Automatic Air Conditioner: Other Nissan Quest III

Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"

The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELT articles .

Precautions for Working with HFC-134a (R-134a)

Contaminated Refrigerant

If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are

1. Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere.
2. Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply.
3. Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred.
4. If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment . If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended.
5. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NISSAN Customer Affairs for further assistance.

General Refrigerant Precautions

Precautions for Leak Detection Dye

1. The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks.
2. Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of the fluorescent dye.
3. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-41995).
4. For your safety and the customer's satisfaction, read and follow all manufacturer's operating instructions and precautions prior to performing work.
5. A compressor shaft seal should not be repaired because of dye . The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
6. Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service.
7. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed .
8. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
9. Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.
10. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C systems or CFC-12 (R-12) leak detection dye in HFC-134A (R-134a) A/C systems or A/C system damage may result.
11. The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs.

Precautions for Refrigerant Connection

A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.

1. Expansion valve to cooling unit
2. Evaporator pipes to evaporator (inside cooling unit)
3. Refrigerant pressure sensor

Scheme 171

1. The O-ring has been relocated. It has also been provided with a groove for proper installation. This reduces the possibility of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics.
2. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

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Precautions for Servicing Compressor

1. Plug all openings to prevent moisture and foreign matter from entering.
2. When the compressor is removed, store it in the same position as it is when mounted on the car.
3. When replacing or repairing compressor, follow "Maintenance of Oil Quantity in Compressor" exactly. Refer to " «MAINTENANCE OF OIL QUANTITY IN COMPRESSOR»(ref-259754-S38590274552007080400000) ".
4. Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with oil, wipe it off by using a clean waste cloth moistened with thinner.
5. After compressor service operation, turn the compressor shaft by hand more than 5 turns in both directions. This will equally distribute oil inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for 1 hour.
6. After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR CLUTCH»(ref-259754-S32056883892007080400000) "

RECOVERY/RECYCLING EQUIPMENT

Follow the manufacturer's instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

Follow the manufacturer's instructions for tester operation and tester maintenance.

VACUUM PUMP

The oil contained inside the vacuum pump is not compatible with the specified oil for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure so the vacuum pump oil may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it.

To prevent this migration, use a manual valve situated near the hose-to-pump connection, as follows.

1. Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump.
2. For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump.
3. If the hose has an automatic shut off valve, disconnect the hose from the pump: as long as the hose is connected, the valve is open and lubricating oil may migrate.

Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump's ability to pull a deep vacuum and are not recommended.

Scheme 174

MANIFOLD GAUGE SET

Be certain that the gauge face indicates HFC-134a (R-134a or 134a). Make sure the gauge set has 1/2"-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) along with specified oil.

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SERVICE HOSES

Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

Scheme 176

SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. If an improper connection is attempted, discharging and contamination may occur.

SHUT-OFF VALVE ROTATION

Scheme 177

REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC134a (R-134a) and specified oils have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2"-16 ACME.

Scheme 178

CHARGING CYLINDER

Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment.

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

SPECIAL SERVICE TOOLS Tool number (Kent-Moore No.) Tool name Description - (J-38873-A) Pulley installer Installing pulley KV99233130 (J-29884) Pulley puller Removing pulley

Scheme 179

HFC-134a (R-134a) Service Tools and Equipment

Never mix HFC-134a refrigerant and/or its specified oil with CFC-12 (R-12) refrigerant and/or its oil.

Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/oil.

Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or oil) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/oil.

Adapters that convert one size fitting to another must never be used refrigerant/oil contamination will occur and compressor failure will result.

TOOL NUMBER DESCRIPTION CHART Tool number (Kent-Moore No.) Tool name Description HFC-134a (R-134a) ( - ) Refrigerant Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size large container 1/2"-16 ACME - ( - ) NISSAN A/C System Oil Type S Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) vane rotary compressors (NISSAN only) Lubricity: 40 m l (1.4 US fl oz, 1.4 Imp fl oz) KV991J0130 (ACR2005-NI) ACR5 A/C Service Center Refrigerant recovery, recycling and recharging - (J-41995) Electronic refrigerant leak detector Checking for refrigerant leaks (Power supply: DC 12V battery terminal) - (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) Refrigerant dye injector (J-41447) Quantity 24, 1/4 ounce bottles of HFC-134a (R-134a) fluorescent leak detection dye (J-43872) Refrigerant dye cleaner Leak detection dye (Power supply: DC 12V battery terminal) - (J-42220) Fluorescent dye leak detector Checking for refrigerant leaks when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety goggles (Power supply: DC 12V battery terminal) - (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) - (J-41459) HFC-134a (R-134a) Dye injector Use with (J-41447) 1/4 ounce bottles For injecting 1/4 ounce of fluorescent leak detection dye into A/C system. - (J-43872) Refrigerant dye cleaner For cleaning dye spills. - (J-39183-C) Manifold gauge set (with hoses and couplers) Identification: The gauge face indicates R-134a. Fitting size: Thread size 1/2"-16 ACME Service hoses: (J-39500-72B) High side hose (J-39500-72R) Low side hose (J-39500-72Y) Utility hose Hose colors: Low side hose: Blue with black stripe High side hose: Red with black stripe Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 1/2"-16 ACME Service couplers: (J-39500-20A) High side coupler (J-39500-24A) Low side coupler Hose fitting to service hose: M14 x 1.5 fitting is optional or permanently attached. - (J-39699) Refrigerant weight scale For measuring of refrigerant Fitting size - thread size: 1/2" - 16 ACME - (J-39649) Vacuum pump (Including the isolator valve) Capacity: Air displacement: 4 CFM Micron rating: 20 microns Oil capacity: 482 g (17 oz) Fitting size: Thread size 1/2"-16 ACME

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Commercial Service Tools

COMMERCIAL SERVICE TOOLS Tool number Tool name Description (J-41810-NI) Refrigerant identifier equipment (R-134a) For checking refrigerant purity and system contamination Power tool Loosening bolts and nuts (J-44614) Clutch disc holding tool Clutch disc holding tool

Scheme 190

REFRIGERANT FLOW

The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the front and rear evaporators, and back to the compressor. The refrigerant evaporation through the evaporator coils are controlled by a front and rear externally equalized expansion valves, located inside the front and rear evaporator cases.

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends a voltage signal to the ECM. The ECM de-energizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm 2 , 398 psi), or below about 120 kPa (1.22 kg/cm 2 , 17.4 psi).

PRESSURE RELIEF VALVE

The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an abnormal level [more than 2,990 kPa (30.5 kg/cm 2 , 433.6 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

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OIL

Name: NISSAN A/C System Oil Type S or equivalent

CHECKING AND ADJUSTING

Start the engine and set the following conditions

test condition

1. Engine speed: Idling to 1,200 rpm
2. A/C switch: On
3. Blower speed: Max. position
4. Temp. control: Optional [set so that intake air temperature is 25° to 30°C (77° to 86°F).]
5. Intake position: Recirculation ( )
6. Perform oil return operation for about ten minutes

Adjust the oil quantity according to the following table.

AIR MIX DOORS CONTROL (AUTOMATIC TEMPERATURE CONTROL)

The air mix doors are automatically controlled so that in-vehicle temperature is maintained at a predetermined value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

BLOWER SPEED CONTROL

Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position.

When AUTO switch is pressed, the blower motor starts to gradually increase air flow volume (if required).

When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

INTAKE DOORS CONTROL

The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. Recirculation is not allowed in floor, floor/defrost or defrost modes.

MODE DOOR CONTROL

The mode door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.

DEFROSTER DOOR CONTROL

The defroster door is controlled by: Turning the defroster dial to front defroster.

Scheme 194

When A/C switch or DEF switch is pressed, front air control outputs compressor ON signal to BCM.

BCM sends compressor ON signal to ECM and front air control, via CAN communication line.

ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle sensor, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line.

Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.

DISPLAY SCREEN

Displays the operational status of the system.

AUTO SWITCH

1. The compressor, intake doors, air mix doors, outlet doors and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.
2. When pressing AUTO switch, air inlet, air outlet, blower speed, and discharge air temperature are automatically controlled.

TEMPERATURE CONTROL DIAL (DRIVER SIDE)

Increases or decreases the set temperature.

TEMPERATURE CONTROL DIAL (PASSENGER SIDE)

Increases or decreases the set temperature.

TEMPERATURE CONTROL DIAL (REAR)

Increases or decreases the set temperature.

RECIRCULATION () SWITCH

1. When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
2. When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF. REC mode can be re-entered by pressing REC switch again.
3. REC switch is not operated when DEF switch is turned ON the D/F position, or in floor mode.

DEFROSTER () SWITCH

Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position. The compressor remains ON until the ignition is turned OFF.

REAR WINDOW DEFOGGER SWITCH

When switch is ON, rear window is defogged.

OFF SWITCH

The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (75% foot and 25% defrost) position.

A/C SWITCH

The compressor is ON or OFF.

(Pressing the A/C switch when the AUTO switch is ON will turn off the A/C switch and compressor.)

MODE DIAL

Controls the air discharge outlets.

FRONT BLOWER CONTROL DIAL

Manually control the blower speed. Seven speeds are available for manual control (as shown on the display screen).

REAR BLOWER CONTROL DIAL

When the rear blower switch (front) is in the OFF position, the rear blower motor cannot operate.

When the rear blower switch (front) is in the REAR position, it allows the rear blower switch (rear) to control the rear blower motor speed. In any other position (1-4), the rear blower switch (front) controls the rear blower motor speed regardless of the rear blower switch (rear) position.

Scheme 195

REAR

Note. Hot air comes from the floor vents, cold air comes from the roof vents, and blend air comes from both vents.

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CONSULT-II Function (HVAC)

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

CONSULT-II FUNCTION

Display Item List

DISPLAY ITEM LIST

Scheme 199

1. Touch "DATA MONITOR" on "SELECT DIAG MODE" screen.
2. Touch either "MAIN SIGNALS" or "SELECTION FROM MENU" on "DATA MONITOR" screen. DATA MONITOR FUNCTIONS REFERENCE Main signals Monitors all the items. Selection from menu Selects and monitors the individual item selected.
3. When "SELECTION FROM MENU" is selected, touch items to be monitored. When "MAIN SIGNALS" is selected, all the items will be monitored.
4. Touch "START".
5. Touch "RECORD" while monitoring, then the status of the monitored item can be recorded. To stop recording, touch "STOP".

DISPLAY ITEM LIST

CONSULT-II Function (BCM)

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

DATA MONITOR FUNCTION REFERENCE

DISPLAY ITEM LIST

Scheme 200

*1 Operational Check

TERMINALS AND REFERENCE VALUE FOR FRONT AIR CONTROL

TERMINALS AND REFERENCE VALUE FOR FRONT AIR CONTROL Terminal No. Wire Color Item Ignition Switch Condition Voltage (V) (Approx.) 1 B Ground - - 0V 2 W/G Sensor power ON - 5V 3 Y/G Air mix door motor (driver) CW ON Clockwise rotation Battery voltage 4 L/B Air mix door motor (driver) CCW ON Counterclockwise rotation Battery voltage 5 SB Mode door motor CW ON Clockwise rotation Battery voltage 6 L/O Mode door motor CCW ON Counterclockwise rotation Battery voltage 7 R/B Intake door motor (driver) CCW ON Clockwise rotation Battery voltage 8 R Intake door motor (driver) CW ON Counterclockwise rotation Battery voltage 9 R/W Intake sensor ON - 0 - 5V 10 L/Y Fan ON signal ON Fan switch OFF 5V ON Fan switch ON 0V 11 W/L Rear defroster request ON - Battery voltage 12 L/R Compressor ON signal ON A/C switch OFF 5V ON A/C switch ON 0V 13 O Variable blower control ON - 0 - 5V 14 G/Y Power supply for IGN ON - Battery voltage 15 Y Sensor ground ON - 0V 16 LG Mode door motor feedback ON - 0 - 5V 17 GR/R Ambient sensor ON - 0 - 5V 18 Y/B Air mix door motor (driver) feedback ON - 0 - 5V 19 W/B Defroster door motor CCW ON Counterclockwise rotation Battery voltage 20 W Defroster door motor CW ON Clockwise rotation Battery voltage 21 O/B Sensor return ON - 0 - 5V 22 Y/R Power supply for BAT - - Battery voltage 23 R/L Illumination + ON Park lamps ON Battery voltage 24 R/Y Illumination - - Park lamps ON 25 G/R Heater pump ON Heater pump OFF Battery voltage Heater pump ON 0V 27 P/L Air mix door motor (rear) CW ON Clockwise rotation Battery voltage 28 LG/R Air mix door motor (rear) CCW ON Counterclockwise rotation Battery voltage 29 P/B Intake door motor (passenger) CCW ON Counterclockwise rotation Battery voltage 30 P Intake door motor (passenger) CW ON Clockwise rotation Battery voltage 31 SB Optical sensor (passenger) ON - 0 - 5V 32 BR/W In-vehicle sensor signal ON - 0 - 5V 33 V Air mix door (rear) set point ON - 0 - 5V 34 L CAN-H ON - - 35 P CAN-L ON - - 36 G/W Air mix door motor (passenger) CW ON Clockwise rotation Battery voltage 37 Y/R Air mix door motor (passenger) CCW ON Counterclockwise rotation Battery voltage 38 W/G Rear blower request ON Front blower motor OFF Battery voltage Front blower motor ON 0V 39 Y/B Rear select signal ON - 0V - Battery voltage 40 LG Optical sensor (driver) ON - 0 - 5V 41 LG/B Air mix door motor (passenger) feedback ON - 0 - 5V 42 G/B Air mix door motor (rear) feedback ON - 0 - 5V 43 BR In-vehicle sensor motor (+) ON - Battery voltage 44 W/R In-vehicle sensor motor (-) ON - 0V

CHECKING BLOWER

1. Rotate blower control dial clockwise to turn system on. Blower should operate on low speed. The fan display should have one bar lit (on display).
2. Rotate the blower control dial clockwise and continue checking blower speed and fan display until all speeds are checked.
3. Leave blower on maximum speed.

If NG, go to trouble diagnosis procedure for " DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR ".

If OK, continue with next check.

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1. Press MODE switch four times and press DEF switch.
2. Each position indicator should change shape (on display).
3. Confirm that discharge air comes out according to the air distribution table. Refer to " «DISCHARGE AIR FLOW»(ref-259754-S23354585942007080400000) ".

Mode door position is checked in the next step.

If NG, go to trouble diagnosis procedure for " MODE DOOR MOTOR CIRCUIT ".

If OK, continue with next check.

Note. Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at fresh when the DEF or D/F is selected.

Scheme 203

CHECKING RECIRCULATION

1. Select panel mode switch to any position other than DEF, D/F, or Floor and then press recirculation ( ) switch one time. Recirculation indicator should illuminate.
2. Press recirculation ( ) switch one more time. Recirculation indicator should go off.
3. Listen for intake door position change (blower sound should change slightly).

If NG, go to trouble diagnosis procedure for " INTAKE DOOR MOTOR CIRCUIT ".

If OK, continue with next check.

Scheme 204

CHECKING TEMPERATURE DECREASE

1. Rotate temperature dial counterclockwise (driver side or passenger side) until 16°C (60°F) is displayed.
2. Check for cold air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation if OK, go to trouble diagnosis procedure for " INSUFFICIENT COOLING ". If air mix door motor appears to be malfunctioning, go to " DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER) " or " DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER) ".

If OK, continue with next check.

Scheme 205

CHECKING TEMPERATURE INCREASE

1. Rotate temperature dial clockwise (driver side or passenger side) until 32°C (90°F) is displayed.
2. Check for hot air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation. If OK, go to trouble diagnosis procedure for " INSUFFICIENT HEATING ". If air mix door motor appears to be malfunctioning, go to " DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER) " or " DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER) ".

If OK, continue with next check.

Scheme 206

CHECK A/C SWITCH

1. Press A/C switch when AUTO switch is ON, or in manual mode.
2. A/C switch indicator will turn ON. Confirm that the compressor clutch engages (sound or visual inspection).

If NG, go to trouble diagnosis procedure for " MAGNET CLUTCH CIRCUIT ".

If OK, continue with next check.

Scheme 207

CHECKING AUTO MODE

1. Press AUTO switch.
2. Display should indicate AUTO. If ambient temperatures is warm, and selected temperature is cool, confirm that the compressor clutch engages (sound or visual inspection). (Discharge air and blower speed will depend on ambient, in-vehicle, and set temperatures.)

If NG, go to trouble diagnosis procedure for " POWER SUPPLY AND GROUND CIRCUIT FOR FRONT AIR CONTROL ", then if necessary, trouble diagnosis procedure for " MAGNET CLUTCH CIRCUIT ". If all operational checks are OK (symptom cannot be duplicated), go to malfunction Simulation Tests in " HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR " and perform tests as outlined to simulate driving conditions environment. If symptom appears. Refer to " HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR ", " SYMPTOM TABLE " and perform applicable trouble diagnosis procedures.

Scheme 208

Power Supply and Ground Circuit for Front Air Control

SYMPTOM: A/C system does not come on.

Scheme 209

*1 Power Supply and Ground Circuit for Front Air Control

*2 Operational Check

Front Air Control

The front air control has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motors, mode door motor, intake door motors, defroster door motor, blower motor and compressor are then controlled.

The front air control is unitized with control mechanisms. When the various switches and temperature dials are operated, data is input to the front air control.

Self-diagnostic functions are also built into the front air control to provide quick check of malfunctions in the auto air conditioner system.

Scheme 210

Potentio Temperature Control (PTC)

There are two PTCs (passenger and driver) built into the front air control. They can be set from 16°C (60°F) to 32°C (90°F) temperature range by rotating the temperature dial. The set temperature is displayed.

Scheme 211

Mode Door Motor Circuit

SYMPTOM

1. Air outlet does not change.
2. Mode door motor does not operate normally.

Scheme 212

*1 Discharge Air Flow

*2 Operational Check

*3 A/C System Self-diagnosis Function

*4 SELF-DIAGNOSIS CODE CHART or SYMPTOM TABLE

*5 DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR

*6 FRONT AIR CONTROL

Component Parts

Mode door control system components are

1. Front air control
2. Mode door motor
3. PBR (built into mode door motor)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

Mode Door Motor

The mode door motor is attached to the heater & cooling unit. It rotates so that air is discharged from the outlet as indicated by the front air control. Motor rotation is conveyed to a link which activates the mode door.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Press the mode switch to the B/L ( ) mode. Check voltage between front air control harness connector M49 terminal 5 and terminal 6 while pressing the mode switch to the floor ( ) mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 6 5 Press mode switch Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK MODE DOOR MOTOR CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check resistance between front air control harness connector M49 terminal 5, 6 and ground. 5 - Ground : Continuity should not exist. 6 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR GROUND AND POWER Press the mode switch to the D/F ( ) mode. Check voltage between front air control harness connector M49 terminal 5 and terminal 6 while pressing the mode switch to the vent ( ) mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 5 6 Press mode switch Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK MODE DOOR MOTOR AND CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 5 and terminal 6. Continuity should exist. OK or NG OK : GO TO 6 . NG : GO TO 5.
5. CHECK MODE DOOR MOTOR CIRCUITS FOR OPEN Disconnect the mode door motor harness connector. Check continuity between front air control harness connector M49 terminal 5, 6 and the mode door motor harness connector terminal 5, 6. 5 - 5 : Continuity should exist. 6 - 6 : Continuity should exist. OK or NG OK : Replace mode door motor. Refer to " «MODE DOOR MOTOR»(ref-259754-S37735502792007080400000) ". NG : Repair or replace harness as necessary.
6. CHECK FRONT AIR CONTROL FOR PBR POWER AND GROUND Reconnect front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 2 and terminal 15. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Voltage (Approx.) (+) (-) Front air control: M49 2 15 5V OK or NG OK : GO TO 8. NG : GO TO 7.
7. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
8. CHECK PBR REFERENCE VOLTAGE AND GROUND CIRCUITS Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and terminal 15. Continuity should exist. OK or NG OK : GO TO 10 . NG : GO TO 9.
9. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR OPEN Disconnect the mode door motor harness connector. Check continuity between mode door motor harness connector (B) M304 terminal 3, 1 and front air control harness connector (A) M49 terminal 2, 15. 2 - 3 : Continuity should exist. 15 - 1 : Continuity should exist. OK or NG OK : Replace mode door motor. Refer to " «MODE DOOR MOTOR»(ref-259754-S37735502792007080400000) ". NG : Repair or replace harness as necessary.
10. CHECK PBR FEEDBACK VOLTAGE Reconnect the front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 16 and ground while cycling mode switch through all modes. Voltage : Approx. 1.V - 4.5V OK or NG OK : GO TO 12 . NG : GO TO 11.
11. CHECK PBR FEEDBACK SIGNAL CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect front air control harness connector. Check continuity between front air control harness connector M49 terminal 16 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
12. CHECK PBR FEEDBACK CIRCUIT FOR OPEN Turn ignition switch OFF. Disconnect the mode door motor harness connector and front air control harness connector. Check continuity between mode door motor harness connector M304 terminal 2 and front air control harness connector M49 terminal 16. Continuity should exist. OK or NG OK : Replace mode door motor. Refer to " «MODE DOOR MOTOR»(ref-259754-S37735502792007080400000) ". NG : Repair or replace harness as necessary.

Air Mix Door Motor Circuit

SYMPTOM

1. Discharge air temperature does not change.
2. Air mix door motor does not operate.

Scheme 226

*1 Operational Check

*2 A/C System Self-diagnosis Function

*3 SELF-DIAGNOSIS CODE CHART

*4 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER)

*5 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER)

*6 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR)

Air mix door control system components are

1. Front air control.
2. Air mix door motors (driver, passenger, and rear)
3. PBR (built-into air mix motors)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

Air Mix Door Motors

The driver and front passenger air mix door motors are attached to the front heater & cooling unit. The rear air mix door motor is attached to the rear heater & cooling unit. These motors rotate so that the air mix door is opened or closed to a position set by the front (or rear) air control. Motor rotation is then conveyed through a shaft and the air mix door position is then fed back to the front air control by the PBR built into the air mix door motors.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (driver) to 32°C (90°F). Check voltage between front air control harness connector M49 terminal 3 and terminal 4 while rotating temperature control dial (driver) to 16°C (60°F). CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 3 4 Rotate temp control dial Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK AIR MIX DOOR MOTOR (DRIVER) CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 3, 4 and ground. 3 - Ground : Continuity should not exist. 4 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (driver) to 32°C (90°F). Check voltage between front air control harness connector M49 terminal 3 and terminal 4 while rotating temperature control dial (driver) to 16°C (60°F). CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 4 3 Rotate temp control dial Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK AIR MIX DOOR MOTOR (DRIVER) CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 3 and terminal 4. Continuity should exist. OK or NG OK : GO TO 6 . NG : GO TO 5.
5. CHECK AIR MIX DOOR MOTOR (DRIVER) CIRCUITS FOR OPEN Disconnect the air mix door motor (driver) harness connector. Check continuity between front air control harness connector M49 terminal 3, 4 and the air mix door motor (driver) harness connector M39 terminal 5, 6. 3 - 5 : Continuity should exist. 4 - 6 : Continuity should exist. OK or NG OK : Replace air mix door motor (driver). Refer to " «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-259754-S27778579922007080400000) ". NG : Repair or replace harness as necessary.
6. CHECK FRONT AIR CONTROL FOR PBR POWER AND GROUND Reconnect front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 2 and terminal 15. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Voltage (Approx.) (+) (-) Front air control: M49 2 15 5V OK or NG OK : GO TO 8 . NG : GO TO 7.
7. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
8. CHECK PBR REFERENCE VOLTAGE AND GROUND CIRCUITS Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and terminal 15. Continuity should exist. OK or NG OK : GO TO 10 . NG : GO TO 9.
9. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR OPEN Disconnect the air mix door motor (driver) harness connector. Check continuity between air mix door motor (driver) harness connector (B) M39 terminal 3, 1 and front air control harness connector (A) M49 terminal 2, 15. 2 - 3 : Continuity should exist. 15 - 1 : Continuity should exist. OK or NG OK : Replace air mix door motor (driver). Refer to " «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-259754-S27778579922007080400000) ". NG : Repair or replace harness as necessary.
10. CHECK PBR FEEDBACK VOLTAGE Reconnect the front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 18 and ground while rotating temperature control dial from 32°C (90°F) to 16°C (60°F). Voltage : Approx. .5V - 4.5V OK or NG OK : GO TO 12 . NG : GO TO 11.
11. CHECK PBR FEEDBACK SIGNAL CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect front air control harness connector. Check continuity between front air control harness connector M49 terminal 18 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
12. CHECK PBR FEEDBACK CIRCUIT FOR OPEN Turn ignition switch OFF. Disconnect the air mix door motor (driver) harness connector and front air control harness connector. Check continuity between air mix door motor (driver) harness connector M39 terminal 2 and front air control harness connector M49 terminal 18. Continuity should exist. OK or NG OK : Replace air mix door motor (driver). Refer to " «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-259754-S27778579922007080400000) ". NG : Repair or replace harness as necessary.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (passenger) to 32°C (90°F). Check voltage between front air control harness connector M50 terminal 36 and terminal 37 while rotating temperature control dial (passenger) to 16°C (60°F). CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 37 36 Rotate temp control dial Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK AIR MIX DOOR MOTOR (PASSENGER) CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 36, 37 and ground. 36 - Ground : Continuity should not exist. 37 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (passenger) to 16°C (60°F). Check voltage between front air control harness connector M50 terminal 36 and terminal 37 while rotating temperature control dial (passenger) to 32°C (90°F). CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 36 37 Rotate temp control dial Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK AIR MIX DOOR MOTOR (PASSENGER) CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 36 and terminal 37. Continuity should exist. OK or NG OK : GO TO 6. NG : GO TO 5.
5. CHECK AIR MIX DOOR MOTOR (PASSENGER) CIRCUITS FOR OPEN Disconnect the air mix door motor (passenger) harness connector. Check continuity between front air control harness connector M50 terminal 36, 37 and the air mix door motor (passenger) harness connector M306 terminal 5, 6. 36 - 5 : Continuity should exist. 37 - 6 : Continuity should exist. OK or NG OK : Replace air mix door motor (passenger). Refer to " «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-259754-S27778579922007080400000) ". NG : Repair or replace harness as necessary.
6. CHECK FRONT AIR CONTROL FOR PBR POWER AND GROUND Reconnect front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 2 and terminal 15. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Voltage (Approx.) (+) (-) Front air control: M49 2 15 5V OK or NG OK : GO TO 8 . NG : GO TO 7.
7. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
8. CHECK PBR REFERENCE VOLTAGE AND GROUND CIRCUITS Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and terminal 15. Continuity should exist. OK or NG OK : GO TO 10 . NG : GO TO 9.
9. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR OPEN Disconnect the air mix door motor (passenger) harness connector. Check continuity between air mix door motor (passenger) harness connector (B) M306 terminal 3, 1 and front air control harness connector (A) M49 terminal 2, 15. 2 - 3 : Continuity should exist. 15 - 1 : Continuity should exist. OK or NG OK : Replace air mix door motor (passenger). Refer to " «FRONT AIR MIX DOOR MOTOR (PASSENGER)»(ref-259754-S16571598302007080400000) ". NG : Repair or replace harness as necessary.
10. CHECK PBR FEEDBACK VOLTAGE Reconnect the front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M50 terminal 41 and ground while rotating temperature control dial (passenger) from 32°C (90°F) to 16°C (60°F)°. Voltage : Approx. .5V - 4.5V OK or NG OK : GO TO 12 . NG : GO TO 11.
11. CHECK PBR FEEDBACK SIGNAL CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect front air control harness connector. Check continuity between front air control harness connector M50 terminal 41 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
12. CHECK PBR FEEDBACK CIRCUIT FOR OPEN Turn ignition switch OFF. Disconnect the air mix door motor (passenger) harness connector and front air control harness connector. Check continuity between air mix door motor (passenger) harness connector M306 terminal 2 and front air control harness connector M50 terminal 41. Continuity should exist. OK or NG OK : Replace air mix door motor (passenger). Refer to " «FRONT AIR MIX DOOR MOTOR (PASSENGER)»(ref-259754-S16571598302007080400000) ". NG : Repair or replace harness as necessary.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (rear) to maximum hot. Check voltage between front air control harness connector M50 terminal 27 and terminal 28 while rotating temperature control dial (rear) to maximum cold. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 27 28 Rotate temp control dial Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK AIR MIX DOOR MOTOR (REAR) CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 27, 28 and ground. 27 - Ground : Continuity should not exist. 28 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Rotate temperature control dial (rear) to maximum cold. Check voltage between front air control harness connector M50 terminal 27 and terminal 28 while rotating temperature control dial (rear) to maximum hot. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 28 27 Rotate temp control dial Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK AIR MIX DOOR MOTOR (REAR) CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 27 and terminal 28. Continuity should exist. OK or NG OK : GO TO 6. NG : GO TO 5.
5. CHECK AIR MIX DOOR MOTOR (REAR) CIRCUITS FOR OPEN Disconnect the air mix door motor (rear) harness connector. Check continuity between front air control harness connector M50 terminal 27, 28 and the air mix door motor (rear) harness connector B146 terminal 1, 6. 27 - 1 : Continuity should exist. 28 - 6 : Continuity should exist. OK or NG OK : Replace air mix door motor (rear). Refer to " «REAR AIR MIX DOOR MOTOR»(ref-259754-S29373098742007080400000) ". NG : Repair or replace harness as necessary.
6. CHECK FRONT AIR CONTROL FOR PBR POWER AND GROUND Reconnect front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 2 and terminal 15. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Voltage (Approx.) (+) (-) Front air control: M49 2 15 5V OK or NG OK : GO TO 8. NG : GO TO 7.
7. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
8. CHECK PBR REFERENCE VOLTAGE AND GROUND CIRCUITS Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 2 and terminal 15. Continuity should exist. OK or NG OK : GO TO 10. NG : GO TO 9.
9. CHECK PBR REFERENCE VOLTAGE CIRCUIT FOR OPEN Disconnect the air mix door motor (rear) harness connector. Check continuity between air mix door motor (rear) harness connector (B) B146 terminal 3, 2 and front air control harness connector (A) M49 terminal 2, 15. 2 - 3 : Continuity should exist. 15 - 2 : Continuity should exist. OK or NG OK : Replace air mix door motor (rear). Refer to " «REAR AIR MIX DOOR MOTOR»(ref-259754-S29373098742007080400000) ". NG : Repair or replace harness as necessary.
10. CHECK PBR FEEDBACK VOLTAGE Reconnect the front air control harness connector. Turn ignition switch ON. Check voltage between front air control harness connector M50 terminal 42 and ground while rotating temperature control dial (rear) from maximum cold to maximum hot. Voltage : Approx. 1V - 4.5V OK or NG OK : GO TO 12. NG : GO TO 11.
11. CHECK PBR FEEDBACK SIGNAL CIRCUIT FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect front air control harness connector. Check continuity between front air control harness connector M50 terminal 42 and ground. Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
12. CHECK PBR FEEDBACK CIRCUIT FOR OPEN Turn ignition switch OFF. Disconnect the air mix door motor (rear) harness connector and front air control harness connector. Check continuity between air mix door motor (rear) harness connector B146 terminal 4 and front air control harness connector M50 terminal 42. Continuity should exist. OK or NG OK : Replace air mix door motor (rear). Refer to " «REAR AIR MIX DOOR MOTOR»(ref-259754-S29373098742007080400000) ". NG : Repair or replace harness as necessary.

Intake Door Motor Circuit

SYMPTOM

1. Intake door does not change.
2. Intake door motor does not operate normally.

Scheme 266

*1 Operational Check

*2 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR (DRIVER)

*3 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR (PASSENGER)

*4 FRONT AIR CONTROL

*5 DRIVER SIDE

*6 PASSENGER SIDE

Intake door control system components are

1. Front air control
2. Intake door motor (driver and passenger)
3. PBR (built into intake door motors)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

Intake door motors

The driver and passenger intake door motors are attached to the intake unit. They rotate so that air is drawn from inlets set by the front air control. Motor rotation is conveyed to a lever which activates the intake door.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 7 and terminal 8 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 7 8 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK INTAKE DOOR MOTOR (DRIVER) CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 7, 8 and ground. 7 - Ground : Continuity should not exist. 8 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR GROUND AND POWER Press the "BACK" button to back out of self-diagnostic mode. Check voltage between front air control harness connector M49 terminal 7 and terminal 8 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 8 7 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK INTAKE DOOR MOTOR (DRIVER) AND CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 7 and terminal 8. Continuity should exist. OK or NG OK : Replace intake door motor (driver). Refer to " «DRIVER SIDE»(ref-259754-S25620656642007080400000) ". NG : GO TO 5.
5. CHECK INTAKE DOOR MOTOR (DRIVER) CIRCUITS FOR OPEN Disconnect the intake door motor (driver) harness connector. Check continuity between front air control harness connector M49 terminal 7, 8 and the intake door motor (driver) harness connector terminal 1, 6. 1 - 7 : Continuity should exist. 6 - 8 : Continuity should exist. OK or NG OK : Replace intake door motor (driver). Refer to " «DRIVER SIDE»(ref-259754-S25620656642007080400000) " " «MODE DOOR MOTOR»(ref-259754-S37735502792007080400000) ". NG : Repair or replace harness as necessary.

Scheme 273

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Check voltage between front air control harness connector M50 terminal 29 and terminal 30 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 30 29 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 3 . NG : GO TO 2.
2. CHECK INTAKE DOOR MOTOR (PASSENGER) CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 29, 30 and ground. 29 - Ground : Continuity should not exist. 30 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR GROUND AND POWER Press the "BACK" button to back out of self-diagnostic mode. Check voltage between front air control harness connector M50 terminal 29 and terminal 30 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M50 29 30 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK INTAKE DOOR MOTOR (PASSENGER) AND CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M50 terminal 29 and terminal 30. Continuity should exist. OK or NG OK : Replace intake door motor (passenger). Refer to " «PASSENGER SIDE»(ref-259754-S00011775982007080400000) ". NG : GO TO 5.
5. CHECK INTAKE DOOR MOTOR (PASSENGER) CIRCUITS FOR OPEN Disconnect the intake door motor (passenger) harness connector. Check continuity between front air control harness connector M50 terminal 29, 30 and the intake door motor (passenger) harness connector terminal 1, 6. 29 - 1 : Continuity should exist. 30 - 6 : Continuity should exist. OK or NG OK : Replace intake door motor (passenger). Refer to " «PASSENGER SIDE»(ref-259754-S00011775982007080400000) ". NG : Repair or replace harness as necessary.

Defroster door control system components are

1. Front air control
2. Defroster door motor
3. PBR (built into defroster door motor)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

Defroster door motor

The defroster door motor is attached to the front heater & cooling unit. The front air control sends a voltage to rotate to the defroster door directing the air flow either to the defroster ducts, or to the floor ducts, depending on which way the voltage and ground are applied to the motor leads. Motor rotation is conveyed to a lever which activates the defroster door.

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1. CHECK FRONT AIR CONTROL FOR POWER AND GROUND Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 19 and terminal 20 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 20 19 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 3. NG : GO TO 2.
2. CHECK DEFROSTER DOOR MOTOR CIRCUITS FOR SHORT TO GROUND Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 20, 19 and ground. 19 - Ground : Continuity should not exist. 20 - Ground : Continuity should not exist. OK or NG OK : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ". NG : Repair or replace harness as necessary.
3. CHECK FRONT AIR CONTROL FOR GROUND AND POWER Press the "BACK" button to back out of self-diagnostic mode. Check voltage between front air control harness connector M49 terminal 20 and terminal 19 while placing the HVAC system into self-diagnostic mode. CONNECTOR TERMINALS VOLTAGE REFERENCE Connector Terminals Condition Voltage (Approx.) (+) (-) Front air control: M49 19 20 Self-diagnostic mode Battery voltage OK or NG OK : GO TO 4. NG : Replace front air control. Refer to " «FRONT AIR CONTROL»(ref-259754-S32069075902007080400000) ".
4. CHECK DEFROSTER DOOR MOTOR AND CIRCUITS FOR OPEN Turn ignition switch OFF. Disconnect the front air control harness connector. Check continuity between front air control harness connector M49 terminal 19 and terminal 20. Continuity should exist. OK or NG OK : Replace defroster door motor. Refer to " «DEFROSTER DOOR MOTOR»(ref-259754-S07165592612007080400000) ". NG : GO TO 5.
5. CHECK DEFROSTER DOOR MOTOR CIRCUITS FOR OPEN Disconnect the defroster door motor harness connector. Check continuity between front air control harness connector M49 terminal 19, 20 and the defroster door motor harness connector terminal 1, 6. 19 - 1 : Continuity should exist. 20 - 6 : Continuity should exist. OK or NG OK : Replace defroster door motor. Refer to " «DEFROSTER DOOR MOTOR»(ref-259754-S07165592612007080400000) ". NG : Repair or replace harness as necessary.

Front Blower Motor Circuit

SYMPTOM

1. Blower motor operation is malfunctioning.

Scheme 284

*1 Operational Check

*2 A/C System Self-diagnosis Function

*3 SELF-DIAGNOSIS CODE CHART

*4 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR

*5 DTC P0117, P0118 ECT SENSOR

*6 SYMPTOM TABLE

Blower speed control system components are

1. Front air control
2. Front Blower motor
3. Front Blower motor relay
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

Scheme 285

Automatic Mode

In the automatic mode, the blower motor speed is calculated by the front air control and variable blower control based on input from the in-vehicle sensor, optical sensor, intake sensor and ambient sensor, and potentio temperature control (PTC).

When the air flow is increased, the duty ratio of the blower fan motor's drive signal is changed at 8%/sec. to prevent a sudden increase in air flow.

In addition to manual air flow control and the usual automatic air flow control, starting air flow control, low water temperature starting control and high passenger compartment temperature starting control are available.

Starting Fan Speed Control

Start up from cold soak condition (Automatic mode).

In a cold start up condition where the engine coolant temperature is below 50°C (122°F), the blower will not operate at blower speed 1 for a short period of time (up to 210 seconds). The exact start delay time varies depending on the ambient and engine coolant temperatures.

In the most extreme case (very low ambient temperature) the blower starting delay will be 210 seconds as described above. After the coolant temperature reaches 50°C (122°F), or the 210 seconds has elapsed, the blower speed will increase to the objective blower speed.

Start up from normal operating or hot soak condition (Automatic mode).

The blower will begin operation momentarily after the AUTO switch is pushed. The blower speed will gradually rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective blower speed).

Blower Speed Compensation

Sunload

When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low speed. The speed will vary depending on the sunload. During conditions of low or no sunload, the blower operates at low speed. During high sunload conditions, the front air control causes the blower speed to increase.

Scheme 286

Variable Blower Control

The variable blower control is located on the cooling unit. The variable blower control receives a gate voltage from the front air control to steplessly maintain the blower fan motor voltage in the 0 to 5 volt range (approx.).

Scheme 287

Front Blower Motor Relay

Check continuity between terminals by supplying 12 volts and ground to coil side terminals of relay.

Scheme 288

Front Blower Motor

Confirm smooth rotation of the blower motor.

Scheme 289

1. Ensure that there are no foreign particles inside the blower unit.
2. Apply 12 volts to terminal (+) and ground to terminal (-) and verify that the motor operates freely and quietly.

Rear Blower Motor Circuit

SYMPTOM

1. Blower motor operation is malfunctioning.

Scheme 290

*1 Operational Check

*2 Rear Blower Switch (Front)

*3 SYMPTOM TABLE

Rear blower speed control system components are

1. Front air control
2. Rear blower switch (front)
3. Rear blower switch (rear)
4. Rear blower motor resistor
5. Rear blower motor
6. Rear blower motor relay

Scheme 291

Rear Blower Control

Note. The rear blower motor can only operate when the front blower motor is on.

When the rear blower switch (front) is in the OFF position, the rear blower motor cannot operate.

When the rear blower switch (front) is in the REAR position, it allows the rear blower switch (rear) to control the rear blower motor speed. In any other position (1-4), the rear blower switch (front) controls the rear blower motor speed regardless of the rear blower switch (rear) position.

Rear Blower Switch (Rear) Circuit

SYMPTOM

1. Rear blower motor does not rotate when rear blower switch (front) is set to REAR position.

Scheme 292

1. CHECK REAR BLOWER MOTOR OPERATION Blower motor rotates normally when rear blower switch (front) is set at 1 - 4 speed. OK or NG OK : GO TO 2. NG : Refer to " «TROUBLE DIAGNOSIS PROCEDURE FOR REAR BLOWER MOTOR (1 - 4 SPEED)»(ref-259754-S12768952422007080400000) ".
2. CHECK REAR BLOWER SWITCH (FRONT) Check rear blower switch (front). Refer to " «REAR BLOWER SWITCH (FRONT)»(ref-259754-S30582735642007080400000) ". OK or NG OK : GO TO 3. NG : Replace rear blower switch (front). Refer to " «REMOVAL AND INSTALLATION»(ref-259754-S23219064872007080400000) ".
3. CHECK REAR BLOWER SWITCH (REAR) Check rear blower switch (rear). Refer to " «REAR BLOWER SWITCH (REAR)»(ref-259754-S18882960942007080400000) ". OK or NG OK : GO TO 4. NG : Replace rear blower switch (rear). Refer to " «REAR AIR CONTROL»(ref-259754-S05030219622007080400000) ".
4. CHECK CIRCUIT CONTINUITY Turn ignition switch OFF. Disconnect rear blower switch (front) harness connector and rear blower switch (rear) harness connector. Check continuity between rear blower switch (front) harness connector M52 terminal 2 and rear blower switch (rear) harness connector B141 terminal 10. Continuity should exist. OK or NG OK : Inspection End. NG : Repair harness or connector.

Rear Blower Motor Relay

Check circuit continuity between terminals by supplying 12 volts and ground to coil side terminals of relays.

Scheme 293

Rear Blower Switch (Rear)

Check continuity between terminals at each switch position.

Scheme 294

Rear Blower Switch (Front)

Check continuity between terminals at each switch position.

Scheme 295

Rear Blower Motor

Check that there are no foreign particles inside the intake unit.

Apply 12 volts to terminal (+) and ground to terminal (-) and ensure that the blower motor rotates freely and quietly.

Scheme 296

Rear Blower Motor Resistor

Check continuity between terminals. There will be resistance, but there should not be an open or short between any two terminals.

Scheme 297

Rear Air Control Circuit

SYMPTOM

1. Temperature cannot be adjusted from the rear air control.

Scheme 298

*1 Operational Check

*2 A/C System Self-diagnosis Function

*3 SELF-DIAGNOSIS CODE CHART

*4 DIAGNOSTIC PROCEDURE FOR REAR AIR CONTROL

*5 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR)

Rear air control system components are

1. Front air control
2. Rear air control
3. Air mix door motor (rear)

Scheme 299

Rear Air Control

When the rear blower switch (front) (integral to the front air control) is in the REAR position the rear blower motor speeds and the rear temperature/mode are controlled by the rear blower switch (rear) and the rear temperature switch (rear) (both integral to the rear air control).

Magnet Clutch Circuit

SYMPTOM: Magnet clutch does not engage.

Scheme 300

*1 Operational Check

*2 A/C System Self-diagnosis Function

*3 SELF-DIAGNOSIS CODE CHART

*4 Ambient Sensor Circuit

*5 Intake Sensor Circuit

*6 SYMPTOM TABLE

*7 FRONT AIR CONTROL

Low Temperature Protection Control

The front air control will turn the compressor ON or OFF as determined by a signal detected by the intake sensor and the ambient sensor.

When intake air temperature is higher than the preset value, the compressor turns ON. The compressor turns OFF when intake air temperature is lower than the preset value. That preset value is dependent on the ambient temperature, refer to the following table.

SYSTEM DESCRIPTION

Insufficient Cooling

SYMPTOM: Insufficient cooling

Scheme 301

*1 Operational Check

*2 A/C System Self-diagnosis Function

*3 SELF-DIAGNOSIS CODE CHART

*4 DESCRIPTION

*5 Contaminated Refrigerant

*6 PERFORMANCE TEST DIAGNOSES

*7 Test Reading

*8 CHECKING DRIVE BELTS

Scheme 302

*1, 2 PERFORMANCE CHART

*3 TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE

*4 Air Mix Door Motor Circuit

Scheme 303

*1 Removal and Installation for Compressor Clutch

*2 Front Blower Motor Circuit

*3 CHECKING DRIVE BELTS

Both High- and Low-pressure Sides are Too High

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action Both high- and low-pressure sides are too high. Pressure is reduced soon after water is splashed on condenser. Excessive refrigerant charge in refrigeration cycle Reduce refrigerant until specified pressure is obtained. Air suction by cooling fan is insufficient. Insufficient condenser cooling performance ↓ Condenser fins are clogged. Improper fan rotation of cooling fan Clean condenser. Check and repair cooling fan as necessary. Low-pressure pipe is not cold. When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (2 kg/cm 2 , 28 psi). It then decreases gradually thereafter. Poor heat exchange in condenser (After compressor operation stops, high-pressure decreases too slowly.) ↓ Air in refrigeration cycle Evacuate repeatedly and recharge system. Engine tends to overheat. Engine cooling systems malfunction. Check and repair engine cooling system. An area of the low-pressure pipe is colder than areas near the evaporator outlet. Plates are sometimes covered with frost. Excessive liquid refrigerant on low-pressure side Excessive refrigerant discharge flow Expansion valve is open a little compared with the specification. ↓ Improper expansion valve adjustment Replace expansion valve

High-pressure Side is Too High and Low-pressure Side is Too Low

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action High-pressure side is too high and low-pressure side is too low. Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. Check and repair or replace malfunctioning parts. Check lubricant for contamination

High-pressure Side is Too Low and Low-pressure Side is Too High

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action High-pressure side is too low and low-pressure side is too high. High- and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor. No temperature difference between high- and low-pressure sides. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor

Both High- and Low-pressure Sides are Too Low

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action Both high- and low-pressure sides are too low. There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. Liquid tank inlet and expansion valve are frosted. Liquid tank inside is slightly clogged. Replace liquid tank. Check lubricant for contamination. Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. Expansion valve inlet may be frosted. Temperature difference occurs somewhere in high pressure side. High-pressure pipe located between liquid tank and expansion valve is clogged. Check and repair malfunctioning parts. Check lubricant for contamination. Expansion valve and liquid tank are warm or only cool when touched. Low refrigerant charge. ↓ Leaking fittings or components. Check refrigerant system for leaks. Refer to " CHECKING FOR REFRIGERANT LEAKS ". There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted. Expansion valve closes a little compared with the specification. ↓ Improper expansion valve adjustment. Malfunctioning expansion valve. Outlet and inlet may be clogged. Remove foreign particles by using compressed air. Check lubricant for contamination. An area of the low-pressure pipe is colder than areas near the evaporator outlet. Low-pressure pipe is clogged or crushed. Check and repair malfunctioning parts. Check lubricant for contamination. Air flow volume is too low. Evaporator is frozen. Check intake sensor circuit. Refer to " INTAKE SENSOR CIRCUIT ". Replace compressor

Low-pressure Side Sometimes Becomes Negative

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action Low-pressure side sometimes becomes negative. Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant. Drain water from refrigerant or replace refrigerant. Replace liquid tank

Low-pressure Side Becomes Negative

TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE Gauge indication Refrigerant cycle Probable cause Corrective action Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve's pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted. Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). If either of the above methods cannot correct the malfunction, replace expansion valve. Replace liquid tank. Check lubricant for contamination

Scheme 304

Insufficient Heating

SYMPTOM: Insufficient heating

Scheme 305

*1 Operational Check

*2 Air Mix Door Motor Circuit

*3 A/C System Self-diagnosis Function

*4 A/C System Self-diagnosis Function

*5 Front Blower Motor Circuit

*6 DTC P0117, P0118 ECT SENSOR

*7 CHANGING ENGINE COOLANT

*8 CHECKING RADIATOR CAP

*9 Heater Pump Circuit

Heater pump control system components are

1. Front air control
2. Heater pump relay
3. Heater pump
4. Intake sensor

Heater Pump Relay

Check continuity between terminals 3 and 5.

CONNECTOR TERMINALS CONTINUITY REFERENCE

If NG, replace relay.

Scheme 306

Memory Function

SYMPTOM: Memory function does not operate.

Scheme 307

*1 Power Supply and Ground Circuit for Front Air Control

*2 Operational Check

*3 A/C System Self-diagnosis Function

*4 SELF-DIAGNOSIS CODE CHART

Ambient Sensor

The ambient sensor is attached on the radiator core support (left side). It detects ambient temperature and converts it into a resistance value which is then input into the front air control.

Scheme 308

AMBIENT TEMPERATURE INPUT PROCESS

The front air control includes a processing circuit for the ambient sensor input. However, when the temperature detected by the ambient sensor increases quickly, the processing circuit retards the front air control function. It only allows the front air control to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds.

This prevents constant adjustments due to momentary conditions, such as stopping after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor will increase. This is because the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.

After disconnecting ambient sensor connector, measure resistance between terminals 2 and 1 at sensor component side, using the table below.

CONNECTOR TERMINALS RESISTANCE REFERENCE

If NG, replace ambient sensor.

Scheme 309

In-vehicle Sensor

The in-vehicle sensor is located on instrument lower driver panel. It converts variations in temperature of passenger compartment air (drawn in through the integrated fan) into a resistance value. It is then input into the front air control.

Scheme 310

Scheme 311

After disconnecting in-vehicle sensor connector, measure resistance between terminals 1 and 2 at sensor component side, using the table below.

CONNECTOR TERMINALS RESISTANCE REFERENCE

Scheme 312

If NG, replace in-vehicle sensor.

OPTICAL INPUT PROCESS

The front air control also includes a processing circuit which averages the variations in detected sunload over a period of time. This prevents adjustments in the ATC system operation due to small or quick variations in detected sunload.

For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the optical sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly.

Intake Sensor

The intake sensor is located on the heater & cooling unit. It converts temperature of air after it passes through the evaporator into a resistance value which is then input to the front air control.

Scheme 313

After disconnecting intake sensor connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below.

CONNECTOR TERMINALS RESISTANCE REFERENCE

If NG, replace intake sensor.

Scheme 314

Scheme 315

1. Remove the five control knobs from the control unit.
2. Remove cluster lid C, disconnect the front air control electrical connector. Refer to «CLUSTER LID C»(ref-239968-S11558126192006080400000) .
3. Remove the screws securing the front air control to cluster lid C.
4. Remove the front air control.

FUNCTION

The air inside the passenger compartment is filtered by the in-cabin microfilters when the heater or A/C controls are set on either the recirculation or fresh mode. The two in-cabin microfilters are located in the front heater and cooling unit assembly. The rear heater and cooling unit assembly only draws in air from the passenger compartment to recirculate into the passenger compartment, so the rear heater and cooling unit assembly is not equipped with in-cabin microfilters.

Scheme 316

Clutch Disc

If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Scheme 317

Pulley

Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

Coil

Check magnet coil for loose connections or any cracked insulation.

Scheme 318

Scheme 319

Scheme 320

Scheme 321

Scheme 322

1. Install the magnet coil. CAUTION: Be sure to align the magnet coil pin with the hole in the compressor front head.
2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install the snap ring using snap ring pliers. Tool number : - (J-38873-A)
4. Install the clutch disc on the compressor shaft, together with the original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc from turning and tighten the bolt to specification. Refer to " «COMPONENTS»(ref-259754-S20132182412007080400000) ". Tool number : J-44614 CAUTION: After tightening the clutch pulley bolt, check that the clutch pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as shown. Clutch disc-to-pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in)
7. If the specified clearance is not obtained, replace the adjusting spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer to «DRIVE BELTS»(ref-239943-S33744599052006080300000) .
10. Install the engine under cover and the splash shield.

Checking for Refrigerant Leaks

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C oil leakage, damage, and corrosion. Any A/C oil leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector (J-41995) or fluorescent dye leak detector (J-42220).

If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that was repaired and not properly cleaned.

When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections.

When searching for refrigerant leaks using an electronic refrigerant leak detector (J-41995), move the probe along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the component.

Checking System for Leaks Using the Fluorescent Dye Leak Detector

1. Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent future misdiagnosis.
4. Perform a system performance check and then verify the leak repair using a electronic refrigerant leak detector (J-41995). NOTE: Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and oils, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. Do not allow the sensor tip of the electronic refrigerant leak detector (J-41995) to contact with any substance. This can also cause false readings and may damage the detector.

Dye Injection

Note. This procedure is only necessary when recharging the system or when the compressor has seized and must be replaced.

1. Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm 2 , 50 psi).
2. Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into the HFC-134a (R-134a) dye injector (J-41459). CAUTION: If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) directly into the open system connection and proceed with the service procedures.
3. Connect the injector tool (J-41459) to the low-pressure service valve.
4. Start the engine and switch the A/C system ON.
5. When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a (R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC- 134a (R-134a) dye injector (J-41459). Refer to the manufacturer's operating instructions.
6. With the engine still running, disconnect the HFC-134a (R-134a) dye injector (J-41459) from the low-pressure service valve.
7. Operate the A/C system for a minimum of 20 minutes to mix the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) with the A/C system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the HFC-134a (R-134a) fluorescent leak detection dye to penetrate an A/C system leak and become visible.

PRECAUTIONS FOR HANDLING LEAK DETECTOR

Note. When performing a refrigerant leak check, use a electronic refrigerant leak detector (J-41995) or equivalent. Ensure that the electronic refrigerant leak detector (J-41995) is calibrated and set properly according to the manufacturer's operating instructions.

The electronic refrigerant leak detector (J-41995) is a delicate device. To use the leak detector properly, read the manufacturer's operating instructions and perform any specified maintenance.

Scheme 323

Scheme 324

Scheme 325

Scheme 326

1. Position the probe approximately 5 mm (3/16 in) away from the point to be checked as shown.
2. When checking for leaks, circle each fitting completely with the probe as shown.
3. Move the probe along each component at a speed of approximately 25 - 50 mm (1 - 2 in)/second as shown.

CHECKING PROCEDURE

Note. To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle. Perform the leak test in a calm area (low air/wind movement) so that the leaking refrigerant is not dispersed.

Scheme 327

1. Turn the engine OFF.
2. Connect the manifold gauge set (J-39183-C) to the A/C service ports. Refer to " «SETTING OF SERVICE TOOLS AND EQUIPMENT»(ref-259754-S38237708382007080400000) ".
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm 2 , 50 psi) above a temperature of 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. Refer to " «HFC-134A (R-134A) SERVICE PROCEDURE»(ref-259754-S32572440232007080400000) ". NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm 2 , 50 psi) pressure.
4. Conduct the leak test from the high pressure side (compressor discharge to evaporator inlet) to the low pressure side (evaporator drain hose to shaft seal). Refer to " «COMPONENTS»(ref-259754-S20132182412007080400000) ". Clean the component to be checked and carefully move the electronic refrigerant leak detector probe completely around the following connections and components. Compressor High and low-pressure pipe and hose fittings, relief valve, and compressor shaft seal Liquid tank Refrigerant pressure sensor Service valves. Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). NOTE: After removing manifold gauge set (J-39183-C) from the service valves, wipe any residue from the service valves to prevent any false readings by the electronic refrigerant leak detector (J-41995). Evaporator With engine OFF, turn blower fan on "High" for at least 15 seconds to dissipate any refrigerant trace in the heater and cooling unit assembly. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer's recommended procedure for actual wait time) before inserting the electronic refrigerant leak detector probe into the heater and cooling unit assembly drain hose. NOTE: Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose.
5. If a leak is detected, verify at least once by blowing compressed air into the area of the suspected leak, then repeat the leak check.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components and connections.
7. If no leaks are found, perform steps 8 - 11.
8. Start the engine.
9. Set the heater A/C controls as follows: NOTE: For the automatic system, turn OFF the automatic controls and set the heater A/C controls manually. A/C switch to ON Air flow to VENT mode Intake position to RECIRCULATION mode Temperature to MAX cold Blower speed to HIGH
10. Run the engine at 1,500 rpm for at least 2 minutes.
11. Turn the engine OFF and perform the leak check again following steps 4 through 6 above. Refrigerant leaks should be checked immediately after turning the engine OFF. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after the refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when the pressure is high.
12. Before connecting the recovery/recycling equipment to the vehicle, check the recovery/recycling equipment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover the refrigerant from the equipment lines and then check the refrigerant purity.
13. Confirm refrigerant purity in supply tank using recovery/recycling equipment and refrigerant identifier equipment (J-41810-NI).
14. Confirm the refrigerant purity in the vehicle's A/C system using recovery/recycling equipment and refrigerant identifier equipment (J-41810-NI).
15. Discharge the A/C system using recovery/recycling equipment. Repair the leaking fitting or component as necessary.
16. Evacuate and recharge the A/C system and perform the leak test to confirm that there are no refrigerant leaks.
17. Conduct the Operational Check to ensure system works properly. Refer to " «OPERATIONAL CHECK»(ref-259754-S15663854702007080400000) ".

COMPRESSOR

SERVICE DATA AND SPECIFICATIONS - COMPRESSOR

SERVICE DATA AND SPECIFICATIONS - OIL

REFRIGERANT

SERVICE DATA AND SPECIFICATIONS - REFRIGERANT

ENGINE IDLING SPEED

Refer to IDLE SPEED AND IGNITION TIMING CHECK .

BELT TENSION

Refer to TENSION ADJUSTMENT .