next Step
2. INSPECT AIR CONDITIONING AMPLIFIER (IG+ - GND) Remove the A/C amplifier with its connectors still connected. Turn the engine switch on (IG). Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition J58-21 (IG+) - J58-20 (GND) Engine switch on (IG) 10 to 14 V NG: Go to step 3 OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE
3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) Disconnect the A/C amplifier connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition J58-21 (IG+) - Body ground Engine switch off Below 1 V Engine switch on (IG) 10 to 14 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: Go To Next Step
4. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BODY GROUND) Disconnect the A/C amplifier connector. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition J58-20 (GND) - Body ground Always Below 1 ohms NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: REPLACE AIR CONDITIONING AMPLIFIER

The back-up power source circuit for the A/C amplifier is shown below. Power is supplied even when turning the engine switch off and is used for diagnostic trouble code memory, etc.

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1. INSPECT FUSE (A/C) Remove the A/C fuse from the cowl side junction block LH. Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Item Condition Specified Condition A/C fuse Always Below 1 ohms NG: REPLACE FUSE (A/C) OK: Go To Next Step
2. INSPECT AIR CONDITIONING AMPLIFIER (AIR CONDITIONING AMPLIFIER - BODY GROUND) Disconnect the A/C amplifier connector. Measure the voltage according to the value(s) in the table below. Standard voltage VOLTAGE SPECIFICATION Tester Connection Condition Specified Condition J58-1 (B) - Body ground Always 10 to 14 V NG: REPAIR OR REPLACE HARNESS OR CONNECTOR OK: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE

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1. INSPECT REFRIGERANT VOLUME Check the sight glass on the liquid tube subassembly. Test conditions: Engine is running at 1,500 rpm. Blower speed control switch is at HI. A/C switch is ON. Temperature control switch is at MAX. COOL. Doors are fully open. SYMPTOM CHART Item Symptom Amount of Refrigerant Corrective Procedures 1 Bubbles visible Insufficient (1) Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 2 No bubbles visible Empty, insufficient or too much Refer to items 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty Check for gas leakage with gas leak detector and repair if necessary Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Correct or too much Refer to items 5 and 6 5 Immediately after A/C is turned OFF, refrigerant becomes clear Too much Drain or discharge refrigerant Bleed air and supply proper amount of purified refrigerant 6 Immediately after A/C is turned OFF, refrigerant foams and then becomes clear Correct - HINT: (1) If the ambient temperature is higher than usual but cooling is sufficient, bubbles in the sight glass are permissible.
2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This method uses a manifold gauge set to locate problem areas. Read the manifold gauge pressure when the following conditions are established. Test conditions: Temperature at the air inlet is 30 to 35°C (86 to 95°F). Engine is running at 1,500 rpm. All doors are fully open. Blower speed control switch is at HI. Temperature control switch is at MAX. COOL. A/C switch is ON. Gauge readings (Reference) Normally functioning refrigeration system Gauge reading GAUGE READING REFERENCE Pressure side Refrigerant volume Low 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm 2 ) High 1.37 to 1.57 MPa (14 to 16 kgf/cm 2 ) The A/C system periodically changes between normal and improper function due to moisture in the refrigeration system. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low - pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing temporary stop of cycle. However, when melted, normal state is restored Drier is oversaturated Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation Replace cooler drier Remove moisture from cycle by repeatedly evacuating air Supply appropriate volume of new refrigerant The A/C system does not function effectively due to insufficient cooling. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure low on both low and high-pressure sides Cooling performance insufficient Gas leakage from refrigeration system Insufficient refrigerant Refrigerant leakage Check for gas leakage and repair if necessary Supply appropriate volume of new refrigerant If indicated pressure value is close to 0 when connected to gauge, create vacuum after inspecting and repairing the location of leakage The A/C system does not function effectively due to poor circulation of the refrigerant. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure low on both low and high-pressure sides Frost exists on piping from condenser to A/C unit Refrigerant flow obstructed by dirt in condenser Condenser clogged Replace condenser The A/C system does not function intermittently because the refrigerant does not circulate. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Vacuum indicated on lowpressure side, and extremely low pressure indicated on highpressure side Frost or condensation seen on piping on both sides of condenser or expansion valve Refrigerant flow obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leakage from expansion valve Refrigerant does not circulate Check expansion valve Clean expansion valve by blowing air Replace condenser Evacuate air and charge appropriate volume of new refrigerant For gas leakage from expansion valve, replace expansion valve The A/C system does not function effectively due to overcharged refrigerant or insufficient cooling of the condenser. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides Excessive refrigerant Cooling performance of condenser insufficient Condenser is dirty Condenser fan motor is malfunctioning Excessive refrigerant Clean condenser Check condenser fan motor operation If 1 and 2 are normal, check the amount of refrigerant and supply appropriate volume of refrigerant The A/C system does not function due to air in the refrigeration system. CAUTION: The low-pressure piping may be very hot and cause serious burns. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides The low-pressure piping is too hot to touch Air in refrigeration system Air in refrigeration system Vacuum purging insufficient Check if compressor oil is dirty or insufficient Evacuate air and charge new refrigerant The A/C system does not function effectively due to an expansion valve malfunction. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides Frost or condensation on piping on low-pressure side Problem with expansion valve Excessive refrigerant in low pressure piping Expansion valve too wide open Replace expansion valve The A/C system does not function due to a defective compressor. PROBABLE SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure extremely high on both low and high-pressure sides Pressure extremely low on highpressure side Internal leakage in compressor Compression failure Leakage from damaged valve or broken sliding parts Repair or replace compressor

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor. Stop the engine. Using SST, discharge the refrigerant gas. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. CHARGE REFRIGERANT Perform vacuum purging using a vacuum pump. Charge refrigerant HFC-134a (R134a). Standard: 430 +- 30 g (15.17 +- 1.06 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) NOTE: Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
3. WARM UP ENGINE Warm up the engine at less than 1,850 rpm for 2 minutes or more after charging the refrigerant. NOTE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
4. CHECK FOR LEAKAGE OF REFRIGERANT After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector. Perform the operation under the following conditions: Stop the engine. Secure good ventilation (the gas leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas). Repeat the test 2 or 3 times. Make sure that some refrigerant remains in the refrigeration system. When compressor is off: approximately 392 to 588 kPa (4 to 6 kgf*cm 2 57 to 85 psi) Using a gas leak detector, check the refrigerant line for leakage. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

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1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235451-S13841571552006062200000) )
3. REMOVE ENGINE ROOM SIDE COVER LH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
4. REMOVE ENGINE ROOM SIDE COVER RH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
5. DISCHARGE REFRIGERANT FROM REFRIGERATION Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
6. DISCONNECT CABLE FROM NEGATIVE BATTERY CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See «PRECAUTION»(ref-235542-S10058841152006062400000) )
7. REMOVE FRONT UPPER FENDER PROTECTOR LH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
8. REMOVE FRONT UPPER FENDER PROTECTOR RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
9. REMOVE ROOF DRIP SIDE FINISH MOULDING LH (See «REMOVAL»(ref-235598-S34002898732006062400000) )
10. REMOVE ROOF DRIP SIDE FINISH MOULDING RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
11. REMOVE FRONT WIPER ARM HEAD CAP (See «REMOVAL»(ref-235575-S42063685122006062400000) )
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
14. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See «REMOVAL»(ref-235575-S42063685122006062400000) )
15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See «REMOVAL»(ref-235575-S42063685122006062400000) )
16. SEPARATE SUCTION PIPE SUB-ASSEMBLY Remove the bolt, and slide the hook connector. Disconnect the suction pipe sub-assembly. Remove the O-ring from the suction pipe subassembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
17. SEPARATE LIQUID TUBE SUB-ASSEMBLY Disconnect the liquid tube sub-assembly. Remove the O-ring from the liquid tube subassembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
18. REMOVE HEATER WATER OUTLET HOSE Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water outlet hose.
19. REMOVE HEATER WATER INLET HOSE HINT: Disconnection of the heater water outlet hose is the same as for the heater water inlet hose.
20. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
21. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
22. REMOVE UPPER NO. 1 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
23. REMOVE UPPER NO. 2 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
24. REMOVE CONSOLE PANEL SUB-ASSEMBLY (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
25. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
26. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
27. REMOVE FRONT ASH RECEPTACLE SUBASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
28. REMOVE CONSOLE BOX REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
29. REMOVE CONSOLE BOX (See «REMOVAL»(ref-235591-S20751754672006062400000) )
30. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
31. REMOVE CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL (See «REMOVAL»(ref-235591-S20751754672006062400000) )
32. REMOVE MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System) (See «REMOVAL»(ref-235589-S20177326342006062400000) )
33. REMOVE INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System) (See «REMOVAL»(ref-235589-S20177326342006062400000) )
34. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See «REMOVAL»(ref-235542-S05597931522006062400000) )
35. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See «REMOVAL»(ref-235542-S05597931522006062400000) )
36. REMOVE STEERING PAD (See «REMOVAL»(ref-235542-S05597931522006062400000) )
37. REMOVE STEERING WHEEL ASSEMBLY (See «REMOVAL»(ref-235546-S15909269792006062400000) )
38. REMOVE STEERING COLUMN COVER (for Power Tilt and Power Telescopic) (See «REMOVAL»(ref-235546-S01736682752006062400000) )
39. REMOVE STEERING COLUMN COVER (for Manual Tilt and Telescopic) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
40. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See «REMOVAL»(ref-235546-S15909269792006062400000) )
41. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
42. REMOVE FRONT DOOR SCUFF PLATE LH (w/Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
43. REMOVE FRONT DOOR OPENING TRIM COVER LH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
44. REMOVE SIDE INSTRUMENT PANEL LH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
45. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
46. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
47. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «REMOVAL»(ref-235542-S32764164272006062400000) )
48. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
49. REMOVE COMBINATION METER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
50. REMOVE FRONT DOOR SCUFF PLATE RH (w/o Illumination) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
51. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
52. REMOVE FRONT DOOR OPENING TRIM COVER RH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
53. REMOVE SIDE INSTRUMENT PANEL RH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
54. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
55. REMOVE FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY (See «REMOVAL»(ref-235542-S26525252422006062400000) )
56. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
57. REMOVE FRONT PILLAR GARNISH LH (See «REMOVAL»(ref-235599-S10274364092006062400000) )
58. REMOVE FRONT PILLAR GARNISH RH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
59. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
60. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
61. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
62. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker) (See «REMOVAL»(ref-235589-S20738965952006062400000) )
63. REMOVE NO. 2 CONSOLE BOX DUCT (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
64. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
65. REMOVE NO. 2 CONSOLE BOX DUCT (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
66. DISCONNECT PASSENGER AIRBAG CONNECTOR
67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
68. REMOVE NO. 1 AIR DUCT (See «REMOVAL»(ref-235546-S15909269792006062400000) )
69. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (for 2WD) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
70. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
71. REMOVE STEERING COLUMN ASSEMBLY (for Manual Tilt) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
72. REMOVE STEERING COLUMN ASSEMBLY (for Power Tilt and Power Telescopic) (See «REMOVAL»(ref-235546-S01736682752006062400000) )
73. REMOVE DEFROSTER NOZZLE LOWER ASSEMBLY Release the 4 claws and remove the defroster nozzle lower assembly.
74. REMOVE IMMOBILISER CODE ECU
75. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Remove the 27 clamps and 19 connectors, and then disconnect the wire harness. Remove the 2 nuts, 2 bolts and 2 junction E104604E01 blocks. Remove the cap and bolt. Remove the 3 bolts and nut. Using a T40 "torx" socket, remove the 5 "torx" bolts. NOTE: The "torx" bolts on the passenger side can be removed with the collar for adjustment. Using a 12 mm hexagon wrench, remove the 2 collars and instrument panel reinforcement.
76. REMOVE AIR CONDITIONER UNIT ASSEMBLY Remove the 2 screws, 3 bolts, and air conditioner unit assembly.
77. REMOVE NO. 2 AIR DUCT Remove the screw and No. 2 air duct.
78. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See «REMOVAL»(ref-235579-S36269459702006062400000) )
79. REMOVE BLOWER ASSEMBLY Disconnect the connector. Remove the screw. Release the claw and remove the blower assembly.

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. REMOVE AIR OUTLET CONTROL SERVO MOTOR Disconnect the connector. Remove the 3 screws and air outlet control servo motor.
2. REMOVE AIR MIX CONTROL SERVO MOTOR Remove the 4 clamps and connector, and disconnect the wire harness. Remove the 3 screws and heater piping cover. Remove the 3 screws and air mix control servo motor.
3. REMOVE COOLER EXPANSION VALVE Remove the packing from the air conditioning tube assembly. Using a hexagon wrench 4 mm, remove the 2 hexagon bolts and air conditioning tube assembly. Remove the 2 O-rings from the air conditioning tube assembly. Remove the cooler expansion valve from the No. 1 cooler evaporator sub-assembly.
4. REMOVE AIR CONDITIONING HARNESS ASSEMBLY Remove the 2 connectors and 5 clamps, and then disconnect the wire harness. Remove the air conditioning harness assembly as shown in the illustration.
5. REMOVE AIR OUTLET CONTROL SERVO MOTOR Remove the 2 screws and the air duct. Remove the 4 screws and the servo motor plate. Remove the 2 screws. Release the claw and remove the air outlet control servo motor from the servo motor plate.
6. REMOVE AIR MIX CONTROL SERVO MOTOR Remove the 2 screws. Release the claw and remove the air mix control servo motor from the servo motor plate.
7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY Remove the screw and clamp. Remove the heater radiator unit sub-assembly.
8. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY Remove the 5 screws. Release the 3 claws and remove the air duct. Remove the No. 1 cooler evaporator sub-assembly from the air duct. Remove the 2 O-rings from the No. 1 cooler evaporator sub-assembly.

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

1. INSTALL COOLER EVAPORATOR SUB-ASSEMBLY Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the cooler evaporator subassembly. Compressor oil: ND-OIL 8 or equivalent Install the 2 O-rings on the cooler evaporator subassembly. Install the air duct with the 3 claws and 5 screws.
2. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY Install the heater radiator unit sub-assembly. Install the clamp with the screw.
3. INSTALL AIR OUTLET CONTROL SERVO MOTOR Install the air outlet control servo motor with the 2 screws. Temporarily install the drive gear to the air outlet control servomotor. Check that the drive gear and the driven gear are engaged at point with the same number of gear teeth from the standard position. Install the drive gear to the air outlet control servomotor. NOTE: If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the drive gear, adjust the driven gear, and reinstall the drive gear. The number of gear teeth from the standard position varies according to the stop position of the air outlet control servomotor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position. If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servo motor may not operate normally.
4. INSTALL AIR MIX CONTROL SERVO MOTOR Install the air mix control servo motor with the 2 screws. Install the drive gear to the air mix control servo motor. Temporarily install the mode damper servo assembly so that the levers fit into each groove. Slightly lift the air outlet control servo motor. Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position from the view indicated by arrow (A). NOTE: If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, lift the air outlet control servo motor to adjust the driven gear and reinstall the air outlet control servo motor. If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air outlet control servo motor may not operate normally. Install the air outlet control servo motor with the 4 screws.
5. INSTALL AIR CONDITIONING HARNESS ASSEMBLY Attach the 4 clamps to install the air conditioning harness assembly. Install the air conditioning harness as shown in the illustration. Connect the 2 connectors and attach the clamp.
6. INSTALL COOLER EXPANSION VALVE Install the expansion valve. Sufficiently apply compressor oil to 2 new O-rings and the fitting surface of the air conditioning tube assembly. Compressor oil: ND-OIL 8 or equivalent Install the 2 O-rings on the air conditioning tube assembly. Using a hexagon wrench 4 mm, install the air conditioning tube assembly with the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) Install a new packing.
7. INSTALL AIR MIX CONTROL SERVO MOTOR Check that the drive gear and the driven gear are engaged at a point with the same number of gear teeth from the standard position. Temporarily install the air mix control servo motor. NOTE: If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, remove the air mix control servo motor to adjust the driven gear and reinstall the air mix control servo motor. The number of gear teeth from the standard position varies according to the stop position of the air mix control servo motor. Make sure that the gears are engaged at a point with the same number of gear teeth from the standard position. If there is not the same number of gear teeth from the standard position on each gear at the point where the two gears are engaged, the air mix control servo motor may not operate normally. Install the air mix control servo motor with the 3 screws.
8. INSTALL AIR OUTLET CONTROL SERVO MOTOR Install the air outlet control servo motor with the 3 screws. Connect the connector.

Scheme 168

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

1. INSTALL BLOWER ASSEMBLY Install the blower assembly with the claw and screw. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) Connect the connector.
2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (See «REMOVAL»(ref-235579-S36269459702006062400000) )
3. INSTALL NO. 2 AIR DUCT Install the No. 2 air duct with the screw. Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
4. INSTALL AIR CONDITIONER UNIT ASSEMBLY Install the air conditioner unit assembly with the 3 bolts and 2 screws. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) (bolt 1)
5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Driver seat side: Using a T40 "torx" socket, install the instrument panel reinforcement with the 3 "torx" bolts. Passenger seat side: Using a 12 mm hexagon wrench, install the instrument panel reinforcement with the 2 bolts. Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf) Using a T40 "torx" socket, install the instrument panel reinforcement with the 2 "torx" bolts. Torque: 20 N*m (204 kgf*cm, 15 ft.*lbf) Install the instrument panel reinforcement with the 4 bolts and nut. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf) (nut 1) Install the bolt and cap. Connect the 19 connectors and attach the 27 clamps. Install the 2 junction blocks with the 2 bolts and nut.
6. INSTALL IMMOBILISER CODE ECU
7. INSTALL DEFROSTER NOZZLE LOWER ASSEMBLY Attach the 4 claws to install the defroster nozzle lower.
8. INSTALL STEERING COLUMN ASSEMBLY (for Manual Tilt) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
9. INSTALL STEERING COLUMN ASSEMBLY (for Power Tilt and Power Telescopic) (See «INSTALLATION»(ref-235546-S34210807472006062400000) )
10. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (for 2WD) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
11. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
12. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
13. CONNECT PASSENGER AIRBAG CONNECTOR
14. INSTALL NO. 2 CONSOLE BOX DUCT (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
15. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
16. INSTALL NO. 2 CONSOLE BOX DUCT (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
17. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker) (See «INSTALLATION»(ref-235589-S14212054342006062400000) )
18. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
19. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
20. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
21. INSTALL FRONT PILLAR GARNISH LH (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
22. INSTALL FRONT PILLAR GARNISH RH
23. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
24. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY (See «INSTALLATION»(ref-235542-S26749810932006062400000) )
25. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
26. INSTALL SIDE INSTRUMENT PANEL RH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
27. INSTALL FRONT DOOR OPENING TRIM COVER RH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
28. INSTALL FRONT DOOR SCUFF PLATE RH (w/o Illumination)
29. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination)
30. INSTALL COMBINATION METER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
31. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
32. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «INSTALLATION»(ref-235542-S26103287292006062400000) )
33. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
34. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
35. INSTALL SIDE INSTRUMENT PANEL LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
36. INSTALL FRONT DOOR OPENING TRIM COVER LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
37. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
38. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
39. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
40. INSTALL STEERING COLUMN COVER (for Manual Tilt) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
41. INSTALL STEERING COLUMN COVER (for Power Tilt and Power Telescopic) (See «INSTALLATION»(ref-235546-S34210807472006062400000) )
42. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See «INSTALLATION»(ref-235542-S27816112932006062400000) )
43. INSTALL STEERING WHEEL ASSEMBLY (See «INSTALLATION»(ref-235542-S27816112932006062400000) )
44. INSTALL STEERING PAD (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
45. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
46. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
47. INSTALL INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System) (See «INSTALLATION»(ref-235589-S18433754322006062400000) )
48. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System) (See «INSTALLATION»(ref-235589-S18433754322006062400000) )
49. INSTALL CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
50. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
51. INSTALL CONSOLE BOX (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
52. INSTALL CONSOLE BOX REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
53. INSTALL FRONT ASH RECEPTACLE SUBASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
54. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
55. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
56. INSTALL CONSOLE PANEL SUB-ASSEMBLY (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
57. INSTALL UPPER NO. 2 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
58. INSTALL UPPER NO. 1 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
59. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission)
60. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transmission)
61. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
62. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
63. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
64. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
65. INSTALL FRONT WIPER ARM HEAD CAP (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
66. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
67. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
68. INSTALL FRONT FENDER PROTECTOR UPPER LH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
69. INSTALL FRONT FENDER PROTECTOR UPPER RH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
70. INSTALL HEATER WATER INLET HOSE Install the water hose and attach the clip.
71. INSTALL HEATER WATER OUTLET HOSE Use the same procedures described for the water hose inlet.
72. INSTALL LIQUID TUBE SUB-ASSEMBLY Remove the vinyl tape attached to the tube. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the liquid tube. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the liquid tube. Install the liquid tube to the fitting hole.
73. INSTALL SUCTION PIPE SUB-ASSEMBLY Remove the vinyl tape attached to the pipe. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the suction pipe. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the suction pipe. Move the hook connector in the direction indicated by the arrow in the illustration. Insert the pipe joints into the fitting holes securely and tighten the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
74. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
75. PERFORM INITIALIZATION NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal (See «INITIALIZATION»(ref-235541-S32349848442006062400000) )
76. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
77. WARM UP ENGINE (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
78. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
79. INSTALL ENGINE ROOM SIDE COVER LH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
80. INSTALL ENGINE ROOM SIDE COVER RH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
81. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-235451-S29453453712006062200000) )

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

1. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD
2. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235451-S13841571552006062200000) )
3. REMOVE ENGINE ROOM SIDE COVER LH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
4. REMOVE ENGINE ROOM SIDE COVER RH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
5. DISCHARGE REFRIGERANT FROM REFRIGERATION Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
6. DISCONNECT CABLE FROM NEGATIVE BATTERY CAUTION: Wait for 90 seconds after disconnecting the cable to prevent airbag deployment (See «PRECAUTION»(ref-235542-S10058841152006062400000) )
7. REMOVE FRONT FENDER PROTECTOR UPPER LH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
8. REMOVE FRONT FENDER PROTECTOR UPPER RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
9. REMOVE ROOF DRIP SIDE FINISH MOULDING LH (See «REMOVAL»(ref-235598-S34002898732006062400000) )
10. REMOVE ROOF DRIP SIDE FINISH MOULDING RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
11. REMOVE FRONT WIPER ARM HEAD CAP (See «REMOVAL»(ref-235575-S42063685122006062400000) )
12. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY LH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
13. REMOVE FRONT WIPER ARM AND BLADE ASSEMBLY RH (See «REMOVAL»(ref-235575-S42063685122006062400000) )
14. REMOVE COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See «REMOVAL»(ref-235575-S42063685122006062400000) )
15. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See «REMOVAL»(ref-235575-S42063685122006062400000) )
16. SEPARATE SUCTION PIPE SUB-ASSEMBLY (See «REMOVAL»(ref-235579-S01894918482006062400000) )
17. SEPARATE LIQUID TUBE SUB-ASSEMBLY (See «REMOVAL»(ref-235579-S01894918482006062400000) )
18. REMOVE HEATER WATER OUTLET HOSE (See «REMOVAL»(ref-235579-S01894918482006062400000) )
19. REMOVE HEATER WATER INLET HOSE (See «REMOVAL»(ref-235579-S01894918482006062400000) )
20. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
21. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
22. REMOVE UPPER NO. 1 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
23. REMOVE UPPER NO. 2 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
24. REMOVE CONSOLE PANEL SUB-ASSEMBLY (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
25. REMOVE REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
26. REMOVE FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
27. REMOVE FRONT ASH RECEPTACLE SUBASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
28. REMOVE CONSOLE BOX REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
29. REMOVE CONSOLE BOX (See «REMOVAL»(ref-235591-S20751754672006062400000) )
30. REMOVE NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
31. REMOVE CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL (See «REMOVAL»(ref-235591-S20751754672006062400000) )
32. REMOVE MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System) (See «REMOVAL»(ref-235589-S20177326342006062400000) )
33. REMOVE INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System) (See «REMOVAL»(ref-235589-S20177326342006062400000) )
34. REMOVE LOWER NO. 2 STEERING WHEEL COVER (See «REMOVAL»(ref-235542-S05597931522006062400000) )
35. REMOVE LOWER NO. 3 STEERING WHEEL COVER (See «REMOVAL»(ref-235542-S05597931522006062400000) )
36. REMOVE STEERING PAD (See «REMOVAL»(ref-235542-S05597931522006062400000) )
37. REMOVE STEERING WHEEL ASSEMBLY (See «REMOVAL»(ref-235546-S15909269792006062400000) )
38. REMOVE STEERING COLUMN COVER (for Power Tilt and Power Telescopic) (See «REMOVAL»(ref-235546-S01736682752006062400000) )
39. REMOVE STEERING COLUMN COVER (for Manual Tilt) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
40. REMOVE TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See «REMOVAL»(ref-235546-S15909269792006062400000) )
41. REMOVE FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
42. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See «REMOVAL»(ref-235599-S10274364092006062400000) )
43. REMOVE FRONT DOOR OPENING TRIM COVER LH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
44. REMOVE SIDE INSTRUMENT PANEL LH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
45. REMOVE NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
46. REMOVE LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
47. REMOVE DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «REMOVAL»(ref-235542-S32764164272006062400000) )
48. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
49. REMOVE COMBINATION METER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
50. REMOVE FRONT DOOR SCUFF PLATE RH (w/o Illumination) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
51. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
52. REMOVE FRONT DOOR OPENING TRIM COVER RH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
53. REMOVE SIDE INSTRUMENT PANEL RH (See «REMOVAL»(ref-235591-S20751754672006062400000) )
54. REMOVE NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
55. REMOVE FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY (See «REMOVAL»(ref-235542-S26525252422006062400000) )
56. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
57. REMOVE FRONT PILLAR GARNISH LH (See «REMOVAL»(ref-235599-S10274364092006062400000) )
58. REMOVE FRONT PILLAR GARNISH RH
59. REMOVE NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
60. REMOVE NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
61. REMOVE NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
62. REMOVE FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker) (See «REMOVAL»(ref-235589-S20738965952006062400000) )
63. REMOVE NO. 2 CONSOLE BOX DUCT (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
64. REMOVE NO. 1 CONSOLE BOX DUCT (for Automatic Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
65. REMOVE NO. 2 CONSOLE BOX DUCT (for Manual Transmission) (See «REMOVAL»(ref-235591-S20751754672006062400000) )
66. DISCONNECT PASSENGER AIRBAG CONNECTOR
67. REMOVE INSTRUMENT PANEL SAFETY PAD ASSEMBLY (See «REMOVAL»(ref-235591-S20751754672006062400000) )
68. REMOVE NO. 1 AIR DUCT (See «REMOVAL»(ref-235546-S15909269792006062400000) )
69. REMOVE STEERING SLIDING YOKE SUBASSEMBLY (for 2WD) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
70. REMOVE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
71. REMOVE STEERING COLUMN ASSEMBLY (for Manual Tilt) (See «REMOVAL»(ref-235546-S15909269792006062400000) )
72. REMOVE STEERING COLUMN ASSEMBLY (for Power Tilt and Power Telescopic) (See «REMOVAL»(ref-235546-S01736682752006062400000) )
73. REMOVE DEFROSTER NOZZLE LOWER ASSEMBLY (See «REMOVAL»(ref-235579-S01894918482006062400000) )
74. REMOVE IMMOBILISER CODE ECU
75. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See «REMOVAL»(ref-235579-S01894918482006062400000) )
76. REMOVE AIR CONDITIONER UNIT ASSEMBLY (See «REMOVAL»(ref-235579-S01894918482006062400000) )
77. REMOVE NO. 2 AIR DUCT (See «REMOVAL»(ref-235579-S01894918482006062400000) )
78. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (See «REMOVAL»(ref-235579-S36269459702006062400000) )
79. REMOVE BLOWER ASSEMBLY Disconnect the connector. Remove the screw. Release the 2 claws and remove the blower assembly.

Scheme 182

Scheme 183

Scheme 184

Scheme 185

1. REMOVE INLET CONTROL SERVO MOTOR Detach the claw and remove the lever. Remove the 2 screws and inlet control servo motor.
2. REMOVE CLEAN AIR FILTER Detach the 2 claws and remove the air filter. HINT: Be sure to turn the engine switch on (IG) and set the A/C to RECIRCULATION mode before removing the air filter.
3. REMOVE COOLING UNIT WITH FAN MOTOR SUBASSEMBLY Remove the 3 screws and fan motor.

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. INSTALL COOLING UNIT WITH FAN MOTOR SUBASSEMBLY Install the fan motor with the 3 screws.
2. INSTALL CLEAN AIR FILTER Attach the 2 claws to install the air filter.
3. INSTALL INLET CONTROL SERVO MOTOR Install the inlet control servo motor with the 2 screws. Attach the claw and install the lever.

Scheme 190

1. INSTALL BLOWER ASSEMBLY Install the blower assembly with the 2 claws and screw. Torque: 3.0 N*m (31 kgf*cm, 27 in.*lbf) Connect the connector.
2. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (See «REMOVAL»(ref-235579-S36269459702006062400000) )
3. INSTALL NO. 2 AIR DUCT (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
4. INSTALL AIR CONDITIONER UNIT ASSEMBLY (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
5. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
6. INSTALL IMMOBILISER CODE ECU
7. INSTALL DEFROSTER NOZZLE LOWER ASSEMBLY (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
8. INSTALL STEERING COLUMN ASSEMBLY (for Manual Tilt) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
9. INSTALL STEERING COLUMN ASSEMBLY (for Power Tilt and Power Telescopic) (See «INSTALLATION»(ref-235546-S34210807472006062400000) )
10. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (for 2WD) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
11. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
12. INSTALL NO. 1 AIR DUCT (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
13. INSTALL INSTRUMENT PANEL SAFETY PAD ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
14. CONNECT PASSENGER AIRBAG CONNECTOR
15. INSTALL NO. 2 CONSOLE BOX DUCT (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
16. INSTALL NO. 1 CONSOLE BOX DUCT (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
17. INSTALL NO. 2 CONSOLE BOX DUCT (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
18. INSTALL FRONT STEREO COMPONENT SPEAKER ASSEMBLY (w/ Front Center Speaker) (See «INSTALLATION»(ref-235589-S14212054342006062400000) )
19. INSTALL NO. 3 INSTRUMENT PANEL SPEAKER PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
20. INSTALL NO. 2 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
21. INSTALL NO. 1 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
22. INSTALL FRONT PILLAR GARNISH LH (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
23. INSTALL FRONT PILLAR GARNISH RH
24. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
25. INSTALL FRONT PASSENGER SIDE KNEE AIRBAG ASSEMBLY (See «INSTALLATION»(ref-235542-S26749810932006062400000) )
26. INSTALL NO. 2 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
27. INSTALL SIDE INSTRUMENT PANEL RH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
28. INSTALL FRONT DOOR OPENING TRIM COVER RH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
29. INSTALL FRONT DOOR SCUFF PLATE RH (w/o Illumination)
30. REMOVE FRONT DOOR SCUFF PLATE RH (w/ Illumination)
31. INSTALL COMBINATION METER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
32. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
33. INSTALL DRIVER SIDE KNEE AIRBAG ASSEMBLY (See «INSTALLATION»(ref-235542-S26103287292006062400000) )
34. INSTALL LOWER INSTRUMENT PANEL FINISH PANEL SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
35. INSTALL NO. 1 INSTRUMENT PANEL UNDER COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
36. INSTALL SIDE INSTRUMENT PANEL LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
37. INSTALL FRONT DOOR OPENING TRIM COVER LH (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
38. INSTALL FRONT DOOR SCUFF PLATE LH (w/o Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
39. REMOVE FRONT DOOR SCUFF PLATE LH (w/ Illumination) (See «INSTALLATION»(ref-235599-S41342360772006062400000) )
40. INSTALL TURN SIGNAL SWITCH ASSEMBLY WITH SPIRAL CABLE SUB-ASSEMBLY (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
41. INSTALL STEERING COLUMN COVER (for Manual Tilt) (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
42. INSTALL STEERING COLUMN COVER (for Power Tilt and Power Telescopic) (See «INSTALLATION»(ref-235546-S34210807472006062400000) )
43. ADJUST SPIRAL CABLE SUB-ASSEMBLY (See «INSTALLATION»(ref-235542-S27816112932006062400000) )
44. INSTALL STEERING WHEEL ASSEMBLY (See «INSTALLATION»(ref-235546-S07122382332006062400000) )
45. INSTALL STEERING PAD (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
46. INSTALL LOWER NO. 3 STEERING WHEEL COVER (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
47. INSTALL LOWER NO. 2 STEERING WHEEL COVER (See «INSTALLATION»(ref-235542-S14674145642006062400000) )
48. INSTALL INTEGRATION CONTROL PANEL WITH RADIO RECEIVER ASSEMBLY (w/o Navigation System) (See «INSTALLATION»(ref-235589-S18433754322006062400000) )
49. INSTALL MULTI-DISPLAY WITH RADIO RECEIVER ASSEMBLY (w/ Navigation System) (See «INSTALLATION»(ref-235589-S18433754322006062400000) )
50. INSTALL CENTER LOWER INSTRUMENT CLUSTER FINISH PANEL (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
51. INSTALL NO. 3 INSTRUMENT PANEL REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
52. INSTALL CONSOLE BOX (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
53. INSTALL CONSOLE BOX REGISTER ASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
54. INSTALL FRONT ASH RECEPTACLE SUBASSEMBLY (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
55. INSTALL FRONT CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
56. INSTALL REAR CONSOLE PANEL SUB-ASSEMBLY (for Manual Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
57. INSTALL CONSOLE PANEL SUB-ASSEMBLY (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
58. INSTALL UPPER NO. 2 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
59. INSTALL UPPER NO. 1 CONSOLE PANEL GARNISH (for Automatic Transmission) (See «INSTALLATION»(ref-235591-S32740741772006062400000) )
60. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transmission)
61. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Automatic Transmission)
62. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
63. INSTALL COWL TOP VENTILATOR LOUVER SUBASSEMBLY (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
64. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY LH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
65. INSTALL FRONT WIPER ARM AND BLADE ASSEMBLY RH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
66. INSTALL FRONT WIPER ARM HEAD CAP (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
67. INSTALL ROOF DRIP SIDE FINISH MOULDING LH
68. INSTALL ROOF DRIP SIDE FINISH MOULDING RH
69. INSTALL FRONT FENDER PROTECTOR UPPER LH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
70. INSTALL FRONT FENDER PROTECTOR UPPER RH (See «INSTALLATION»(ref-235575-S04812000522006062400000) )
71. INSTALL HEATER WATER INLET HOSE (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
72. INSTALL HEATER WATER OUTLET HOSE (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
73. INSTALL LIQUID TUBE SUB-ASSEMBLY (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
74. INSTALL SUCTION PIPE SUB-ASSEMBLY (See «INSTALLATION»(ref-235579-S21480697162006062400000) )
75. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
76. PERFORM INITIALIZATION NOTE: Some systems need initialization after reconnecting the cable to the negative battery terminal (See «INITIALIZATION»(ref-235541-S32349848442006062400000) )
77. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
78. WARM UP ENGINE (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
79. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
80. INSTALL ENGINE ROOM SIDE COVER LH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
81. INSTALL ENGINE ROOM SIDE COVER RH (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
82. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-235451-S29453453712006062200000) )

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

1. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235598-S24774280692006062400000) )
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235451-S13841571552006062200000) )
3. REMOVE NO. 1 INLET AIR CLEANER (See «REMOVAL»(ref-235451-S13841571552006062200000) )
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
5. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-235451-S37329974002006062200000) )
6. REMOVE UNDER ENGINE COVER
7. REMOVE REAR UNDER COVER LH (See «REMOVAL»(ref-235451-S13841571552006062200000) )
8. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the bolt and disconnect the No. 1 cooler refrigerant suction hose from the compressor. Remove the O-ring from the cooler refrigerant suction hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
9. REMOVE DISCHARGE HOSE SUB-ASSEMBLY Remove the bolt and disconnect the discharge hose from the compressor. Remove the O-ring from the discharge hose subassembly. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.
10. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the magnetic clutch connector. Remove the 3 bolts and nut. Remove the compressor and magnetic clutch.

Scheme 196

Scheme 197

Scheme 198

1. REMOVE MAGNETIC CLUTCH ASSEMBLY Place the compressor and magnetic clutch in a vise. Using vise pliers, hold the magnetic clutch hub. Remove the bolt, magnetic clutch hub and magnetic clutch washers. HINT: There is no set number of magnetic clutch washers since they are used for adjusting. Using a snap ring expander, remove the snap ring and magnetic clutch rotor. NOTE: Take care not to damage the seal cover of the bearing when removing the snap ring. Disconnect the connector. Remove the screw. Using a snap ring expander, remove the snap ring and magnetic clutch stator.

Scheme 199

Scheme 200

Scheme 201

Scheme 202

1. INSPECT A/C COMPRESSOR Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-1 (MG+) - A-1 Always Below 1 ohms E8-1 (MG;) - Body ground Always 10 kohms or higher If the resistance is not as specified, replace the A/C compressor.
2. INSPECT MAGNETIC CLUTCH Measure the resistance of the connector. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition A-1 - Body ground Always 3.4 to 3.8 ohms If the resistance is not as specified, replace the magnetic clutch. When connector terminal A1 is connected to the positive (+) battery terminal, check that the following occurs: 1) the magnetic clutch's operating sound can be heard, and 2) the magnetic clutch's hub and rotor lock.
3. INSPECT A/C COMPRESSOR (LOCK SENSOR) Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Specified Condition E8-2 (SSR+) - E8-5 (SSR-) 160 to 320 ohms If the resistance is not as specified, replace the A/C compressor.
4. INSPECT A/C COMPRESSOR (SOLENOID) Measure the resistance according to the value(s) in the table below. Standard resistance RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition E8-3 (SOL+) - E8-6 (SOL-) 20°C (68°F) 10 to 11 ohms If the resistance is not as specified, replace the A/C compressor.

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1. INSTALL MAGNETIC CLUTCH ASSEMBLY Install the magnetic clutch stator with the parts shown in the illustration matched. Using a snap ring expander, install a new snap ring with the chamfered side facing up. NOTE: Take care not to damage the seal cover of the bearing when installing the snap ring. Connect the connector. Using a snap ring expander, install the magnetic clutch rotor and a new snap ring with the chamfered side facing up. NOTE: Do not expand the snap ring by more than 35.5 mm (1.39 in.) when installing it. Do not damage the seal cover of the bearing when installing the snap ring. Install the magnetic clutch washer and magnetic clutch hub. NOTE: Do not change the combination of the magnetic clutch washers used before disassembly. Using vise pliers, hold the magnetic clutch hub and install the bolt. Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf) NOTE: Make sure that there is no foreign matter or oil on the compressor shaft, bolt, and clutch hub.
2. INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the magnetic clutch hub. Connect the battery positive lead to terminal 1 of the magnetic clutch connector and the negative lead to the ground wire. Turn the magnetic clutch on and off and measure the clearance. Standard clearance: 0.26 to 0.60 mm (0.010 to 0.024 in.) If the measured value is not within the standard range, remove the magnetic clutch hub and adjust it with magnetic clutch washers. NOTE: Adjustment should be performed with 3 or less magnetic clutch washers. Remove the compressor and magnetic clutch from the vise.
3. ADJUST COMPRESSOR OIL When replacing the compressor and magnetic clutch with a new one, gradually discharge the refrigerant gas from the service valve, and drain the following amount of oil from the new compressor and magnetic clutch before installation. Standard: (Oil capacity inside the new compressor and magnetic clutch: 130 + 15 cc (4.6 + 0.51 fl.oz.) ) -(Remaining oil amount in the removed compressor and magnetic clutch) = (Oil amount to be removed from the new compressor when replacing) NOTE: When checking the compressor oil level, observe the precautions on the cooler removal/installation. If a new compressor and magnetic clutch is installed without removing some oil remaining in the pipes of the vehicle, the oil amount will be too large. This prevents heat exchange in the refrigerant cycle and causes refrigerant failure. If the volume of oil remaining in the removed compressor and magnetic clutch is too small, check for oil leakage. Be sure to use ND-OIL 8 or equivalent for compressor oil.

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1. INSTALL COMPRESSOR AND MAGNETIC CLUTCH Temporarily install the compressor and magnetic clutch onto the stud bolt. Install the compressor and magnetic clutch with the 3 bolts and nut. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTE: Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.
2. INSTALL DISCHARGE HOSE SUB-ASSEMBLY Remove the attached vinyl tape from the hose. Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent Install the O-ring onto the discharge hose subassembly. Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
3. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE Remove the attached vinyl tape from the hose. Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch. Compressor oil: ND-OIL 8 or equivalent Install the O-ring onto the No.1 cooler refrigerant suction hose. Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
4. INSTALL V-RIBBED BELT (See «INSTALLATION»(ref-235451-S09883656572006062200000) )
5. INSTALL REAR UNDER ENGINE COVER LH
6. INSTALL UNDER ENGINE COVER
7. INSTALL NO. 1 INLET AIR CLEANER (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
8. INSTALL V-BANK COVER SUB-ASSEMBLY (See «INSTALLATION»(ref-235451-S29453453712006062200000) )
9. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
10. WARM UP ENGINE (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
11. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-235579-S02745364222006062400000) )
12. INSTALL COOL AIR INTAKE DUCT SEAL (See «INSTALLATION»(ref-235451-S29453453712006062200000) )

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1. REMOVE COOL AIR INTAKE DUCT SEAL (See «REMOVAL»(ref-235451-S13841571552006062200000) )
2. REMOVE V-BANK COVER SUB-ASSEMBLY (See «REMOVAL»(ref-235451-S13841571552006062200000) )
3. REMOVE NO. 1 INLET AIR CLEANER (See «REMOVAL»(ref-235451-S13841571552006062200000) )
4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Start up the engine. Turn the A/C switch on. Operate the cooler compressor at an engine rpm of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
5. REMOVE UNDER ENGINE COVER
6. REMOVE V-RIBBED BELT (See «REMOVAL»(ref-235451-S37329974002006062200000) )
7. REMOVE OIL FILTER BRACKET Remove the bolt, nut, and oil filter bracket.
8. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY Disconnect the connector and 2 clamps, and separate the wire harness. Remove the 2 nuts, bolts, and oil filter bracket subassembly. HINT: Place a container under the connection because engine oil will leak out when separating the oil filter bracket.
9. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE (See «REMOVAL»(ref-235579-S35142441472006062400000) )
10. REMOVE DISCHARGE HOSE SUB-ASSEMBLY (See «REMOVAL»(ref-235579-S35142441472006062400000) )
11. REMOVE COMPRESSOR AND MAGNETIC CLUTCH Disconnect the connector. Remove the 2 bolts and nut. Using a "Torx " socket wrench (E8), remove the stud bolt and the compressor and magnetic clutch.