Heater & Air Conditioner: Overview Toyota Highlander I рестайлинг

Scheme 117

Scheme 118

Scheme 119

1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. Apply clean petroleum jelly to the skin. Go immediately to a physician or hospital for professional treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc.

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

1. INSPECT PRESSURE SWITCH No. 1. Magnetic clutch control: Inspect pressure switch operation. Set on the manifold gauge set. Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative (-) lead to terminal 1. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Cooling fan control: Inspect pressure switch operation. Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative (-) lead to terminal 3. Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch.
2. INSPECT AIR CONDITIONER AMPLIFIER ASSY CIRCUIT Disconnect the connectors from the A/C amplifier assy and inspect the connector on the wire harness side, as shown the chart. CONNECTOR TERMINALS VOLTAGE AND RESISTANCE Symbols (Terminals No.) Wiring Color Condition Specified condition A10-11 (GND) - Body Ground W-B-Body Ground Constant Continuity A11-5 (TE) - A11-12 (SG-1) LG-P Evaporator temp.: 25°C (77°F) 1.5 kohm A10-2 (IG) - Body Ground BR - Body Ground Turn ignition switch: ON Battery positive voltage A10-2 (IG) - Body Ground BR - Body Ground Turn ignition switch: LOCK or ACC No voltage A10-12 (+B) - Body Ground W - Body Ground Constant Battery positive voltage A10-13 (ACC) - Body Ground GR - Body Ground Turn ignition switch: ACC Battery positive voltage A10-13 (ACC) - Body Ground GR - Body Ground Turn ignition switch: except ACC No voltage If the circuit is as specified, try to replace the A/C amplifier assy with a new one. If the circuit is as specified, inspect the circuits connected to other parts. Connect the connector to A/C amplifier assy and inspect the wire harness side connector from the back side, as shown in the chart. CONNECTOR TERMINALS VOLTAGE Symbols (Terminals No.) Wiring Color Condition Specified condition A10-4 (MR/F) - Body Ground Y - Body Ground Turn ignition switch ON Battery positive voltage A10-4 (MR/F) - Body Ground Y - Body Ground Turn ignition switch OFF Below 1 V A10-5 (AIR) - Body Ground B - Body Ground Turn ignition switch ON and air flow selector at DEF position Below 1 V A10-5 (AIR) - Body Ground B - Body Ground Turn ignition switch ON and air flow selector at except DEF position Battery positive voltage A10-6 (AIF) - Body Ground W - Body Ground Turn ignition switch ON and air inlet control selector at FRESH 10-14 V A10-6 (AIF) - Body Ground W - Body Ground Turn ignition switch ON and air inlet control selector at RECIRCULATION Below 1 V A10-7 (HR) - Body Ground O - Body Ground Turn ignition switch ON and operate the blower motor Below 1 V A10-7 (HR) - Body Ground O - Body Ground Turn ignition switch ON and does not operate the blower motor Battery positive voltage A10-9 (MPX-) G Multiplex communication circuit - A10-15 - A10-21 V (*1) Ignition switch ON and light control rheostat volume DARK No voltage A10-15 - A10-21 V (*1) Ignition switch ON and light control rheostat volume LIGHT Battery voltage A11-2 (MPX+) V (*2) G(*3) Multiplex communication circuit - A11-6 (TPO) - A11-1 (SG-4) R - B Turn ignition switch ON and air flow selector at DEF position 0.5 - 1.5 V A11-6 (TPO) - A11-1 (SG-4) R - B Turn ignition switch ON and air flow selector at FACE position 4.5 - 5.5 V A11-7 (AOD) - Body Ground G - Body Ground Turn ignition switch ON and air flow selector at DEF position Battery positive voltage A11-7 (AOD) - Body Ground G - Body Ground Turn ignition switch ON and air flow selector at except FACE position Below 1 V A11-8 (AOF) - Body Ground V - Body Ground Turn ignition switch ON and air flow selector at except FACE position Below 1 V A11-8 (AOF) - Body Ground V - Body Ground Turn ignition switch ON and air flow selector at FACE position Battery positive voltage A11-9 (S5-4) - A11-1 (SG-4) BR - B Turn ignition switch ON 4.5 - 5.5 V A11-10 (TP) - A11-12 (SG-1) SB - P Turn ignition switch ON and set temp.: MAX. COOL position 4.5 - 5.5 V A11-10 (TP) - A11-12 (SG-1) SB - P Turn ignition switch ON and set temp.: MAX. WARM position 0.5 - 1.5 V A11-11 (SG-1) - A11-12 (SG-1) O - P Turn ignition switch ON 4.5 - 5.5 V A11-13 (AMC) - A11-1 (SG-4) GR - B Turn ignition switch ON and set temp.: MAX.COOL position Battery positive voltage A11-13 (AMC) - A11-1 (SG-4) GR - B Turn ignition switch ON and set temp.: MAX. WARM position Below 1 V A11-14 (AMH) - A11-1 (SG-4) B - B Turn ignition switch ON and set temp.: MAX. COOL position Below 1 V A11-14 (AMH)-A11-1 (SG-4) B - B Turn ignition switch ON and set temp.: MAX. WARM position Battery positive voltage *1:If the circuit is as specified, try to replace the A/C amplifier assy with a new one. If the circuit is as specified, inspect the circuits connected to other parts. *2: w/ Navigation System. *3: w/o Navigation System.

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

1. COOLER THERMISTOR NO. 1 (MANUAL AIR CONDITIONER Remove cooler thermistor No. 1. Check resistance between terminals 1 and 2 of cooler thermistor No. 1 at each temperature, as shown in the chart. Standard: COOLER THERMISTOR CONNECTOR TERMINALS RESISTANCE Tester connection Condition Specified condition E12-1 - E12-2 -10°C (14°F) 8.00 to 10.00 kohm E12-1 - E12-2 -5°C (23°F) 6.15 to 7.65 kohm E12-1 - E12-2 0°C (32°F) 4.75 to 5.85 kohm E12-1 - E12-2 5°C (41°F) 3.70 to 4.55 kohm E12-1 - E12-2 10°C (50°F) 3.00 to 3.73 kohm E12-1 - E12-2 15°C (59°F) 2.45 to 2.88 kohm E12-1 - E12-2 20°c (68°F) 1.95 to 2.30 kohm E12-1 - E12-2 25°C (77°F) 1.60 to 1.80 kohm E12-1 - E12-2 30°C (86°F) 1.28 to 1.47 kohm NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph (Scheme 127) below).
2. HEATER BLOWER SWITCH (MANUAL AIR CONDITIONER) Inspect blower switch continuity. HEATER BLOWER SWITCH TERMINALS SPECIFIED CONDITION Condition/Circuit Tester connection Specified condition OFF - No continuity LO 1 - 8 Continuity M1 1 - 6 - 8 Continuity M2 1 - 5 - 8 Continuity Hl 1 - 4 - 8 Continuity If continuity is not as specified, replace the air conditioner control assy. Inspect illumination operation. Connect the positive (+) lead from the battery to terminal 2 and negative (-) lead to terminal 3 then check that the illuminations light up. If there is bulb not light up, replace the bulb.
3. BLOWER RESISTOR (MANUAL AIR CONDITIONER) Measure resistor between terminals, as shown in the chart below. BLOWER RESISTOR CONNECTOR TERMINALS RESISTANCE Tester connection Specified condition 1 - 2 0.642 - 0.738 ohm 1 - 3 0.205 - 0.235 ohm 1 - 4 1.572 - 1.803 ohm If resistance is not as specified, replace the blower resistor.
4. COOLING UNIT MOTOR SUB-ASSY W/FAN (MANUAL AIR CONDITIONER) Connect the positive (+) lead from the battery to terminal 2 and negative (-) to terminal 1, then check that the motor operation smoothly. If operation is not as specified, replace the blower motor.
5. HEATER BLOWER MOTOR RELAY ASSY (MANUAL AIR CONDITIONER) Check that the continuity exists between each pair of terminals of heater blower motor relay assy, as shown in the chart. HEATER BLOWER MOTOR RELAY TERMINALS RESISTANCE Tester connection Specified condition 1 - 4 No continuity 2 - 4 Continuity 3 - 5 62.5 - 90.9 ohm Apply battery voltage between terminals 3 and 5. Check continuity each pair of terminals, as shown the chart. TESTER CONNECTION AND SPECIFIED CONDITION Tester connection Specified condition 1 - 2 Continuity 2 - 4 No continuity If continuity is not as specified, replace the heater blower motor relay.
6. MAGNET CLUTCH ASSY (MANUAL AIR CONDITIONER) Connect the positive (+) lead from the battery to terminal and the negative (-) lead to the body ground. Check that the magnetic clutch energized. If operation is not as specified, replace the magnet clutch assy.
7. COOLER COMPRESSOR ASSY (MANUAL AIR CONDITIONER) Disconnect the cooler compressor assy connector. Measure resistance between terminals 1 and 2 of cooler compressor assy connector. Resistance: 165 - 205 ohm at 20°C (68°F) If resistance is not as specified, replace the cooler compressor assy.
8. MAGNET-CLUTCH RELAY (MANUAL AIR CONDITIONER) TESTER CONNECTION AND SPECIFIED CONDITION Condition tester connection Specified condition constant 1 - 2 Continuity Apply B+ between terminals 1 and 2. 3 - 5 Continuity If continuity is not as specified, replace the magnet-clutch relay.

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

Scheme 140

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

Scheme 153

1. INSPECT REFRIGERANT VOLUME Check the sight glass on the cooler refrigerant liquid pipe A. Test conditions: Engine is running at 1,500 RPM Blower speed control switch is at "HI" A/C switch is ON Temperature control dial is at "MAX. COOL" Doors are fully open *: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling is sufficient.
2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) Engine is running at 1,500 RPM Blower speed control switch is at "HI" Temperature control dial is at "COOL" A/C switch is ON Doors are fully open Normally functioning refrigeration system Gauge reading: Low pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm 2 ) High pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm 2 ) Moisture is present in refrigeration system Insufficient cooling Poor circulation of refrigerant Refrigerant does not circulate Refrigerant is overcharged or cooling effectiveness of condenser is insufficient Air present in refrigeration system Expansion valve malfunction Defective compressor Gauge readings (Reference)

Scheme 154

Scheme 155

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Turn the A/C switch on. Operate the cooler compressor at an engine RPM of approximately 1,000 for 5 to 6 minutes to circulate the refrigerant and collect compressor oil remaining in each component into the cooler compressor as much as possible. Stop the engine. Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. CHARGE REFRIGERANT Using a vacuum pump, perform vacuum purging. Using SST charge refrigerant, HFC-134a (R134a). Standard: 650 +/- 50 g (22.93 +/- 1.76 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) NOTE: Do not start the engine before charging with refrigerant as the cooler compressor doesn't work properly without any refrigerant, which causes the compressor to overheat.
3. WARM UP ENGINE NOTE: Warm up the engine at less than 2000 RPM for 2 minutes or more after charging with refrigerant.
4. INSPECT LEAKAGE OF REFRIGERANT Perform in these conditions: Stop the engine. Secure good ventilation (the gas leak detector may not react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas). Repeat the test 2 or 3 times. Make sure that there is some refrigerant remaining in the refrigeration system. When compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm 2 , 57 to 85 psi) Bring the gas leak detector close to the drain hose before performing the test. HINT: After the blower motor has stopped, leave the cooling unit for more than 15 minutes. Expose the gas leak detector sensor under the drain hose. When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. If such reaction is unavoidable, the vehicle must be lifted up. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. Disconnect the connector and leave the pressure switch for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. Bring the gas leak detector close to the refrigerant lines and perform the test.

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

1. INSPECT V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Belt tension: Using a belt tension gauge, check the V belt tension. V BELT TENSION SPECIFICATION New belt N (kg, lb) Used belt N (kg, lb) V belt 160 to 180 115 to 135 NOTE: Check the V belt deflection at the specified point. When installing a new belt, set its tension value as specified. When checking a belt used for over 5 minutes, confirm the deflection value is within the specified range. When reinstalling a belt used for over 5 minutes, perform the check based on the used deflection value. V belt tension and deflection values should be checked after 2 revolutions of engine cranking. When using a belt tension gauge, confirm the accuracy first by using a master gauge. Check that the drive belt fits properly in the ribbed grooves.

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

1. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Loosen bolt A. Loosen bolt B. Loosen bolt C and remove the V belt.
2. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Temporarily install the V belt as illustrated.
3. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Apply drive belt tension by turning bolt C. Drive belt tension: New belt: 160 to 180 lbf Used belt: 115 to 135 lbf NOTE: "New V belt" refers to a belt which has been used for less than 5 minutes on a running engine. "Used V belt" refers to a belt which has been used for 5 minutes or more on a running engine. After installing the V belt, check that it fits properly in the ribbed grooves.
4. FULLY TIGHTEN V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Tighten bolt A. Torque: 58 N.m (591 kgf.cm, 43 ft.lbf) Tighten bolt B. Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)

Scheme 166

Scheme 167

Scheme 168

1. ADJUST V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 Loosen bolt A. Loosen bolt B. Apply drive belt tension by turning bolt C. Drive belt tension: New belt: 160 to 180 lbf Used belt: 115 to 135 lbf HINT: "New V belt" refers to a belt which has been used for less than 5 minutes on a running engine. "Used V belt" refers to a belt which has been used for 5 minutes or more on a running engine. Tighten bolt A. Torque: 58 N.m (591 kgf.cm, 43 ft.lbf) Tighten bolt B. Torque: 18 N.m (183 kgf.cm, 13 ft.lbf)

Scheme 169

See also:
• FAN AND GENERATOR V BELT (2AZ-FE)