Control System - HVAC (Full Auto Air Conditioner): Removal & Installation Mazda RX-8 I рестайлинг

AIRFLOW MODE ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]

1. Disconnect the negative battery cable.
2. Remove the TCM. (AT) (See «TCM REMOVAL/INSTALLATION [SJ6A-EL]»(ref-367646-S22574760762010072700000) .)
3. Remove the A/C amplifier. (See «A/C AMPLIFIER REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]»(ref-367648-S16757882682010072700000) .)
4. Remove in the order indicated in the figure.
5. Install in the reverse order of removal.

Scheme 21

Scheme 22

Scheme 23

1. Connect battery positive voltage to airflow mode actuator terminal F (or G), and ground to terminal G (or F), and then verify that the airflow mode actuator operates as shown in «AIRFLOW MODE ACTUATOR OPERATION CHART»(ref-367648-S42666189462010072700000) . Apply the external power supply. If the operation condition is not normal, replace the airflow mode actuator. AIRFLOW MODE ACTUATOR OPERATION CHART Terminal Airflow mode actuator operation F G B+ Ground DEFROSTER-->VENT Ground B+ VENT-->DEFROSTER
2. Verify that the resistance between terminals A and E, and C and E matches the airflow mode actuator operation as shown in the graph. If the operation condition and resistance are not normal, replace the airflow mode actuator.
3. Install the air mix actuator with the lever the position shown in the figure.

Scheme 24

BLOWER MOTOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]

1. Disconnect the negative battery cable.
2. Remove in the order indicated in the figure.
3. Install in the reverse order of removal.

Scheme 25

Scheme 26

1. Connect battery positive voltage to blower motor terminal A, ground to terminal B, and then verify that the blower motor operates smoothly. If the operation condition is not normal, replace the blower motor.

Scheme 27

1. Disconnect the negative battery cable.
2. Remove the glove compartment. (See «GLOVE COMPARTMENT REMOVAL/INSTALLATION»(ref-367662-S24199587722010072700000) .)
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 28

1. Verify that the continuity between the power transistor terminals is as indicated in «RESISTANCE CHART»(ref-367648-S06416362132010072700000) . If there is any malfunction, replace the power transistor. If the blower motor operation is not normal even though no malfunction can be verified, inspect the A/C amplifier. (See «A/C AMPLIFIER INSPECTION [FULL-AUTO AIR CONDITIONER]»(ref-367648-S08976149552010072700000) .) RESISTANCE CHART Tester lead Resistance (kilohm) + - A B infinity A C 11.0 A D infinity B A Continuity detected B C Continuity detected B D 1.5 C A 11.0 C B infinity C D infinity D A Continuity detected D B 1.5 D C Continuity detected

Scheme 29

1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a feeler gauge.
2. Inspect the clearance. If not within the specification, adjust the clearance by changing the shim (0.2 mm {0.008 in}, 0.5 mm {0.02 in}) or the number of shims. Magnetic clutch clearance 0.20-0.45 mm {0.008-0.017 in}

Scheme 30

Scheme 31

1. Connect battery positive voltage to magnetic clutch terminal B and ground to terminal A.
2. Verify that the magnetic clutch turns on. If the magnetic clutch does not turn on, replace the A/C compressor.

Scheme 32

1. Disconnect the negative battery cable.
2. Pry the solar radiation sensor from the dashboard using a flathead screwdriver wrapped with protective tape.
3. Remove in the order indicated in the figure. CAUTION: After the solar radiation sensor removal, the sensor connector could fall in the dashboard making the installation difficult. Therefore, hold the rooted end of the sensor connector using a clip or similar tool to prevent it from falling.
4. Install in the reverse order of removal.

Scheme 33

1. Shine a fluorescent light or expose the solar radiation sensor to natural sunlight.
2. Connect the positive (+) lead to terminal A and the negative (-) lead to terminal B of the solar radiation sensor, and verify that the voltage value is output. If the voltage is 0 V , replace the solar radiation sensor.

Scheme 34

1. Disconnect the negative battery cable.
2. Remove the under cover.
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 35

1. Measure the temperature around the ambient temperature sensor, then measure the resistance between the terminals of the ambient temperature sensor. If the characteristics of the ambient temperature sensor are not (Scheme 35), replace the ambient temperature sensor.

Scheme 36

1. Disconnect the negative battery cable.
2. Remove the driver's side lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-367662-S38463010542010072700000) .)
3. Remove the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 37

Scheme 38

1. Measure the temperature around the passenger compartment temperature sensor and measure the resistance between passenger compartment temperature sensor terminal. If the characteristics of the passenger compartment temperature sensor are not (Scheme 37), replace the passenger compartment temperature sensor.
2. Connect battery positive voltage to passenger compartment temperature sensor terminal A, ground to terminal C, and then verify that the fan operation. If there is any malfunction, replace the passenger compartment temperature sensor.

EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]

1. Remove the evaporator temperature sensor from the A/C unit. (See «A/C UNIT DISASSEMBLY/ASSEMBLY»(ref-367660-S33647174192010072700000) .)

REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER]

1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (See «REFRIGERANT CHARGING»(ref-367641-S12059913632010072700000) .)
3. Hold the piping block with pliers or a similar tool and loosen the refrigerant pressure switch using a wrench.
4. Remove in the order indicated in the figure.
5. Install in the reverse order of removal.

Scheme 39

Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to the O-ring joints.

Scheme 40

Scheme 41

Scheme 42

1. Connect the manifold gauge.
2. Verify the high-pressure side reading.
3. Disconnect the refrigerant pressure switch connector.
4. Verify continuity between the terminals of the refrigerant pressure switch. If the continuity is not normal, replace the refrigerant pressure switch.

Scheme 43

1. Disconnect the negative battery cable.
2. Remove the lower panel. (See «LOWER PANEL REMOVAL/INSTALLATION»(ref-367662-S38463010542010072700000) .)
3. Remove the console. (See «CONSOLE REMOVAL/INSTALLATION»(ref-367662-S08997723562010072700000) .)
4. Remove the center panel unit. (See «CENTER PANEL UNIT REMOVAL/INSTALLATION»(ref-367632-S21389676612010072700000) .)
5. Remove in the order indicated in the figure.
6. Install in the reverse order of removal.

Scheme 44

1. Turn the ignition switch to the ON position.
2. Connect the negative (-) lead of the tester to body ground.
3. By inserting the positive (+) lead of the tester into each climate control unit terminal, measure the voltage according to the «TERMINAL VOLTAGE CHART»(ref-367648-S39973627722010072700000) . If there is any malfunction, inspect the parts under "Inspection item(s)". If the parts under "Inspection item(s)" are found to be normal, replace the climate control unit. «TERMINAL VOLTAGE CHART»(ref-367648-S39973627722010072700000) TERMINAL VOLTAGE CHART Terminal Signal name Connected to Measurement condition Voltage (V) Inspection item(s) A B+ ROOM 15 A fuse Under any condition B+ ROOM 15 A fuse Related wiring harness B ACC Ignition switch Ignition switch ACC B+ Ignition switch Related wiring harness Ignition switch LOCK 1.0 or less C TNS TNS relay When light switch TNS B+ light switch Related wiring harness When light switch OFF 1.0 or less D Panel light control Panel light control switch Light switch ON and panel light control switch at max 1.0 or less Panel light control switch Related wiring harness Light switch ON and panel light control switch at min 11.5 E IG2 Ignition switch Ignition switch ON B+ Ignition switch Related wiring harness Ignition switch LOCK or ACC 1.0 or less F Vehicle speed Instrument cluster When vehicle driving 1.0 or less Instrument cluster Related wiring harness G Shield GND A/C amplifier Under any condition 1.0 or less A/C amplifier Related wiring harness H GND Body ground Under any condition 1.0 or less Related wiring harness I Serial signal 1 A/C amplifier Inspect the continuity in the wiring harness between climate control unit terminal I and A/C amplifier terminal 1R. Because this terminal is for communication, good/no good judgment by terminal voltage is not possible. Continuity A/C amplifier Related wiring harness J MS-CAN_H CAN related module Because this terminal is for communication, good/no good judgment by terminal voltage is not possible. Related wiring harness K Serial signal 2 A/C amplifier Inspect the continuity in the wiring harness between climate control unit terminal K and A/C amplifier terminal 1 P. Because this terminal is for communication, good/no good judgment by terminal voltage is not possible. Continuity A/C amplifier Related wiring harness L MS-CAN_L CAN related module Because this terminal is for communication, good/no good judgment by terminal voltage is not possible. Related wiring harness

Scheme 45

1. Disconnect the negative battery cable.
2. Remove the TCM. (AT) (See «TCM REMOVAL/INSTALLATION [SJ6A-EL]»(ref-367646-S22574760762010072700000) .)
3. Remove in the order indicated in the figure.
4. Install in the reverse order of removal.

Scheme 46

Scheme 47

1. Turn the ignition switch to the ON position.
2. Connect the negative (-) lead of the tester to body ground.
3. By inserting the positive (+) lead of the tester into each A/C amplifier terminal, measure the voltage according to the «TERMINAL VOLTAGE CHART»(ref-367648-S39973627722010072700000). If there is any malfunction, inspect the parts under "Inspection item(s)". If the parts under "Inspection item(s)" are found to be normal (except for terminal 1 A), replace the A/C amplifier. For terminal 1 A, first try replacing the power transistor. If there is still any malfunction, replace the A/C amplifier. «TERMINAL VOLTAGE CHART»(ref-367648-S39973627722010072700000) TERMINAL VOLTAGE CHART Terminal Signal name Connected to Measurement condition Voltage (V) Inspection item(s) 1A Blower fan speed control Power transistor Fan stopped 1.0 or less A/C amplifier: terminal voltage (1A) Fan: manual LO 2.1 Fan: manual HI 2.9 1B Blower motor feedback Blower motor Power transistor Fan stopped B+ Related wiring harness Power transistor Blower motor Blower relay A/C 10 A fuse HEATER 40 A fuse Power transistor replacement Fan: manual LO 9.0 Fan: manual HI 0.7 1C Version signal Body ground Under any condition 1.0 or less Related wiring harness 1D Version signal Body ground Under any condition 1.0 or less Related wiring harness 1E - - - - - 1F - - - - - 1G - - - - - 1H - - - - - 1I Motor operation Air intake actuator Switched to RECIRCULATE 1.0 or less Related wiring harness Air intake actuator Switched to FRESH 12 1J Motor operation Air intake actuator Switched to RECIRCULATE 12 Related wiring harness Air intake actuator Switched to FRESH 1.0 or less 1K Rear window defroster operation Rear window defroster relay Rear window defroster switch OFF B+ Related wiring harness Rear window defroster relay Rear window defroster switch ON 1.0 or less A/C amplifier: terminal voltage (2C, 2L) 1L Blower motor operation Blower relay Fan switch OFF B+ Related wiring harness Blower relay Fan switch ON 1.0 or less A/C amplifier: terminal voltage (2C, 2L) 1M A/C Refrigerant pressure switch Fan stopped B+ Related wiring harness Refrigerant pressure switch PCM: terminal voltage (1AU) Fan switch: ON and A/C switch: ON 1.0 or less A/C amplifier: terminal voltage (2C, 2L) 1N - - - - - 1O - - - - - 1P Serial signal Climate control unit Terminal used for communication therefore determination based on terminal voltage inspection not possible. Only inspect for an open or short circuit in wiring harness between A/C amplifier terminal 1P and climate control unit terminal K. - Related wiring harness 1Q - - - - - 1R Serial signal Climate control unit Terminal used for communication therefore determination based on terminal voltage inspection not possible. Only inspect for an open or short circuit in wiring harness between A/C amplifier terminal 1R and climate control unit terminal I. - Related wiring harness 1S - - - - - 1T - - - - - 1U Motor operation Air mix actuator Moving towards COLD 1.0 or less Related wiring harness Air mix actuator Moving towards HOT 12 1V Motor operation Air mix actuator Moving towards COLD 12 Related wiring harness Air mix actuator Moving towards HOT 1.0 or less 1W Motor operation Airflow mode actuator Switched to DEFROSTER 12 Related wiring harness Airflow mode actuator Switched to VENT 1.0 or less 1X Motor operation Airflow mode actuator Switched to DEFROSTER 1.0 or less Related wiring harness Airflow mode actuator Switched to VENT 12 2A B+ ROOM 10 A fuse Under any condition B+ Related wiring harness ROOM 10 A fuse 2B - - - - - 2C IG2 A/C 10 A fuse IG SW ON B+ Related wiring harness A/C 10 A fuse IG SW LOCK 1.0 or less Related wiring harness 2D Potentiometer input Air mix actuator Set temperature at MAX COLD 3.9 Related wiring harness Air mix actuator A/C amplifier: terminal voltage (2P) Set temperature at MAX HOT 1.1 2E - - - - - 2F Evaporator temperature sensor input Evaporator temperature sensor Compared with temperature detected by evaporator temperature sensor see scheme 26 Related wiring harness Evaporator temperature sensor A/C amplifier: terminal voltage (2C, 2L) 2G Potentiometer input Airflow mode actuator VENT 4.0 Related wiring harness Airflow mode actuator A/C amplifier: terminal voltage (2P) BILEVEL 3.3 HEAT 2.6 HEAT/DEF 1.8 DEFROSTER 1.0 2H - - - - - 21 Solar radiation sensor input Solar radiation sensor Natural sunlight shined directly on the solar radiation sensor 4.0 Related wiring harness A/C amplifier: terminal voltage (2P) Solar radiation sensor Blocking light to solar radiation sensor 1.0 or less 2J Passenger compartment temperature sensor input Passenger compartment temperature sensor Compared with temperature detected by Passenger compartment temperature sensor (Scheme 37)Related wiring harness Passenger compartment temperature sensor A/C amplifier: terminal voltage (2C, 2L) 2K - - - - - 2L GND Body ground Under any condition 1.0 or less Related wiring harness 2M Ambient temperature sensor input Ambient temperature sensor Compared with temperature detected by ambient temperature sensor (Scheme 35) Related wiring harness Ambient temperature sensor A/C amplifier: terminal voltage (2C, 2L) 2N Sensor GND Ambient temperature sensor Passenger compartment temperature sensor Evaporator temperature sensor Air mix actuator Airflow mode actuator Under any condition 1.0 or less A/C amplifier: terminal voltage (2L) 2O ECT sensor input PCM Compared with temperature detected by ECT sensor (Scheme 47) Related wiring harness ECT sensor A/C amplifier: terminal voltage (2C, 2L) 2P +5V Air mix actuator Airflow mode actuator Solar radiation sensor IG SW ON 5.0 Related wiring harness Air mix actuator Airflow mode actuator Solar radiation sensor A/C amplifier: terminal voltage (2C, 2L) IG SW LOCK 1.0 or less A/C amplifier replacement