Air Conditioning: Overview Toyota Prius II рестайлинг

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1. NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. SYSTEM REFERENCE System Name See procedure «POWER WINDOW CONTROL SYSTEM»(ref-289860-S35295794962008070800000) «PRECAUTION»(ref-289860-S14512578192008070800000)
2. NOTICES FOR HYBRID SYSTEM ACTIVATION When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output.
3. BECAUSE COMPRESSOR HAS HIGH-VOLTAGE CIRCUIT, WEAR INSULATED GLOVES AND PULL OUT SERVICE PLUG TO CUT HIGH-VOLTAGE CIRCUIT BEFORE INSPECTION
4. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME
5. ALWAYS WEAR EYE PROTECTION
6. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. Apply clean petroleum jelly to the skin. Go immediately to a hospital or see a physician for professional treatment.
7. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME
8. BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT
9. 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. Necessary care should be taken to avoid this.
10. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valves are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture.
11. 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.
12. PRECAUTIONS TO BE OBSERVED WHILE SERVICING NOTE: For the electric inverter compressor, use the ND-OIL 11. Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing a DTC to be output. Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing a DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug clip before inspection, as some of the procedures require disconnecting the high-voltage connectors.

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TRANSMITTER, RECEIVER AND SIGNALS REFERENCE

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1. GENERAL The air conditioning system has the following features: An ES18 type Electric Inverter Compressor is used. This compressor is driven by an alternating current provided by the A/C inverter, which is built into the inverter of the hybrid system. As a result, the air conditioning system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. A blower motor controller, which regulates the speed of the blower motor by controlling the output voltage in accordance with the duty cycle signal provided by the air conditioning amplifier, is used. As a result, the power loss associated with the heat generation of the conventional blower linear controller is reduced, thus realizing low fuel consumption. A humidity sensor function is added to the room temperature sensor in order to optimize the amount of dehumidification effort during the operation of the air conditioning system. A compact, lightweight and highly efficient RS (Revolutionary Slim) evaporator is used. A compact, lightweight and highly efficient MF-IV (Multi Flow-IV) condenser is used. A compact, lightweight, and highly efficient electrical water pump is used in order to ensure the proper heater performance while the engine is stopped. Fuzzy control is used for calculating the required outlet air temperature (TAO: Temperature Air Outlet) and the blower volume in the automatic air conditioning control system. Accordingly, the air conditioning ECU is able to calculate the outlet air temperature, blower volume, air outlet, and compressor speed that is suited to the operating environment. As a result, the comfort level of the occupants is improved.
2. AIR CONDITIONING OPERATION The air conditioning is controlled by using the switches that appear on the air conditioning screen display of the multi-display and the switches provided on the steering pad. In addition to the air conditioning screen display, the operating conditions of the AUTO, RECIRCULATION, front DEF, and rear DEF switches are indicated by the indicator lights in the combination meter.
3. HEATER CORE AND PTC HEATER A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core is used. A PTC (Positive Temperature Coefficient) heater is built into the heater core tube. The PTC heater contains electrodes that are interposed with a PTC element, to which current is applied in order to warm the air that passes through the fins. The PTC heater is provided in the air duct at the footwell outlet in front of the air conditioning unit. This PTC heater, which is a honeycomb-shaped PTC thermistor, directly warms the air that flows in the duct.
4. COMPRESSOR ES18 Electric Inverter Compressor is actuated by a built-in electric motor. The electric motor is actuated by the alternating current power (201.6 V) supplied by the A/C inverter, which is integrated in the hybrid system inverter. As a result, the air conditioning control system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. The electric inverter compressor controls the compressor speed at the required speed calculated by the air conditioning amplifier. Thus, cooling, dehumidification performance and power consumption are optimized. The suction and discharge hoses at the compressor are low-moisture permeation hoses. This minimizes the entry of moisture into the refrigeration cycle. The compressor uses high-voltage alternating current. If a short or open circuit occurs in the compressor wiring harness, the hybrid control ECU will cut off the A/C inverter circuit in order to stop the power supply to the compressor. The Electric Inverter Compressor consists of a spirally wound fixed scroll and variable scroll that form a pair, a brushless motor, an oil separator, and a motor shaft. The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas. Locating the suction port directly above the scrolls enables direct suction, thus realizing improved suction efficiency. Containing a built-in oil separator, this compressor is able to separate the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle, thus realizing a reduction in the oil circulation rate. HINT: In order ensure the proper insulation of the internal high-voltage portion of the compressor and the compressor housing, a compressor oil (ND-OIL 11) with a high level of insulation performance is used. Therefore, never use a compressor oil other than the ND-OIL 11 type compressor oil or its equivalent.
5. WATER PUMP An electrical water pump is used. This provides a stable heater performance even if the engine is stopped because of a function of the THS-ll. A new type of electrical water pump is used in which the water flow resistance has been reduced.
6. ROOM TEMPERATURE SENSOR AND HUMIDITY SENSOR A humidity sensor function is used by the room temperature sensor. By enabling the detection of humidity in the vehicle interior, this function optimizes the amount of dehumidification effort during the operation of the air conditioning system. As a result, the power consumption of the compressor has been reduced and a comfortable level of humidity has been realized in the vehicle interior. The humidity-sensing resistance film that is built into the humidity sensor absorbs and releases the humidity in the vehicle interior. During the absorption and releasing processes, the humidity-sensing resistance film expands (during the absorption of humidity) and contracts (during drying). The clearance between the carbon particles in the humidity-sensing resistance film expands and contracts during absorption and drying, thus changing the resistance between the electrodes. The air conditioning amplifier determines the humidity in the vehicle interior through the changes in the output voltage of the humidity sensor that are caused by the resistance between the electrodes.
7. BLOWER MOTOR CONTROLLER The blower motor controller controls the voltage that is output to the blower motor in accordance with the duty cycle signals that are input by the air conditioning amplifier. It is characterized by a smaller amount of heat generation than the blower controller used on the previous model. As a result, the power loss associated with the heat generation of the conventional blower linear controller has been reduced, thus realizing low fuel consumption.
8. AIR CONDITIONING AMPLIFIER The air conditioning ECU has the following controls. AIR CONDITIONING AMPLIFIER CONTROLS OUTLINE CHART Control Outline Fuzzy Control The fuzzy control determines the conformity levels of the temperature deviation, ambient temperature, and solar radiation by defining their respective mathematical functions. In addition, a fuzzy calculation method is used to calculate the required outlet air temperature (TAO) and the blower volume. Based on these calculations, the air conditioning amplifier effects the respective controls for the outlet air temperature, blower volume, compressor, and air outlet. Outlet Air Temp. Control Air Mix Damper Control In response to the temperature control switch setting, the required outlet air temperature, evaporator temperature sensor, and engine coolant temperature sensor compensations are used by the air mix control damper control to calculate a tentative damper opening angle, through an arithmetic circuit in the air mix damper, to arrive at a target damper opening angle. Blower Control Blower Motor Start Up Control When the blower motor is started up, the air conditioning amplifier transmits a blower motor actuation signal with a low duty cycle ratio to the blower pulse controller, which applies a low voltage to the blower motor, in order to operate the blower motor for 3 seconds at a low speed. This is designed to protect the blower pulse controller from a sudden start-up voltage surge. Manual Control Sets the blower speed according to operation of the blower switch. Automatic Control Step Less Air Volume Control: When the AUTO switch located on the steering pad switch is pushed, or the air conditioning screen display of the multi-display is touched, the air conditioning amplifier automatically regulates the duty ratio to the blower pulse controller in accordance with a calculation result by the fuzzy control in order to deliver step less air volume. Warm-up Control: When the air outlet is in the FOOT, BI-LEVEL, or FOOT/DEF mode, the blower will not operate until the engine coolant temperature increases above a prescribed value. When the temperature increases above a prescribed value, the blower motor operates at the LO speed. Time-Lagged Air Flow Control: 2 types of time-lagged air flow control (in accordance with the detected by the evaporator temperature sensor) help prevent hot air from being emitted from FACE or BI-LEVEL vent. Sunlight Air Flow Control: Controls the blower speed in accordance with the intensity of the sunlight when the air outlet mode is at FACE or BI-LEVEL. The blower speed can be adjusted in response to the signal received from the solar sensor. Air Outlet Control Manual Control Changes the air outlet in accordance with the selected position of the mode select switch. Automatic Control Mode Damper Switching Servo motor Control: When the AUTO switch is pushed, automatic control causes the mode servo motor to rotate to a desired position in accordance with the target damper opening, which is based on the calculation of the TAO. Low-Temperature FOOT/DEF Control: In accordance with the engine coolant temperature, ambient temperature, amount of sunlight, required outlet temperature (TAO), and vehicle speed conditions, this control automatically switches the blower outlet between the FOOT / DEF modes to prevent the window from becoming fogged when the outside air temperature is low. Air Inlet Control Manual Control Drives the air inlet servo motor according to the operation of the air inlet control switch and fixes the dampers in the FRESH or RECIRC position. Automatic Control Automatic RECIRC / FRESH Control: When the AUTO switch is pressed, the system controls the servo motor so that the air inlet is as calculated in accordance with the TAO. DEF Mode Control: When switching the mode switching switch to DEF mode, air conditioning amplifier turns MAX mode ON forcibly and switched to FRESH mode. When switching the mode switching switch to FOOT / DEF mode, air conditioning amplifier switches to FRESH mode. 2-Way Flow Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as 2-way flow mode when the blower outlet is set to FOOT or FOOT / DEF, the tentative air mix damper opening angle is above the specified value (MAX HOT), and either the blower volume is more than the specified volume or the vehicle speed is less than the specified speed. Half Inlet Air Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as half inlet air mode when the blower outlet mode is set to FACE or BI-LEVEL and TAO is more than the specified temperature, and operates both outlet air introduction and inlet air circulation at the same time. Electric Inverter Compressor Control Compressor Speed Control The air conditioning amplifier calculates target speed of the compressor based on the target evaporator temperature (which is calculated by the room temperature sensor, humidity sensor, ambient temperature sensor, and the solar sensor) and the actual evaporator temperature that is detected by the evaporator temperature sensor in order to control the compressor speed. The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that would not inhibit the proper cooling performance or defogging performance. Electrical Water Pump Control The electrical water pump is used in order to ensure the proper heater performance while the blower motor is ON and the engine is stopped. Engine Start Request Control To ensure the proper heater performance when the hybrid system is started at low temperatures, the air conditioning amplifier transmits an engine start request to the hybrid control ECU in accordance with the TAO, engine coolant temperature sensor signal, and ambient temperature sensor signal. PTC Heater Control When the hybrid system is operating (READY) and the blower motor is turned ON, the air conditioning amplifier turns on the PTC heater if the conditions listed below are met. Heater core integrated PTC heater Air outlet is in the FOOT, FOOT / DEF or DEF mode. Engine coolant temperature is below specified temperature. Ambient temperature is below specified temperature (DEF mode). Tentative air mix damper opening angle is above the specified value (MAX HOT). Footwell air duct integrated PTC heater Air outlet is in the FOOT or FOOT / DEF mode. Engine coolant temperature is below specified temperature. Tentative air mix damper opening angle is above the specified value (MAX HOT). Electric Cooling Fan Control The air conditioning amplifier control the cooling fan in accordance with the vehicle speed signal and compressor speed signal. Rear Window Defogger Control Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger switch is switched on. Switches them off if the switch is pressed while they are operating. Outer Temperature Indication Control Based on the signals from the ambient temperature sensor, this control calculates the outside temperature, which is then corrected in the air conditioning ECU, and shown in the multi-display. Self-Diagnosis Checks the sensor and A/C inverter in accordance with operation of the air conditioning switches, then the heater control panel displays a DTC (Diagnosis Trouble Code) to indicate if there is a malfunction or not (sensor check function). Drives the actuators through a predetermined sequence in accordance with the operation of the air conditioning switches (actuator check function).
9. ELECTRIC INVERTER COMPRESSOR CONTROL The air conditioning amplifier calculates the target compressor speed based on the target evaporator temperature (calculated from the room temperature sensor, humidity sensor, ambient temperature sensor, and solar sensor) and the actual evaporator temperature detected by the evaporator temperature sensor. Then, the air conditioning amplifier transmits the target speed to the hybrid control ECU. The hybrid control ECU controls the A/C inverter based on the target speed data in order to control the compressor to a speed that suits the operating condition of the air conditioning system. The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that does not inhibit the proper cooling performance or defogging performance. As a result, comfort and low fuel consumption can be realized.
10. MODEL POSITION AND DAMPER OPERATION Function of main damper HINT: *1: During 2-way flow control *2: Early stage of COOL during AUTO
11. AIR OUTLETS AND AIR VOLUME RATIOS HINT: The circle size (x) indicates the proportion of the airflow volume. The (-) indicates that the air is not blown out. The (*) indicates the early stage of COOL during AUTO.

DESCRIPTION

The room temperature sensor is installed in the instrument panel to detect the room temperature and control the heater and air conditioner "AUTO" function. The resistance of the room temperature sensor changes in accordance with the room temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases.

The air conditioning amplifier applies voltage (5 V) to the room temperature sensor and reads voltage changes as the resistance of the room temperature sensor changes. This sensor also sends appropriate signals to the air conditioning amplifier. The room temperature sensor is integrated with the room humidity sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

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1. READ VALUE OF TECHSTREAM (ROOM TEMP) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / Open in the circuit: min.: -6.5°C (20.3°F) max.: 57.25°C (135.05°F) Actual room temperature is displayed Open in the circuit: -6.5°C (20.3°F) Short in the circuit: 57.25°C (135.05°F) OK : The display is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TR VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT ROOM TEMPERATURE SENSOR Remove the room temperature sensor. Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition 1 (THR) - 2 (GND) 10°C (50°F) 3.00 to 3.73 kohms 1 (THR) - 2 (GND) 15°C (59°F) 2.45 to 2.88 kohms 1 (THR) - 2 (GND) 20°C (68°F) 1.95 to 2.30 kohms 1 (THR) - 2 (GND) 25°C (77°F) 1.60 to 1.80 kohms 1 (THR) - 2 (GND) 30°C (86°F) 1.28 to 1.47 kohms 1 (THR) - 2 (GND) 35°C (95°F) 1.00 to 1.22 kohms 1 (THR) - 2 (GND) 40°C (104°F) 0.80 to 1.00 kohms 1 (THR) - 2 (GND) 45°C (113°F) 0.65 to 0.85 kohms 1 (THR) - 2 (GND) 50°C (122°F) 0.50 to 0.70 kohms 1 (THR) - 2 (GND) 55°C (131°F) 0.44 to 0.60 kohms 1 (THR) - 2 (GND) 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG : REPLACE ROOM TEMPERATURE SENSOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) Disconnect the A9 sensor connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-8 (TR) - A9-1 (THR) Below 1 ohms A7-22 (SGTR) - A9-2 (GND) Below 1 ohms A7-8 (TR) - Body ground 10 kohms or higher A7-22 (SGTR) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The ambient temperature sensor is installed in the front part of the condenser to detect the ambient temperature and control the heater and air conditioner "AUTO" function. The sensor connected to the ECM detects fluctuation in the ambient temperature that is used for controlling the room temperature. The sensor sends a signal to the air conditioning amplifier via the ECM. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases.

The ECM applies voltage (5 V) to the ambient temperature sensor and reads voltage changes as the resistance of the ambient temperature sensor changes. The ECM sends the read signal to the air conditioning amplifier via CAN and body multiplex communications.

DTC DETECTION CONDITION AND TROUBLE AREA

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1. READ VALUE OF TECHSTREAM (AMBI TEMP SENS) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS Ambient temperature sensor / min.: -23.3°C (-9.94°F) max.: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in the circuit: -23.3°C (- 9.94°F) Short: in the circuit: 65.95°C (150.71°F) OK : The display is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK ECM (TAM VOLTAGE) Remove the ECM with connectors still connected. Measure the voltage of the wire harness side connectors. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AMBIENT TEMPERATURE SENSOR Remove the ambient temperature sensor. Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition 1 - 2 10°C (50°F) 3.00 to 3.73 kohms 1 - 2 15°C (59°F) 2.45 to 2.88 kohms 1 - 2 20°C (68°F) 1.95 to 2.30 kohms 1 - 2 25°C (77°F) 1.60 to 1.80 kohms 1 - 2 30°C (86°F) 1.28 to 1.47 kohms 1 - 2 35°C (95°F) 1.00 to 1.22 kohms 1 - 2 40°C (104°F) 0.80 to 1.00 kohms 1 - 2 45°C (113°F) 0.65 to 0.85 kohms 1 - 2 50°C (122°F) 0.50 to 0.70 kohms 1 - 2 55°C (131°F) 0.44 to 0.60 kohms 1 - 2 60°C (140°F) 0.36 to 0.50 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). NG : REPLACE AMBIENT TEMPERATURE SENSOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - ECM) Disconnect the A6 sensor connector. Disconnect the E4 and E7 ECM connectors. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition E7-21 (TAM) - A6-2 Below 1 ohms E4-28 (E2) - A6-1 Below 1 ohms E7-21 (TAM) - Body ground 10 kohms or higher E4-28 (E2) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The evaporator temperature sensor is installed on the evaporator in the air conditioner unit to detect the cooled air temperature that has passed through the evaporator and control the air conditioning. It sends appropriate signals to the air conditioning amplifier. The resistance of the evaporator temperature sensor changes in accordance with the cooled air temperature that has passed through the evaporator. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases.

The air conditioning amplifier applies voltage (5 V) to the evaporator temperature sensor and reads voltage changes as the resistance of the evaporator temperature sensor changes. This sensor is used for frost prevention.

DTC DETECTION CONDITION AND TROUBLE AREA

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1. READ VALUE OF TECHSTREAM (EVAP TEMP) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP TEMP Evaporator temperature sensor / min.: -29.7°C (-21.46°F) max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in the circuit: -29.7°C (- 21.46°F) Short in the circuit: 59.55°C (139.19°F) OK : The display is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TE VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 0 °C (32°F) 2.0 to 2.4 V A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 15°C (59°F) 1.4 to 1.8 V HINT: As the temperature increases, the voltage decreases. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT EVAPORATOR TEMPERATURE SENSOR Remove the evaporator temperature sensor. Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition 1 - 2 -10°C (14°F) 7.30 to 9.10 kohms 1 - 2 -5°C (23°F) 5.65 to 6.95 kohms 1 - 2 0°C (32°F) 4.40 to 5.35 kohms 1 - 2 5°C (41°F) 3.40 to 4.15 kohms 1 - 2 10°C (50°F) 2.70 to 3.25 kohms 1 - 2 15°C (59°F) 2.14 to 2.58 kohms 1 - 2 20°C (68°F) 1.71 to 2.05 kohms 1 - 2 25°C (77°F) 1.38 to 1.64 kohms 1 - 2 30°C (86°F) 1.11 to 1.32 kohms NOTE: Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph). NG : REPLACE EVAPORATOR TEMPERATURE SENSOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (EVAPORATOR TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) Disconnect the A11 sensor connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-7 (TE) - A11-2 Below 1 ohms A7-5 (SGTE) - A11-1 Below 1 ohms A7-7 (TE) - Body ground 10 kohms or higher A7-5 (SGTE) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

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The solar sensor is installed in the upper part of the instrument panel to detect the amount of solar radiation with a photodiode to control the heater and air conditioner "AUTO" function. It sends appropriate signals to the air conditioning amplifier. The output voltage of the solar sensor changes in accordance with the amount of solar radiation. As the amount increases, the voltage increases. As the amount decreases, the voltage decreases. The air conditioning amplifier reads voltage output from the solar sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

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1. READ VALUE OF TECHSTREAM (SOLAR SENS-P) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P Solar sensor (Passenger side) / min.: 0 max.: 255 Increases as brightness increases Open in the circuit: 0 Short in the circuit: 255 OK : The display is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TS VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-12 (S5TS) - A7-21 (TS) Power switch ON (IG) 0.8 to 4.3 V HINT: As the inspection light is moved away from the sensor, the voltage increases. As the inspection light is moved closer to the sensor, the voltage decreases. Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT SOLAR SENSOR Remove the solar sensor. Measure the resistance of the sensor. Connect the ohmmeter's positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified condition 1 - 2 Sensor is subject to electric light Except infinite ohms 1 - 2 Sensor is covered with a cloth infinite ohms (No continuity) NOTE: The connection procedure for using a digital tester such as an TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 and negative (-) lead to terminal 2 of the solar sensor. HINT: As the inspection light is moved away from the sensor, the resistance increases. Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. NG : REPLACE SOLAR SENSOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (SOLAR SENSOR - AIR CONDITIONING AMPLIFIER) Disconnect the A10 solar sensor connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-12 (S5TS) - A10-1 Below 1 ohms A7-21 (TS) - A10-2 Below 1 ohms A7-12 (S5TS) - Body ground 10 kohms or higher A7-21 (TS) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

Scheme 36

The pressure switch to detect the refrigerant pressure is located in the sight glass side of the pipe on the high-pressure side. This DTC is output when the refrigerant pressure is either significantly low (below 196 kPa (2.0 kgf/cm 2 , 28 psi) or significantly high (over 3,140 kPa (32.0 kgf/cm 2 , 455 psi). Then the pressure switch sends appropriate signals to the air conditioning amplifier. The pressure switch has built-in switches to detect high and low pressure and is turned off when either is determined to be defective. The air conditioning amplifier continuously monitors the pressure switch signal after the power switch is turned ON (IG). It stops compressor control and outputs the DTC when it detects the signal indicating that the switch is turned OFF.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 37

Scheme 38

Scheme 39

1. CHECK REFRIGERANT PRESSURE Set the manifold gauge. 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) Power switch ON (IG) Blower speed control switch at "HI" position Temperature control dial at "COOL" position Air conditioning switch ON Fully open doors Standard pressure: Pressure on high pressure side: 1.37 to 1.57 MPa (13.9 to 16.0 kgf/cm 2 , 198 to 228 psi) HINT: If the refrigerant pressure is below 196 kPa (2.0 kgf/cm 2 , 28 psi), the refrigerant amount in the air conditioning cycle may have decreased significantly for reasons such as a gas leakage. NG : INSPECT AND REPAIR AIR CONDITIONING CYCLE OK : GO TO NEXT STEP
2. CHECK AIR CONDITIONING OPERATION Disconnect the P1 pressure switch connector. Connect terminals 1 and 4 of the connector of the pressure switch on the vehicle wire harness side using a service wire. Turn the power switch ON (IG). Turn the air conditioning switch ON and check that the compressor is operated. Check that the compressor is not operated when disconnecting terminals 1 and 4 (that were connected in the prior step). OK : Terminals 1 and 4 connected: the compressor is operated Terminals 1 and 4 disconnected: the compressor is not operated OK : REPLACE PRESSURE SWITCH NG : GO TO NEXT STEP
3. CHECK WIRE HARNESS (PRESSURE SWITCH - AIR CONDITIONING AMPLIFIER AND BODY GROUND) Disconnect the P1 pressure switch connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-6 (PSW) - P1-4 Below 1 ohms P1-1 - Body ground Below 1 ohms A7-6 (PSW) - Body ground 10 kohms or higher Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C A : REPAIR OR REPLACE HARNESS AND CONNECTOR B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER

Scheme 40

This sensor detects the position of the air mix control servo motor (air mix damper) and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air mix control servo motor. The position sensor resistance changes as the air mix control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

1. READ VALUE OF TECHSTREAM (A/M DAMP POS-P, TARG-P) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": - 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": - 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - OK : The displayed is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TP VOLTAGE) Remove the air conditioning amplifier with its connectors still connected. Change the set temperature to activate the air mix servo motor. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. HOT position 0.97 to 1.03 V A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. COOL position 3.97 to 4.03 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR MIX CONTROL SERVO MOTOR Remove the air mix control servo motor. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A15-1 (VZ) - A15-2 (GND) 4.2 to 7.8 kohms Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL Position 3.6 to 6.7 kohms A15-3 (PT) - A15-2 (GND) MAX. HOT Position 0.8 to 1.6 kohms HINT: Refer to the operation procedure for air mix control servo motor (see «DTC B1431 Air Mix Damper Position Sensor Circuit (Passenger Side)»(ref-289870-S29149523412008070800000) ). As the air mix control servo motor moves from the COOL position to HOT position, the resistance decreases gradually without interruption. NG : REPLACE AIR MIX CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A15 servo connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-20 (TP) - A15-3 (PT) Below 1 ohms A7-14 (SGTP) - A15-2 (GND Below 1 ohms A7-13 (S5TP) - A15-1 (VZ) Below 1 ohms A7-20 (TP) - Body ground 10 kohms or higher A7-14 (SGTP) - Body ground 10 kohms or higher A7-13 (S5TP) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

Scheme 46

This sensor detects the position of the air inlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air inlet control servo motor.

The position sensor's resistance changes as the air inlet control servo motor arm moves.

It outputs voltage (5 V) that is input to terminal 3 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. READ VALUE OF TECHSTREAM (A/I DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK : The displayed is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TPI VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Change the set REC / FRS to activate the air inlet servo motor. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) RECIRC position 3.5 to 4.5 V A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) FRESH position 0.5 to 1.8 V HINT: As the air inlet servo motor is moved from REC position to FRS position, the voltage decreases gradually without interruption. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR INLET CONTROL SERVO MOTOR Remove the air inlet control servo motor. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A14-1 (VZ) - A14-2 (GND) 4.2 to 7.8 kohms Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kohms A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kohms HINT: Refer to the operation procedure of the air inlet control servo motor (see «DTC B1442 Air Inlet Damper Control Servo Motor Circuit»(ref-289870-S22395052612008070800000) ). As the air inlet control servo motor moves from FRESH position to RECIRCULATION position, the resistance decreases gradually without interruption. NG : REPLACE AIR INLET CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A14 servo connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-19 (TPI) - A14-3 (PT) Below 1 ohms A7-4 (SGTPI) - A14-2 (GND) Below 1 ohms A7-3 (S5TPI) - A14-1 (VZ) Below 1 ohms A7-19 (TPI) - Body ground 10 kohms or higher A7-4 (SGTPI) - Body ground 10 kohms or higher A7-3 (S5TPI) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

Scheme 52

This sensor detects the position of the air outlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air outlet control servo motor. The potentiometer's resistance changes as the air outlet control servo motor arm moves.

It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the potentiometer.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

1. READ VALUE OF TECHSTREAM (A/O DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the items below in the DATA LIST, and read the displays on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% OK : The displayed is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (TPM VOLTAGE) Remove the air condition amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) FACE position 3.97 to 4.07 V A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) DEF position 0.97 to 1.03 V HINT: As the air outlet servo motor is moved from the FACE position to the DEF position, the voltage decreases gradually without interruption. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR OUTLET CONTROL SERVO MOTOR Remove the air outlet control servo motor. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A16-1 (VZ) - A16-2 (GND) 4.2 to 7.2 kohms Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A16-3 (PT) - A16-2 (GND) DEF position 0.6 to1.1 kohms A16-3 (PT) - A16-2 (GND) FACE position 3.6 to 6.7 kohms HINT: Refer to the operation procedure for air outlet control servo motor (see «DTC B1443 Air Outlet Damper Control Servo Motor Circuit»(ref-289870-S27166024912008070800000) ). As the air outlet control servo motor moved from DEF position to FACE position, the resistance decreases gradually without interruption. NG : REPLACE AIR OUTLET CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A16 servo connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-18 (TPM) - A16-3 (PT) Below 1 ohms A7-23 (SGTPM) - A16-2 (GND) Below 1 ohms A7-11 (S5TPM) - A16-1 (VZ) Below 1 ohms A7-18 (TPM) - Body ground 10 kohms or higher A7-23 (SGTPM) - Body ground 10 kohms or higher A7-11 (S5TPM) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The air mix control servo motor (air mix damper servo) is controlled by the air conditioning amplifier. The air mix control servo motor moves the air mix damper by rotating (normal, reverse) the motor with electrical power from the air conditioning amplifier.

This adjusts the mix ratio of the air that passes through the evaporator and heater core and controls the airflow temperature. Air flow temperature changes when moving the air mix damper to the target point. The target point can be detected with the air mix damper position sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 58

Scheme 59

Scheme 60

1. READ VALUE OF TECHSTREAM (A/M DAMP POS-P, TARG-P) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": - 10.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": - 10.0% - OK : When the target position is at the "MAX. COOL" (- 10.0%), the actual opening angle is 19.0% or less. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. READ VALUE OF TECHSTREAM (A/M DAMP POS-P, TARG-P) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - OK : When the target position is at the "MAX. HOT" (100.0%), the actual opening angle is 81.0% or more. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR MIX CONTROL SERVO MOTOR Remove the air mix control servo motor. Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4, then check that lever turns to "MAX. HOT" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. HOT position 0.8 to 1.6 kohms Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5, then check that lever turns to "MAX. COOL" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL position 3.6 to 6.7 kohms NG : REPLACE AIR MIX CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A15 servo connector. Disconnect the A8 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-19 (AMC) - A15-4 (MCOOL) Below 1 ohms A8-17 (AMH) - A15-5 (MHOT) Below 1 ohms A8-19 (AMC) - Body ground 10 kohms or higher A8-17 (AMH) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The air inlet control servo motor is controlled by the air conditioning amplifier and moves the air inlet control servo motor to the desired position.

The air inlet control servo motor switches between "RECIRCULATION" and "FRESH" by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier. This controls intake air and switches "RECIRCULATION", "FRESH" and "HALF-RECIRCULATION".

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 61

Scheme 62

Scheme 63

1. READ VALUE OF TECHSTREAM (A/I DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK : When the target position is at the "RECIRCULATION" (-1.0%), the actual opening angle is 19.0% or less. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. READ VALUE OF TECHSTREAM (A/I DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK : When the target position is at the "FRESH" (110.0%), the actual opening angle is 81.0% or more. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR INLET CONTROL SERVO MOTOR Remove the damper air inlet servo motor. Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turns to "FRESH" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kohms Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "RECIRCULATION" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kohms NG : REPLACE AIR INLET CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A14 servo connector. Disconnect the A8 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-22 (AIR) - A14-4 (Mrec) Below 1 ohms A8-23 (AIF) - A14-5 (Mfrs) Below 1 ohms A8-22 (AIR) - Body ground 10 kohms or higher A8-23 (AIF) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

This circuit turns the servo motor and changes each damper position by receiving the signals from the air conditioning amplifier.

The air outlet damper servo switches the air outlet by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier.

When the AUTO switch is on, the air conditioning amplifier changes the mode between "FACE", "BI-LEVEL" and "FOOT" according to the temperature setting.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 64

Scheme 65

Scheme 66

1. READ VALUE OF TECHSTREAM (A/O DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% OK : When the target position is at the "FACE" (-10.0%), the actual opening angle is 19.0% or less. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. READ VALUE OF TECHSTREAM (A/O DAMP POS, TARG) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% OK : When the target position is at the "DEF" (110.0%), the actual opening angle is 81.0% or more. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT AIR OUTLET CONTROL SERVO MOTOR Remove the air outlet control servo motor. Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "FACE" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) FACE position 3.6 to 6.7 kohms Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turn to "DEF" position smoothly. Measure the resistance of the servo motor. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) DEF position 0.6 to 1.1 kohms NG : REPLACE AIR OUTLET CONTROL SERVO MOTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Disconnect the A16 servo connector. Disconnect the A8 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-16 (AOF) - A16-4 (MFACE) Below 1 ohms A8-24 (AOD) - A16-5 (MDEF) Below 1 ohms A8-16 (AOF) - Body ground 10 kohms or higher A8-24 (AOD) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The room humidity sensor detects room humidity. The voltage of the room humidity sensor changes in accordance with room humidity. The air conditioning amplifier reads changes in the room humidity sensor. The room humidity sensor is integrated with room temperature sensor.

DTC DETECTION CONDITION AND TROUBLE AREA

Scheme 67

Scheme 68

Scheme 69

Scheme 70

1. READ VALUE OF TECHSTREAM (HUMIDITY SENS) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the DATA LIST, and read the display on the Techstream. Air conditioning amplifier DATA LIST Item Measurement Item / Display (Range) Normal Condition Diagnostic Note HUMIDITY SENS Humidity sensor / min.: 0% max.: 100% Actual room humidity is displayed - OK : The displayed is as specified in the normal condition. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
2. CHECK AIR CONDITIONING AMPLIFIER (RH VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from the «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) ) B OK (Checking from the DTC) C B : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) C : REPLACE AIR CONDITIONING AMPLIFIER A : Go to next step
3. INSPECT ROOM TEMPERATURE SENSOR (HUMIDITY SENSOR) Remove the room temperature sensor. Measure the voltage of the sensor. Standard voltage: at 25°C (77°F) Humidity 40%: 1.61 to 2.24 V at 25°C (77°F) Humidity 60%: 2.26 to 2.66 V HINT: As the humidity increases, the voltage increases (see the graph). NG : REPLACE ROOM TEMPERATURE SENSOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (ROOM HUMIDITY SENSOR - AIR CONDITIONING AMPLIFIER) Disconnect the A9 sensor connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-9 (RH) - A9-3 (VO) Below 1 ohms A7-10 (S5RM) - A9-4 (S5) Below 1 ohms A7-9 (RH) - Body ground 10 kohms or higher A7-10 (S5RM) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

The A/C inverter monitors the power voltage from the main battery in the self circuit. It stops compressor control and outputs the DTC when the monitored voltage is outside the specified range.

The output DTC is memorized as previous trouble. Compressor control may not resume unless the power switch is turned OFF.

HINT

The hybrid control system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid control system first if any DTCs from those systems are output simultaneously.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 71

The high voltage is output from the A/C inverter to the electric inverter compressor for driving the motor. Compressor control is stopped and the DTC is output if there is an open or short to ground in the output circuit.

The output DTC is memorized as previous trouble. Compressor control remains stopped unless the past and current DTCs are cleared by Techstream.

HINT

The hybrid vehicle system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid system first if any DTCs from those systems are output simultaneously.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 72

Scheme 73

1. CHECK ELECTRIC INVERTER COMPRESSOR Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. Disconnect the C4 electric inverter compressor connector. Measure the resistance of the inverter compressor immediately after the compressor is stopped. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition C4-1 (OUT-W) - C4-2 (OUT-V) 0.5 to 0.8 ohms C4-1 (OUT-W) - C4-3 (OUT-U) 0.5 to 0.8 ohms C4-2 (OUT-V) - C4-3 (OUT-U) 0.5 to 0.8 ohms NG : REPLACE ELECTRIC INVERTER COMPRESSOR OK : REPLACE A/C INVERTER

The inverter activation signal is sent to the A/C inverter from the hybrid control ECU. Compressor control is stopped and the DTC is output if there is an open or short in the signal circuit.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 74

Scheme 75

1. CHECK DIAGNOSTIC TROUBLE CODE Check if DTCs for the hybrid control system are output using Techstream. OK : DTCs are not output in the hybrid control system. NG : GO TO HYBRID CONTROL SYSTEM OK : GO TO NEXT STEP
2. CHECK WIRE HARNESS (HYBRID CONTROL ECU - A/C INVERTER) Disconnect the H11 ECU connector. Disconnect the I11 inverter connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition H11-25 (STB) - I11-5 (STB) 0.5 to 0.8 ohms H11-25 (STB) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE A/C INVERTER

The A/C inverter in the A/C inverter monitors the cooling water temperature with the temperature sensor. It stops compressor control and outputs the DTC when the monitored temperature is outside specified range (too high or too low).

The hybrid system and the air conditioning system monitor the cooling water temperature separately. If DTCs referring to an inverter cooling system malfunction are output simultaneously, there may be trouble such as insufficient cooling water.

If DTCs are output only for the air conditioning system, there may be an open or short in the temperature sensor circuit in the inverter.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

The A/C inverter stops compressor control and outputs the DTC if the rotation load is too great or too small while controlling motor rotation in the A/C inverter.

HINT

Possible reasons could be as follows: Load is low when the refrigerant gas leaks, or load is too great when refrigerant gas is excessively charged, insufficient cooling performance due to condenser fan circuit trouble, or the compressor locked up.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 76

1. CHECK COOLER CONDENSER ASSEMBLY Turn the power switch OFF and ON (READY). Set the A/C temperature setting to "MAX. COOL" and the blower to "LO", and turn the A/C switch ON. Check operation of the condenser fan. OK : The condenser fan rotates. NG : INSPECT COOLING FAN SYSTEM OK : GO TO NEXT STEP
2. CHECK HFC-134A (R134A) Inspect refrigerant volume. Check the sight glass of the cooler unit refrigerant liquid pipe E. Set the vehicle according to the conditions below. ITEM AND CONTENT REFERENCE Item Condition All Doors Fully open Temperature Setting Max. COOL Blower Speed HI A/C ON Check the sight glass. PROBLEM SYMPTOMS CHART Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 2 No bubbles exist (DTC B1476 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty Check for gas leakage with gas leak detector and repair if necessary Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive Discharge refrigerant Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: *: Bubbles in the sight glass with room temperature higher than usual can be considered normal if cooling is sufficient. NG : CHARGE REFRIGERANT OK : REPLACE ELECTRIC INVERTER COMPRESSOR

The A/C inverter monitors the controlling power voltage in the self circuit. It stops compressor circuit and outputs the DTC when the monitored voltage is outside the specified range.

The output DTC is memorized as previous trouble. The compressor control may not resume unless the power switch is turned OFF.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

The hybrid control ECU and A/C inverter transmit information to one another via communication line.

Compressor control is stopped and the DTC is output if communication information is cut off or abnormal information occurs.

The output DTC is memorized as previous trouble.

DTC DETECTION CONDITION AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 77

Scheme 78

1. CHECK WIRE HARNESS (HYBRID CONTROL ECU - INVERTER WITH CONVERTER) Disconnect the H15 and H16 ECU connectors. Disconnect the I11 inverter connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition H15-24 (ETI) - I11-3 (TOINV) Below 1 ohms H16-14 (ITE) - I11-2 (TOECU) Below 1 ohms H16-17 (CLK) - I11-4 (CLK) Below 1 ohms H15-24 (ETI) - Body ground 10 kohms or higher H16-14 (ITE) - Body ground 10 kohms or higher H16-17 (CLK) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
2. CHECK DIAGNOSTIC TROUBLE CODE Connect the H15 and H16 ECU connectors. Connect the I11 inverter connector. Check if DTCs for the hybrid control system are output using Techstream. OK : DTCs are not output in the hybrid control system. NG : GO TO HYBRID CONTROL SYSTEM OK : REPLACE A/C INVERTER

The DTC is output if there is insulation trouble with the high-voltage circuits in the air conditioning system. Insulation trouble with the electric inverter compressor or A/C inverter may be the cause. Any oil other than ND-OIL 11 may have entered the refrigeration cycle.

The motor driven with high-voltage is built into the electrical compressor and is cooled directly with refrigerant. Compressor oil (ND-OIL 11) with high insulation performance is used because a leakage of electrical power may occur if regular compressor oil (ND-OIL 8) is used.

Note. Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing the DTC to be output. If other oil is accidentally used and a DTC is output, collect the oil in the refrigeration cycle into the compressor and replace it with ND-OIL 11 to increase the ND-OIL 11 ratio amount. Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing the DTC to be output.

DETECTION ITEM AND TROUBLE AREA

Note. The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone.

Scheme 79

Scheme 80

Scheme 81

1. CHECK A/C INVERTER Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. Disconnect the C4 inverter connector. Measure the resistance of the wire harness side connector immediately after the compressor is stopped. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition C4-1 (OUT-W) - Body ground 2 Mohms or higher C4-2 (OUT-V) - Body ground 2 Mohms or higher C4-3 (OUT-U) - Body ground 2 Mohms or higher NG : REPLACE A/C INVERTER OK : GO TO NEXT STEP
2. CHECK ELECTRIC INVERTER COMPRESSOR Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. Disconnect the C4 compressor connector. Measure the resistance of the connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition C4-1 - Body ground 2 Mohms or higher C4-2 - Body ground 2 Mohms or higher C4-3 - Body ground 2 Mohms or higher NG : REPLACE ELECTRIC INVERTER COMPRESSOR OK : GO TO NEXT STEP
3. CHECK ELECTRIC INVERTER COMPRESSOR Connect the electric inverter compressor connector. Install the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. Turn the power switch ON (IG). Set the A/C setting temperature to 25°C (77°F) and the blower switch LO. Then operate the compressor for 10 minutes to circulate the refrigerant cycle with refrigerant and collect as much compressor oil remaining in each component into the compressor as possible. HINT: Inspect with sufficient oil in the compressor since the insulation resistance of the compressor changes depending on the amount of oil in the compressor. Turn the power switch OFF, and leave the vehicle for a night to cool down the compressor's internal temperature. NOTE: Do not operate the compressor before inspection. HINT: Leave the vehicle until the compressor temperature decreases below ambient temperature. (As the compressor temperature decreases below the temperature of the condenser and evaporator, more oil can be stored in the compressor.) If there is significant difference in temperature between day and night time, it will take approximately 4 hours to cool down the compressor. Remove the service plug grip. Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. Disconnect the C4 compressor connector. Measure the resistance of the connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition C4-1 - Body ground 3 Mohms or higher C4-2 - Body ground 3 Mohms or higher C4-3 - Body ground 3 Mohms or higher NOTE: If the results are out of the specified range, replace the compressor without operating. NG : REPLACE ELECTRIC INVERTER COMPRESSOR OK : SYSTEM IS OK

Scheme 82

The blower motor is operated by signals from the air conditioning amplifier. Blower motor speed signals are transmitted by changes in the duty ratio.

Duty Ratio

The duty ratio is the ratio of the period of continuity in one cycle. For example, A is the period of continuity in one cycle, and B is the period of non-continuity.

The blower motor controller controls the blower motor speed.

The blower motor controller reads the signal from the air conditioning amplifier and controls rotation and speed.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

1. PERFORM ACTIVE TEST BY TECHSTREAM (BLOWER MOTOR) Connect the Techstream to DLC3. Turn the power switch ON (IG) and push the Techstream main switch ON. Select the item below in the ACTIVE TEST and then check that the relay operates. Air conditioning amplifier ACTIVE TEST DETAIL Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / min.: 0 max.: 31 - Result RESULT REFERENCE Result Proceed to NG (Blower motor does not operate) A NG (Blower motor operate but does not change speed) B OK C B : Go to step 6 C : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) A : Go to next step
2. INSPECT BLOWER W/ FAN MOTOR SUB-ASSEMBLY Remove the cooling unit motor w/ fan. Connect the battery's positive (+) lead to terminal 1 of blower motor and negative (-) lead to terminal 2. OK : Blower motor operates smoothly. NG : REPLACE BLOWER W/ FAN MOTOR SUBASSEMBLY OK : GO TO NEXT STEP
3. CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BATTERY) Disconnect the B3 controller connector. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
4. CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BODY GROUND) Disconnect the B3 controller connector. Measure the resistance of the wire harness side connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition B3-3 (GND) - Body ground Below 1 ohms NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
5. CHECK WIRE HARNESS (BLOWER MOTOR - BLOWER MOTOR CONTROLLER) Disconnect the B2 motor connector. Disconnect the B4 controller connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition B4-1 (M-) - B2-2 Below 1 ohms B4-2 (M+) - B2-1 Below 1 ohms B4-1 (M-) - Body ground 10 kohms or higher B4-2 (M+) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
6. CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - AIR CONDITIONING AMPLIFIER) Disconnect the B3 controller connector. Disconnect the A8 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-2 (BLW) - B3-2 (SI) Below 1 ohms A8-2 (BLW) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
7. CHECK BLOWER MOTOR CONTROLLER (BLW VOLTAGE) Disconnect the A8 amplifier connector. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG : REPLACE BLOWER MOTOR CONTROLLER OK : GO TO NEXT STEP
8. CHECK AIR CONDITIONING AMPLIFIER (BLW - BODY GROUND) Remove the air conditioning amplifier with its connectors still connected. Turn the power switch ON (IG). Turn the blower switch ON (Lo). Using an oscilloscope, measure the waveform of the amplifier. OK : Waveform is as shown in the illustration. ITEM AND CONTENT REFERENCE Item Content Tester Connection A8-2 (BLW) - Body ground Tool Setting 2 V/DIV., 500 msec./DIV. Condition Blower switch ON (Lo) HINT: Waveform varies depending on the blower switch setting. NG : REPLACE AIR CONDITIONING AMPLIFIER OK : REPLACE BLOWER MOTOR CONTROLLER

The heater relay is turned on by signals from the air conditioning amplifier. It supplies power to the blower motor controller.

Scheme 92

Scheme 93

Scheme 94

Scheme 95

1. INSPECT FUSE (GAUGE, HTR) Remove the GAUGE fuse from the driver side junction block. Remove the HTR H-fuse from the engine room junction block. Measure the resistance of the fuses. Standard resistance: Below 1 ohms NG : REPLACE FUSE OK : GO TO NEXT STEP
2. INSPECT HEATER RELAY (Marking: HTR) Remove the heater relay from the driver side junction block. Measure the resistance of the relay. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition 3 - 5 10 kohms or higher 3 - 5 Below 1 ohms (When battery voltage applied to terminals 1 and 2) 3 - 4 Below 1 ohms 3 - 5 10 kohms or higher (When battery voltage applied to terminals 1 and 2) NG : REPLACE HEATER RELAY OK : GO TO NEXT STEP
3. CHECK WIRE HARNESS (BATTERY - AIR CONDITIONING AMPLIFIER) Disconnect the A8 amplifier connector. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch ON (IG) 10 to 14 V NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
4. CHECK AIR CONDITIONING AMPLIFIER (HR VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch OFF Blower switch position ON Below 1 V A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position ON Below 1 V A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position OFF 10 to 14 V NG : REPLACE AIR CONDITIONING AMPLIFIER OK : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000)

The heater water pump sends engine coolant to the heater core while the engine is stopped to prevent heater effectiveness from becoming low.

Directed by the air conditioning amplifier, hybrid control ECU operates the water pump relay and drives the heater water pump.

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. INSPECT INTEGRATION RELAY (UNIT C: AC W/P) Remove the integration relay from the engine room junction block. NOTE: As the integration relay is connected to the relays and fuses in the other systems, remove it with the power switch OFF. (A DTC may be output if the power switch is ON (IG). Measure the resistance of the relay. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Terminal No. Specified Condition 3H-4 - 3H-5 10 kohms or higher 3H-4 - 3H-5 Below 1 ohms (When battery voltage applied to terminals 3H-5 and 3H-3) NG : REPLACE INTEGRATION RELAY OK : GO TO NEXT STEP
2. CHECK WIRE HARNESS (HYBRID CONTROL ECU - BATTERY) Install the integration relay. Disconnect the H16 ECU connectors. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Power switch ON (IG) 10 to 14 V NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
3. CHECK HYBRID CONTROL ECU (WP VOLTAGE) Measure the voltage of the connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Heater water pump not operated 10 to 14 V H16-5 (WP) - Body ground Heater water pump operated Below 1 V NG : REPLACE HYBRID CONTROL ECU OK : GO TO NEXT STEP
4. INSPECT HEATER WATER PUMP ASSEMBLY Remove the heater water pump. Connect positive (+) lead to terminal 1 of the heater water pump connector and negative (-) lead to terminal 2. OK : Heater water pump operates smoothly. NOTE: Complete operation within 10 seconds if there is no water in the heater water pump. NG : REPLACE HEATER WATER PUMP ASSEMBLY OK : REPAIR OR REPLACE HARNESS AND CONNECTOR

The PTC heater is installed in the radiator in the heater unit on the driver and passenger's FOOT sides and operates when cooling water temperature is low and normal heater effectiveness is insufficient.

The air conditioning amplifier switches the circuit in the PTC relay and operates the PTC heater when the operating conditions (cooling water temperature is below 55°C (131°F), setting temperature is MAX. HOT, air outlet damper position is FOOT or FOOT / DEF and blower switch in not OFF) are met.

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1. INSPECT FUSE (PS HTR, PTC HTR1, PTC HTR2, GAUGE) Remove the PS HTR H-fuse, PTC HTR1 and PTC HTR2 fuses from the engine room junction block. Remove the GAUGE fuse from the driver side junction block. Measure the resistance of the fuses. Standard resistance: Below 1 ohms NG : REPLACE FUSE OK : GO TO NEXT STEP
2. INSPECT PTC HEATER RELAY (Marking: PS HTR, PTC HTR 1, PTC HTR 2) Remove the PS HTR, PTC HTR 1 and PTC HTR 2 heater relays from the engine room No. 2 relay block. Measure the resistance of the relays. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition 3 - 5 10 kohms or higher 3 - 5 Below 1 ohms (When battery voltage applied to terminals 1 and 2) NG : REPLACE PTC HEATER RELAY OK : GO TO NEXT STEP
3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) Disconnect the A7 air conditioning amplifier connector. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (IG) 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (IG) 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (IG) 10 to 14 V NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : GO TO NEXT STEP
4. CHECK AIR CONDITIONING AMPLIFIER (PTC, HT-1, HT-2, VOLTAGE) Connect the connectors. Measure the voltage of the connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF --> LO (after 30 sec.) Below 1 V --> 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF --> LO (after 30 sec.) Below 1 V --> 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF --> LO (after 30 sec.) Below 1 V --> 10 to 14 V HINT: PTC operation may stop when the electric load on the vehicle is high. Perform the inspection under conditions with low electric load (such as with headlights turned OFF). Since the 2 PTC heaters are gradually turned to the ON position, perform the inspection 30 seconds after the blower switch is turned to the LO position. NG : REPLACE AIR CONDITIONING AMPLIFIER OK : GO TO NEXT STEP
5. INSPECT PTC HEATER Disconnect the connector from the PTC heater. Check the continuity between each terminal. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition P12-1 - P12-2 Continuity (0.5 kohms or higher) P12-3 - P12-4 Continuity (0.5 kohms or higher) NG : REPLACE PTC HEATER OK : REPAIR OR REPLACE HARNESS AND CONNECTOR

AUTO, TEMP UP (+), TEMP DOWN (-), Recirculation / Fresh, Fr. DEF and Rr. DEF switches are located on the steering pad switch.

The resistance of the steering pad switch changes in accordance with switch operation. The air conditioning amplifier outputs voltage to the steering pad switch and reads voltage changes according to the resistance changes with switch operation.

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1. CHECK AIR CONDITIONING AMPLIFIER (ST1, ST2 VOLTAGE) Remove the air conditioning with connectors still connected. Measure the voltage of the wire harness side connectors. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Fr. DEF switch ON Below 0.3 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Rr. DEF switch ON 0.8 to 1.5 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Recirculation/Fresh switch ON 2.0 to 2.9 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) AUTO switch ON Below 0.3 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP+ switch ON 0.8 to 1.5 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP- switch ON 2.0 to 2.9 V OK : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) NG : GO TO NEXT STEP
2. INSPECT STEERING PAD SWITCH LH Remove the steering pad switch LH. Measure the resistance of the connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition A2 (AC2) - B5 (AC1) Always 1,210 ohms A7 (EAC) - B6 (EAC) Always Below 1 ohms A3 (AC1) - B5 (AC1) Always Below 1 ohms A2 (AC2) - A7 (EAC) AUTO switch ON Below 1 ohms A2 (AC2) - A7 (EAC) TEMP + switch ON 300 ohms A2 (AC2) - A7 (EAC) TEMP - switch ON 1,210 ohms NG : REPLACE STEERING PAD SWITCH LH OK : GO TO NEXT STEP
3. INSPECT STEERING PAD SWITCH RH Remove the steering pad switch RH. Measure the resistance of the connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition 2 (AC1) -1 (EAC) Fr. DEF switch ON Below 1 ohms 2 (AC1) -1 (EAC) Rr. DEF switch ON 300 ohms 2 (AC1) -1 (EAC) Recirculation/Fresh switch ON 1,210 ohms NG : REPLACE STEERING PAD SWITCH RH OK : GO TO NEXT STEP
4. INSPECT STEERING PAD SWITCH ASSEMBLY Connect the steering pad switch RH and LH to the steering pad switch cable. Measure the resistance of the connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Condition Specified Condition 3 (AC1) - 7 (EAC) Fr. DEF switch ON Below 1 ohms 3 (AC1) - 7 (EAC) Rr. DEF switch ON 300 ohms 3 (AC1) - 7 (EAC) Recirculation/Fresh switch ON 1,210 ohms NG : REPLACE STEERING PAD SWITCH ASSEMBLY OK : GO TO NEXT STEP
5. INSPECT SPIRAL CABLE SUB-ASSEMBLY Remove the spiral cable. Measure the resistance of the connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition C12-3 (EAC) - 7 (EAC) Below 1 ohms C12-9 (AC2) - 2 (AC2) Below 1 ohms C12-10 (AC1) - 3 (AC1) Below 1 ohms NG : REPLACE SPIRAL CABLE SUB-ASSEMBLY OK : GO TO NEXT STEP
6. CHECK WIRE HARNESS (STEERING PAD SWITCH - AIR CONDITIONING AMPLIFIER) Disconnect the C12 steering pad connector. Disconnect the A7 amplifier connector. Measure the resistance of the wire harness side connectors. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A7-2 (ST1) - C12-10 (AC1) Below 1 ohms A7-15 (SGST) - C12-3 (EAC) Below 1 ohms A7-1 (ST2) - C12-9 (AC2) Below 1 ohms A7-2 (ST1) - Body ground 10 kohms or higher A7-15 (SGST) - Body ground 10 kohms or higher A7-1 (ST2) - Body ground 10 kohms or higher NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

This is the main power source supplied to the air conditioning amplifier when the power switch is turned ON (IG). The power source supplied is used for operating the air conditioning amplifier, servo motor, etc.

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1. INSPECT FUSE (A/C (HTR)) Remove the A/C (HTR) fuse from the driver side junction block. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG : REPLACE FUSE OK : GO TO NEXT STEP
2. CHECK AIR CONDITIONING AMPLIFIER (IG VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A8-5 (IG) - A8-1 (GND) Power switch ON (IG) 10 to 14 V NG : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) NG : GO TO NEXT STEP
3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Condition Specified Condition A8-5 (IG) - Body ground Power switch ON (IG) 10 to 14 V Measure the resistance of the wire harness side connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 ohms NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

This is the back-up power source circuit for the air conditioning amplifier. Power is supplied even when turning the power switch OFF and is used for diagnostic trouble code memory, etc.

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1. INSPECT FUSE (ECU-B) Remove the ECU-B fuse from the driver side junction block. Measure the resistance of the fuse. Standard resistance: Below 1 ohms NG : REPLACE FUSE OK : GO TO NEXT STEP
2. CHECK AIR CONDITIONING AMPLIFIER (+B VOLTAGE) Remove the air conditioning amplifier with connectors still connected. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V OK : PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN «PROBLEM SYMPTOMS TABLE»(ref-289870-S07489490512008070800000) NG : GO TO NEXT STEP
3. CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) Disconnect the A8 amplifier connector. Measure the voltage of the wire harness side connector. Standard voltage TERMINALS VOLTAGE SPECIFICATIONS Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V Measure the resistance of the wire harness side connector. Standard resistance TERMINALS RESISTANCE SPECIFICATIONS Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 ohms NG : REPAIR OR REPLACE HARNESS AND CONNECTOR OK : REPLACE AIR CONDITIONING AMPLIFIER

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1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET Check the sight glass of the cooler unit refrigerant liquid pipe E. Set the vehicle according to the conditions below. ITEM AND CONTENT REFERENCE Item Condition All doors Fully open Temperature setting MAX COLD Blower speed HI A/C switch ON Check the sight glass under these conditions. PROBLEM SYMPTOMS CHART Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 2 No bubbles exist (DTC 76 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty Check for gas leakage and repair if necessary Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive Discharge refrigerant Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: Bubbles in the sight glass with the room temperature 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. Gauge readings (Reference) Test conditions: Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) Blower speed control switch at "HI" position Temperature control switch at "MAX COLD" position A/C switch ON Fully open doors The refrigeration system functions normally 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 present in refrigeration system PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low-pressure side cycles between normal and vacuum Moisture in refrigerating system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. - Cooler dryer in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant Replace cooler dryer Remove moisture in cycle by repeatedly evacuating air Supply proper amount of new refrigerant Insufficient cooling PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure is low on both low and high-pressure sides Bubbles are continuously seen through sight glass Insufficient cooling performance Gas leakage in refrigeration system Insufficient refrigerant Refrigerant leaking Check for gas leakage and repair if necessary Supply proper amount of new refrigerant If the indicated pressure value is close to 0 when connected to the gauge, create a vacuum after inspecting and repairing location of leakage Poor circulation of refrigerant PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure low on both low and high-pressure sides Frost exists on pipe from cooler condenser to A/C unit Refrigerant flow is obstructed by dirt in cooler condenser core Cooler condenser core is clogged Replace cooler condenser core Refrigerant does not circulate PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Vacuum is indicated on low-pressure side and very low pressure is indicated on high-pressure side Frost or condensation is seen on piping on both sides of cooler condenser core or expansion valve Refrigerant flow is obstructed by moisture or dirt in refrigeration system Refrigerant flow obstructed by gas leaked from cooler expansion valve Refrigerant does not circulate Check expansion valve Clean out dirt in cooler expansion valve by blowing air Replace cooler condenser core Evacuate and charge new refrigerant For gas leakage from cooler expansion valve, replace cooler expansion valve Refrigerant overcharged or insufficient cooling of condenser PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure is too high on both low and high-pressure sides No air bubbles are seen through the sight glass when compressor speed decreases Excessive refrigerant Insufficient cooling of cooler condenser core Excessive refrigerant in cycle (excessive refrigerant is supplied) Insufficient cooling of cooler condenser core Clean cooler condenser core fins Check cooling fan with condenser fan motor operation If 1 and 2 normal, check the amount of refrigerant and supply proper amount of refrigerant Air present in refrigeration system PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure is too high on both low and high-pressure sides Low-pressure piping is too hot to touch Bubbles are seen through sight glass Air in system Air present in refrigeration system Insufficient vacuum purging Check compressor oil to see if it is dirty or insufficient Evacuate and charge new refrigerant Expansion valve malfunction PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure is too high on both low and high-pressure sides Frost or large amount of condensation on piping on low-pressure side Trouble in cooler expansion valve Excessive refrigerant in low pressure piping Cooler expansion valve is opened too wide Replace cooler expansion valve Defective compression in compressor PROBLEM SYMPTOMS CHART Symptoms Probable Cause Diagnosis Corrective Actions Pressure is too high on both low and high-pressure sides Pressure is too low on high-pressure side Internal leak in cooler compressor Compression failure Leakage from damaged valve or broken sliding parts Repair or replace compressor Gauge readings (Reference)

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM Turn the A/C switch on. Operate the A/C with the setting temperature at 25 °C (77°F) and the blower level at LO for 10 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 Perform vacuum purging using a vacuum pump. Charge refrigerant HFC-134a (R134a). Amount: 450 +-30 g (15.9 +-1.1 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) NOTE: Do not turn the A/C on before charging refrigerant as the cooler compressor does not work properly without any refrigerant. Operating without any refrigerant causes it to overheat. Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass. HINT: Prepare a service can to recharge the refrigerant if using the refrigerant gas collected with the Freon collection/recycling device because the collective rate of the device is approximately 90%.
3. WARM UP COMPRESSOR Turn the A/C switch on for at least 1 minute to warm up the compressor. NOTE: Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor.
4. INSPECT LEAKAGE OF REFRIGERANT After recharging the refrigerant gas, inspect leakage of refrigerant gas using a halogen leak detector. After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met. The ignition switch is OFF. The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up. Some refrigerant remains in the refrigerant system. The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm 2 ). Bring the gas leak detector close to the drain hose with the detector's power off. HINT: After the blower motor has stopped, leave the cooling unit as it is 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 a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

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1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-289870-S06283493382008070800000) )
2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY Check SST installation direction. SST 09870-00015 HINT: Set SST so that the stopper side is on the piping clamp lock side. Install SST on the piping clamp. Push down on SST with your thumb while holding the pipe with both hands. NOTE: Be careful not to bend the pipe. Pull SST until the stopper touches the pipe. Raise SST stopper and remove the piping clamp with SST from the pipe. Remove the piping clamp from SST. Disconnect the suction hose by hand or using a screwdriver. Remove the 2 O-rings from the suction hose. NOTE: Do not apply excessive force to the suction hose. Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering it.
3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) SST 09870-00025 HINT: Use the same procedures described for the suction hose.
4. DISCONNECT HEATER WATER HOSE B Slide the clip and disconnect the heater water hose B. NOTE: Do not apply excessive force to the water hose B. Prepare a drain pan or cloth for when the cooling water leaks.
5. DISCONNECT HEATER WATER HOSE A Slide the clip and disconnect the heater water hose A. NOTE: Do not apply excessive force to the water hose A. Prepare a drain pan or cloth for when the cooling water leaks.
6. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see «REMOVAL»(ref-289871-S38188274822008070800000) ).
7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see «REMOVAL»(ref-289871-S24621283232008070800000) ).
8. REMOVE NO. 3 AIR DUCT REAR Fold back the floor carpet. HINT: Fold back the floor carpet so that the No. 3 air duct rear can be removed. Detach the 10 claws and then remove the No. 3 air duct rear.
9. REMOVE NO. 3 HEATER TO REGISTER DUCT Remove the clip and No. 3 heater to register duct with the No. 2 side defroster nozzle duct.
10. REMOVE NO. 1 HEATER TO REGISTER DUCT Remove the No. 1 duct with the No. 1 side defroster nozzle duct.
11. REMOVE NO. 2 HEATER TO REGISTER DUCT
12. REMOVE DEFROSTER NOZZLE ASSEMBLY Remove the 2 clips. Detach the 3 claws and then remove the defroster nozzle.
13. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY
14. REMOVE ECM
15. REMOVE NETWORK GATEWAY ECU
16. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY Detach the clamp and disconnect the harness. Remove the 2 bolts, nut and instrument panel brace.
17. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY Remove the air conditioning amplifier (see «AIR CONDITIONING AMPLIFIER»(ref-289870-S26821117522008070800000) ).
18. REMOVE STEERING COLUMN ASSEMBLY Remove the steering column (see «REMOVAL»(ref-289864-S22159702112008070800000) ).
19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Disconnect each connector and remove each clamp. Disconnect the wire harness. Remove the 7 bolts, 2 nuts and then remove the instrument panel reinforcement with the air conditioner unit.
20. REMOVE AIR CONDITIONING UNIT ASSEMBLY Disconnect the 5 connectors. Detach the 9 clamps and disconnect the wire harness. Remove the bolt. Detach the clamp and disconnect the junction connector. Remove the 2 screws and air conditioning unit from the instrument panel reinforcement.

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1. REMOVE BLOWER ASSEMBLY Remove the 2 screws. Disengage the fittings with the air conditioner and then remove the blower.
2. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER Detach the 2 claws and remove the defroster nozzle lower.
3. REMOVE AIR MIX CONTROL SERVO MOTOR Remove the 2 screws and air mix control servo motor.
4. REMOVE AIR OUTLET CONTROL SERVO MOTOR Remove the 2 screws and disengage the claw. Detach the claw and remove the air outlet control servo motor.
5. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY Remove the 2 screws and expansion valve cover. Using a 4 mm hexagon wrench, remove the 2 hexagon bolts. Remove the air conditioning tube. Remove the 2 O-rings from the air conditioning tube assembly.
6. REMOVE COOLER EXPANSION VALVE Remove the cooler expansion valve from the No. 1 cooler evaporator.
7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY Detach the clamp and disconnect the evaporator temperature sensor connector. Detach the clamp and 2 claws, and remove the heater piping cover. Remove the 4 screws and 4 clamps. Remove the radiator heater unit from the air conditioner radiator. NOTE: Prepare a drain pan or cloth for when the cooling water leaks.
8. REMOVE NO. 1 AIR DUCT Remove the 2 screws and No. 1 air duct.
9. REMOVE QUICK HEATER ASSEMBLY Remove the 4 screws and quick heater.
10. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY Remove the 7 screws and No. 1 cooler evaporator from the heater case. Remove the 2 O-rings from the No. 1 cooler evaporator.
11. REMOVE EVAPORATOR TEMPERATURE SENSOR Detach the 2 claws and remove the evaporator temperature sensor.

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1. INSTALL EVAPORATOR TEMPERATURE SENSOR Install the evaporator temperature sensor and attach the 2 claws.
2. INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 O-rings to the No. 1 cooler evaporator. Compressor oil: ND-OIL 11 or equivalent NOTE: Do not use any compressor oil other than ND-OIL 11. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. Install the No. 1 cooler evaporator with the 7 screws.
3. INSTALL QUICK HEATER ASSEMBLY Install the quick heater with the 4 screws.
4. INSTALL NO. 1 AIR DUCT Install the No. 1 air duct with the 2 screws.
5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY Install the air conditioning radiator to the radiator heater unit. Install the 4 clamps and 4 screws. Attach the 2 claws and clamp to install the heater piping cover. Attach the clamp and connect the evaporator temperature sensor connector.
6. INSTALL COOLER EXPANSION VALVE Install the cooler expansion valve to the No. 1 cooler evaporator.
7. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 O-rings to the air conditioning tube assembly. Compressor oil: ND-OIL 11 or equivalent NOTE: Do not use any compressor oil other than ND-OIL 11. If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. Install the air conditioning tube to the No. 1 cooler evaporator, placing the cooler expansion valve between them. Using a 4 mm (0.16 in.) hexagon wrench, install the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) Install the expansion cover with the 2 screws.
8. INSTALL AIR OUTLET CONTROL SERVO MOTOR Install the air outlet control servo motor and attach the claw. Attach the claw and install the 2 screws.
9. INSTALL AIR MIX CONTROL SERVO MOTOR Install the air mix control servo motor with the 2 screws.
10. INSTALL DEFROSTER NOZZLE ASSEMBLY LOWER Install the defroster nozzle lower and attach the 2 claws.
11. INSTALL BLOWER ASSEMBLY Install the blower and then attach the fittings with the air conditioner. Install the 2 screws.

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1. INSTALL AIR CONDITIONING UNIT ASSEMBLY Install the air conditioning unit to the instrument panel reinforcement with the 2 screws. HINT: Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened. Attach the clamp to connect the junction connector. Install the bolt. Attach the 9 clamps to connect the instrument panel wire harness. Connect the 5 connectors.
2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY Install the instrument panel reinforcement with the 7 bolts. Install the 2 nuts to the air conditioning unit and temporarily tighten them. Connect each connector and install each clamp. Then connect the wire harness.
3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY Install the air conditioning amplifier (see «AIR CONDITIONING AMPLIFIER»(ref-289870-S26821117522008070800000) ).
4. INSTALL STEERING COLUMN ASSEMBLY Install the steering column (See «INSTALLATION»(ref-289864-S00120491412008070800000) ).
5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY Install the instrument panel brace with the 2 bolts and nut. Attach the clamp to connect the harness.
6. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY Fully tighten the air conditioning unit with the 2 nuts. NOTE: Tighten the nuts in the order indicated in the illustration.
7. INSTALL NETWORK GATEWAY ECU
8. INSTALL ECM
9. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY
10. INSTALL DEFROSTER NOZZLE ASSEMBLY Install the defroster nozzle and attach the 3 claws. Install the 2 clips.
11. INSTALL NO. 2 HEATER TO REGISTER DUCT
12. INSTALL NO. 1 HEATER TO REGISTER DUCT Install the duct with the No. 1 side defroster nozzle duct.
13. INSTALL NO. 3 HEATER TO REGISTER DUCT Install the clip and then the duct with the No. 2 side defroster nozzle duct.
14. INSTALL NO. 3 AIR DUCT REAR Attach the 10 claws to install the No. 3 air duct rear. Return the carpet to its original position.
15. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel lower (See «INSTALLATION»(ref-289871-S30577160482008070800000) ).
16. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag (see «INSTALLATION»(ref-289871-S39684456092008070800000) ).
17. CONNECT HEATER WATER HOSE A Connect the heater water hose A and slide the clip.
18. CONNECT HEATER WATER HOSE B Connect the heater water hose B and slide the clip.
19. CONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) Remove the attached vinyl tape from the pipe's disconnected part. Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the pipe's connecting part. NOTE: Do not use any compressor oil other than ND-OIL 11 (see page ). If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. Install the O-rings to the pipe. Insert the pipe joint into the cooler unit fitting hole securely. Using the piping clamp, connect the cooler unit refrigerant liquid pipe E. NOTE: Ensure that the piping clamp is securely engaged.
20. CONNECT SUCTION HOSE SUB-ASSEMBLY HINT: Use the same procedures described for the cooler unit refrigerant liquid pipe E.
21. INSPECT LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-289870-S06283493382008070800000) )
22. ADD ENGINE COOLANT (See «ON-VEHICLE INSPECTION»(ref-289901-S10570958782008070800000) )
23. CHECK FOR ENGINE COOLANT LEAKS (See «ON-VEHICLE INSPECTION»(ref-289901-S10570958782008070800000) )
24. WARM UP COMPRESSOR (See «REPLACEMENT»(ref-289870-S06283493382008070800000) )
25. INSPECT LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-289870-S06283493382008070800000) )
26. PERFORM CALIBRATION Perform calibration (see «CALIBRATION»(ref-289882-S08061411722008070800000) ).

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see «REMOVAL»(ref-289871-S38188274822008070800000) ).
2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see «REMOVAL»(ref-289871-S24621283232008070800000) ).
3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY
4. REMOVE ECM
5. REMOVE NETWORK GATEWAY ECU
6. REMOVE NO. 1 HEATER TO REGISTER DUCT
7. REMOVE AIR DUCT SUB-ASSEMBLY Remove the 2 screws and air duct.
8. REMOVE BLOWER ASSEMBLY Disconnect the 10 connectors. Detach the 4 clamps and disconnect the wire harness. Remove the 3 screws, nut and blower.

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

1. REMOVE AIR INLET SERVO MOTOR Remove the 3 screws and air inlet servo motor.
2. REMOVE BLOWER MOTOR CONTROL Disconnect the connector. Remove the 2 screws and blower motor control.
3. REMOVE NO. 2 COOLER WIRING HARNESS SUBASSEMBLY Remove the 5 screws and blower motor cover. Remove the No. 2 cooler wiring harness from the blower with fan motor.
4. REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY Remove the 3 screws and blower with fan motor.
5. REMOVE CLEAN AIR FILTER Detach the 2 claws and then remove the air filter cover plate with the clean air filter. Remove the clean air filter from the air filter cover plate.

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

1. INSTALL CLEAN AIR FILTER Install the clean air filter to the air filter cover plate. Attach the 2 claws to install the air filter cover.
2. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY Install the blower with fan motor with the 3 screws.
3. INSTALL NO. 2 COOLER WIRING HARNESS SUBASSEMBLY Install the No. 2 cooler wiring harness to the blower with fan motor. Install the blower motor cover with the 5 screws.
4. INSTALL BLOWER MOTOR CONTROL Install the blower motor control with the 2 screws. Connect the connector.
5. INSTALL AIR INLET SERVO MOTOR Install the air inlet servo motor with the 3 screws.

Scheme 204

Scheme 205

1. INSTALL BLOWER ASSEMBLY Install the blower with the 3 screws. HINT: Use a repair screw (part No. 90159-70003) if the screw (A) removed before cannot be tightened. Attach the 4 clamps to connect the wire harness. Connect the connectors. Install the 10 connectors of the transponder key ECU.
2. INSTALL AIR DUCT SUB-ASSEMBLY Install the air duct with the 2 screws.
3. INSTALL NO. 1 HEATER TO REGISTER DUCT
4. INSTALL NETWORK GATEWAY ECU
5. INSTALL ECU
6. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY
7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel sub-assembly lower (see «INSTALLATION»(ref-289871-S30577160482008070800000) ).
8. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assembly (see «INSTALLATION»(ref-289871-S39684456092008070800000) ).