Air Conditioning: Diagnosis Toyota RAV4 III

HOW TO PROCEED WITH TROUBLESHOOTING

HINT

1. Use these procedures to troubleshoot the air conditioning system.
2. *: Use the intelligent tester.

1. VEHICLE BROUGHT TO WORKSHOP
2. CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK
3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding.
4. CHECK CAN COMMUNICATION SYSTEM* Use the intelligent tester to check if the CAN communication system is functioning. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B: Go to «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000) A: GO TO NEXT STEP.
5. CHECK DTC OR CHECK SENSOR CHECK CODE THROUGH PANEL DIAGNOSIS* Check DTCs or sensor check codes. Write down the DTCs or sensor check codes. Clear the DTCs or sensor check codes. Check whether the DTCs or sensor check codes recur. Reproduce the problem symptoms in accordance with the DTCs or sensor check codes that were written down, and check whether the DTCs or sensor check codes recur. HINT: Refer to «DIAGNOSTIC TROUBLE CODE CHART»(ref-265087-S34560590442007092000000) when any DTCs or sensor check codes are output. Result RESULT REFERENCE Result Proceed to DTC or sensor check code is not output A DTC or sensor check code is output B B: Go to step 8 A: GO TO NEXT STEP.
6. REFER TO «PROBLEM SYMPTOMS TABLE»(ref-265087-S41324774392007092000000) . Result RESULT REFERENCE Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B: Go to step 8 A: GO TO NEXT STEP.
7. OVERALL ANALYSIS AND TROUBLESHOOTING* «DATA LIST / ACTIVE TEST»(ref-265087-S14456009052007092000000) Panel diagnosis (indicator check) (see «CHECK MODE PROCEDURE»(ref-265087-S04618455462007092000000) ) Panel diagnosis (sensor check) (see «CHECK MODE PROCEDURE»(ref-265087-S04618455462007092000000) ) Panel diagnosis (actuator check) (see «CHECK MODE PROCEDURE»(ref-265087-S04618455462007092000000) ) «TERMINALS OF ECU»(ref-265087-S15889631752007092000000)
8. ADJUST, REPAIR OR REPLACE
9. CONFIRMATION TEST NEXT: END

PROBLEM SYMPTOMS TABLE

HINT

1. Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary.
2. Inspect the fuses and relays related to this system before inspecting the suspected areas below.

Air conditioning system

PROBLEM SYMPTOMS CHART

Scheme 218

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Scheme 224

1. CHECK AIR CONDITIONING AMPLIFIER Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. AIR CONDITIONING AMPLIFIER TERMINALS VOLTAGE AND RESISTANCE SPECIFICATION Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition B (E37-21) - GND (E37-14) R - W-B Power source (Back-up) Always 10 to 14 V SOL+ (E37-2) - GND (E37-14) GR - W-B A/C compressor operation signal Engine idling Pulse generation (Scheme 219)Blower switch LO A/C switch ON BLW (E37-23) - GND (E37-14) R - W-B Blower motor control signal Ignition switch ON Pulse generation (Scheme 220)Blower switch LO PRE (E37-9) - SG-2 (E37-13) L - G Air conditioning pressure sensor signal Refrigerant pressure: Normal 0.76 to 4.74 V PRE (E37-9) - SG-2 (E37-13) L - G Air conditioning pressure sensor signal Refrigerant pressure: Abnormal (less than 0.196 MPa [2.0 kgf/cm 2, 28 psi]) Below 0.76 V PRE (E37-9) - SG-2 (E37-13) L - G Air conditioning pressure sensor signal Refrigerant pressure: Abnormal (more than 3.14 MPa [32 kgf/cm 2, 455 psi]) 4.74 V or higher TSD (E37-33) - S5-4 (E37-31) L - LG Driver side solar sensor signal Ignition switch ON 0.8 to 4.3 V Solar sensor subject to electric light TSP (E37-32) - S5-4 (E37-31) P - LG Passenger side solar sensor signal Ignition switch ON 0.8 to 4.3 V Solar sensor subject to electric light TR (E37-29) - SG-1 (E37-34) CR - V Room temperature sensor signal Ignition switch ON 1.8 to 2.2 V Vehicle interior temperature: 25°C (77°F) SG-1 (E37-34) - Body ground V - Body ground Ground for room temperature sensor Always Below 1 GND (E37-14) - Body ground W-B - Body ground Ground for main power supply Always Below 1 IG+ (E37-1) - GND (E37-14) Y - W-B Power source (IG) Ignition switch ON 10 to 14 V S5-3 (E37-10) - GND (E37-14) B - W-B Power supply for pressure sensor Ignition switch ON 4.5 to 5.5 V CANH (E37-11) - GND (E37-14) V - W-B Hi-level CAN bus line Ignition switch ON Pulse generation (Scheme 221)CANL (E37-12) - GND (E37-14) W - W-B Lo-level CAN bus line Ignition switch ON Pulse generation (Scheme 222)SG-2 (E37-13) - Body ground G - Body ground Ground for pressure sensor Always Below 1 RDFG (E37-38) - GND (E37-14) B - W-B Rear defogger switch signal Ignition switch ON Rear defogger switch OFF 10 to 14 V RDFG (E37-38) - GND (E37-14) B - W-B Rear defogger switch signal Ignition switch ON Rear defogger switch ON Below 1 V LIN1 (E37-37) - GND (E37-14) B - W-B LIN communication signal Ignition switch ON Pulse generation BUS G (c1-2) - Body ground - Ground for BUS IC Always Below 1 BUS (c1-3) - BUS G (c1-2) - BUS IC control signal Ignition switch ON Pulse generation B BUS (c1-4) - BUS G (c1-2) - Power supply for BUS IC Ignition switch ON 11 to 13 V SGA (c1-5) - Body ground - Ground for evaporator temperature sensor Always Below 1 TEA (c1-6) - SGA (c1-5) - Evaporator temperature sensor signal Ignition switch ON 1.4 to 1.8 V Evaporator temperature: 15°C (59°F) LOCK (E37-8)* - SG-2 (E37-13) W - G Compressor lock sensor signal Ignition switch ON AUTO switch ON A/C switch ON Magnetic clutch ON Pulse generation (Scheme 223)MGC (E37-20)* - GND (E37-14) V - W-B Magnetic clutch relay signal Ignition switch ON Magnetic clutch OFF 10 to 14 V MGC (E37-20)* - GND (E37-14) V - W-B Magnetic clutch relay signal Ignition switch ON Magnetic clutch ON Below 1.5 V HINT: *: for 2GR-FE Using an oscilloscope, check waveform 1. A/C Compressor* operation signal ITEM AND CONTENT REFERENCE (WAVEFORM 1) Item Content Symbols (Terminal No.) SOL+ (E37-2) - GND (E37-14) Tool Setting 5 V/DIV., 500 msec./DIV. Condition Engine idling, Blower switch LO, A/C switch ON HINT: *: Compressor and pulley for 2AZ-FE, Compressor and magnetic clutch for 2GR-FE. Using an oscilloscope, check waveform 2. Blower motor control signal ITEM AND CONTENT REFERENCE (WAVEFORM 2) Item Content Symbols (Terminal No.) BLW (E37-23) - GND (E37-14) Tool Setting 1 V/DIV., 500 msec./DIV. Condition Ignition switch ON, Blower switch LO HINT: When the blower level is increased, the duty ratio changes accordingly. Using an oscilloscope, check waveform 3. CAN communication signal ITEM AND CONTENT REFERENCE (WAVEFORM 3) Item Content Symbols (Terminal No.) CANH (E37-11) - GND (E37-14) Tool Setting 1 V/DIV., 10 msec./DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Using an oscilloscope, check waveform 4. CAN communication signal ITEM AND CONTENT REFERENCE (WAVEFORM 4) Item Content Symbols (Terminal No.) CANL (E37-12) - GND (E37-14) Tool Setting 1 V/DIV., 10 msec./DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Using an oscilloscope, check waveform 5. Compressor lock sensor signal* ITEM AND CONTENT REFERENCE (WAVEFORM 5) Item Content Symbols (Terminal No.) LOCK (E37-8)* - SG-2 (E37-13) Tool Setting 500 mV/DIV., 20 msec./DIV. Condition Ignition switch ON, AUTO switch ON, A/C switch ON, Magnetic clutch ON HINT: *: for 2GR-FE
2. CHECK AIR CONDITIONING CONTROL Measure the voltage and resistance of the connectors. AIR CONDITIONING CONTROL TERMINALS VOLTAGE AND RESISTANCE SPECIFICATION Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition IG+ (E23-2) - GND (E23-7) L - W-B Power source (IG) Ignition switch ON 10 to 14 V GND (E23-7) - Body ground W-B - Body ground Ground for air conditioning control assembly Always Below 1 LIN1 (E23-11) - GND (E23-7) B - W-B LIN communication signal Ignition switch ON Pulse generation +B (E23-1) - GND (E23-7) R - W-B Power source (Back-up) Always 10 to 14 V ACC (E23-8) - GND (E23-7) GR - W-B ACC power supply Always Below 1

Scheme 225

1. DESCRIPTION Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform troubleshooting.
2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. DLC3 TERMINALS RESISTANCE SPECIFICATION Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 SG (5) - Body ground Signal ground Always Below 1 BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) CAN bus line Ignition switch LOCK (1) 54 to 69 CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch LOCK (1) 200 or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch LOCK (1) 1 M or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch LOCK (1) 200 or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch LOCK (1) 1 M or higher (1) Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.

Scheme 226

1. CHECK DTC Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details.
2. CLEAR DTC Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Clear the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details.

Scheme 227

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Scheme 231

Scheme 232

1. PANEL DIAGNOSIS (INDICATOR CHECK) Turn the ignition switch to LOCK. Turn the ignition switch ON while simultaneously pressing the A/C control AUTO switch and the REC/FRS switch. Check that all indicators and the display area are turned on and off 4 times in succession at 1 second intervals. HINT: After the indicator check is completed, the system automatically enters sensor check mode. Press the OFF switch to terminate the panel diagnosis.
2. PANEL DIAGNOSIS (SENSOR CHECK) Perform the indicator check. HINT: After the indicator check is completed, the system automatically enters sensor check mode. Press the REC/FRS switch to enter actuator check mode. After the actuator check is completed, press the AUTO switch to enter sensor check mode. NOTE: The sensor check must be performed again after the actuator check is completed because sensor check mode, which starts automatically after the indicator check, cannot fully detect malfunctions. Check the sensor check results displayed on the set temperature display. RESULT REFERENCE Results Code Display Present malfunction Blinks Past malfunction Blinks HINT: The illustration shows the display when code 21 is output. When 2 or more sensor check codes are detected, the codes are displayed in ascending numerical order. In cases with 2 or more codes, if they are difficult to read, press the DEF switch to activate the step operation and display them one by one. The codes are displayed in ascending numerical order as the DEF switch is pressed. When any sensor check codes are displayed, Refer to (see «DIAGNOSTIC TROUBLE CODE CHART»(ref-265087-S34560590442007092000000) ). Press the OFF switch to terminate the panel diagnosis. HINT: Pressing the REC/FRS switch returns the system to actuator check mode.
3. PANEL DIAGNOSIS (CLEAR SENSOR CHECK CODE) Inspect, and repair or replace the malfunctioning parts. Clear the sensor check codes. While pressing the DEF switch during sensor check mode, press the Rr DEF switch. HINT: Sensor check codes can be cleared by removing the ECU-B2 fuse from the engine room No. 2 relay block for more than 60 seconds. Perform the sensor check and confirm that normal code 00 is displayed.
4. PANEL DIAGNOSIS (ACTUATOR CHECK) Start the engine and warm it up. Perform the indicator check. When the sensor check is started after the indicator check, press the REC/FRS switch to start the actuator check. HINT: Perform the actuator check with the engine running. Check the temperature and blower levels by hand at each step while the actuator check proceeds from step 0 to 9 at 1 second intervals (continuous operation). HINT: Each step number is displayed on the set temperature display. To display step numbers one by one manually, press the DEF switch to activate the step operation. The step number changes each time the DEF switch is pressed. HINT: Each step number blinks at 1 second intervals during the step operation. The illustration shows the display when step number 5 is displayed. Press the OFF switch to terminate the panel diagnosis. HINT: Pressing the AUTO switch returns to sensor check mode. ACTUATOR INSPECTION CHART Step No. Blower Level Air Mix Damper Air Flow Vent Air Inlet Damper Cool Air Bypass Compressor 0 0 0% (MAX COLD) FACE FRESH - OFF 1 1 0% (MAX COLD) FACE FRESH - OFF 2 17 0% (MAX COLD) FACE RECIRCULATION / FRESH - ON 3 17 0% (MAX COLD) FACE RECIRCULATION - ON 4 17 50% BI-LEVEL RECIRCULATION - ON 5 17 50% BI-LEVEL RECIRCULATION - ON 6 17 50% FOOT FRESH - ON 7 17 100% (MAX HOT) FOOT FRESH - ON 8 17 100% (MAX HOT) FOOT/DEF FRESH - ON 9 31 100% (MAX HOT) DEF FRESH - ON

Scheme 233

1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Read the DATA LIST by following the prompts on the tester. Air conditioning amplifier DATA LIST DETAIL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / Min.: -6.5°C (20.3°F) Max.: 57.25°C (135.05°F) Actual room temperature is displayed Open circuit: -6.5°C (20.3°F) Short circuit: 57.25°C (135.05°F) 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 circuit: -23.3°C (-9.94°F) Short circuit: 65.95°C (150.71°F) SOLAR SENS-D Driver side solar sensor / Min.: 0, Max.: 255 Driver side temperature increases as brightness increases - SOLAR SENS-P Passenger side solar sensor / Min.: 0, Max.: 255 Passenger side temperature increases as brightness increases - COOLANT TEMP Engine coolant temperature / Min.: 1.3°C (34.34°F) Max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed after engine warmed up - SET TEMP-D Driver side set temperature / Min.: 0°C (32°F) Max.: 30°C (54°F) Driver side actual set temperature is displayed - SET TEMP-P Passenger side set temperature / Min.: 0°C (32°F) Max.: 30°C (54°F) Passenger side actual set temperature is displayed - ESTIMATE TEMP-D Driver side estimated temperature / Min.: -358.4°C (-613.12°F) Max.: 358.4°C (677.12°F) Driver side estimated temperature is displayed - ESTIMATE TEMP-P Passenger side estimated temperature / Min.: -358.4°C (-613.12°F) Max.: 358.4°C (677.12°F) Passenger side estimated temperature is displayed - BLOWER LEVEL Blower motor speed level / Min.: 0, Max.: 31 Increases in range between 0 and 31 as blower motor speed increases - AMBI TEMP Adjusted ambient temperature / Min.: -30.8°C (-23.44°F) Max.: 50.8°C (123.44°F) - - AIR MIX PULSE-D Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed - AIR MIX PULSE-P Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed - AIR OUT PULSE Air outlet servo motor target / Min.: 0, Max.: 255 Customized value displayed - A/I DAMP PLS Air inlet damper target pulse / Min.: 0, Max.: 255 Customized value displayed - EVAP FIN TEMP Evaporator temperature sensor / Min.: -29.7°C (-21.46°F) Max.: 59.6°C (139.28°F) Actual evaporator temperature is displayed Open circuit: -29.7°C (-21.46°F) Short circuit: 59.6°C (139.28°F) REG PRESS SENS Regulator pressure sensor / Min.: 0 MPaG Max.: 3.187 MPaG Actual regulator pressure is displayed - REG CTRL CURRNT Regulator control current / Min.: 0 A Max.: 0.997 A Value changes between 0 A and 0.997 A in accordance with compressor and magnetic clutch operation - AIR INLET MODE Air inlet mode / AUTO, MANUAL Customized value displayed - COMPRESSOR MODE Compressor mode / AUTO, MANUAL Customized value displayed - COMPRS/DEF MODE Compressor / DEF Mode / LINK, NORMAL Customized value displayed - EVAP CTRL Evaporator Control / AUTO, MANUAL Customized value displayed - AUTO BLOW UP Foot / DEF automatic blow up function / ON, OFF Customized value displayed - FOOT/DEF MODE Foot / DEF auto mode / ON, OFF Customized value displayed - SET TEMP SHIFT Shift set temperature / +2 C, +1 C, NORMAL, -1 C, -2 C Customized value displayed - DESTINATION Destination / DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Destinations displayed - #CODES Number of trouble codes / Min.: 0, Max.: 255 Number of DTCs displayed
2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Perform the ACTIVE TEST by following the prompts on the tester. Air conditioning amplifier ACTIVE TEST DETAIL Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / Min.: 0, Max.: 31 - A/C COMPRESSOR*1 A/C Compressor OFF, ON - A/C MAG CLUTCH*2 Magnetic clutch relay / OFF, ON Operating sound can be heard DEFOGGER RLY-R Defogger relay (Rear) / OFF, ON - AIR MIX PULSE Air mix servo motor pulse / Min.: 0, Max.: 255 - AIR MIX PULSE-P Air mix servo motor pulse (P side) / Min.: 0, Max.: 255 - AIR OUT PULSE Air outlet servo motor pulse / Min.: 0, Max.: 255 - A/I DAMP PLS Air inlet damper target pulse / Min.: 0, Max.: 255 - HINT: *1: for 2AZ-FE *2: for 2GR-FE

DIAGNOSTIC TROUBLE CODE CHART

HINT

When the air conditioning system functions properly, DTC B1400/00 is output.

Air conditioning system

DIAGNOSTIC TROUBLE CODE CHART

HINT

*1: DTC B1422/22 (Compressor Lock Sensor Circuit) is indicated only for a currently occurring malfunction for 2GR-FE.

To confirm DTC B1422/22, perform the following steps

1. With the ignition switch ON, enter the DTC check mode.
2. Press the R/F (Recirculation/Fresh) switch to enter actuator check mode, and set the operation to Step No. 3.
3. Press the AUTO switch to return to DTC check mode.
4. The DTC is displayed after approximately 3 seconds.

*2: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE

INSPECTION PROCEDURE

1. READ VALUE OF INTELLIGENT TESTER (AIR MIX PULSE-P) Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester main switch ON. Select the items below in the DATA LIST, and read the value displayed on the intelligent tester. Air conditioning amplifier DATA LIST DETAIL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-P Passenger side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed - OK : The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: GO TO NEXT STEP.
2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK : Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK

1. READ VALUE OF INTELLIGENT TESTER (A/I DAMP TARG PLS) Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester main switch ON. Select the items below in the DATA LIST, and read the value displayed on the intelligent tester. Air conditioning amplifier DATA LIST DETAIL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP PLS Air inlet damper target pulse / Min.: 0, Max.: 255 Customized value displayed - OK : The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: GO TO NEXT STEP.
2. REPLACE DAMPER SERVO SUB-ASSEMBLY HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK : Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK

1. READ VALUE OF INTELLIGENT TESTER (AIR OUT PULSE) Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester main switch ON. Select the items below in the DATA LIST, and read the value displayed on the intelligent tester. Air conditioning amplifier DATA LIST DETAIL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR OUT PULSE Air outlet servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed - OK : The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: GO TO NEXT STEP.
2. REPLACE MODE DAMPER SERVO SUB-ASSEMBLY HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK : Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS ASSEMBLY OK: SYSTEM IS OK

1. READ VALUE OF INTELLIGENT TESTER (AIR MIX SERVO TARG PULSE (D)) Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester main switch ON. Select the items below in the DATA LIST, and read the value displayed on the intelligent tester. Air conditioning amplifier DATA LIST DETAIL Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AIR MIX PULSE-D Driver side air mix servo motor target pulse / Min.: 0, Max.: 255 Customized value displayed - OK : The display is as specified in the normal condition column. Result RESULT REFERENCE Result Proceed to NG A OK (Checking from PROBLEM SYMPTOMS TABLE) B OK (Checking from DTC) C B: PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C: REPLACE AIR CONDITIONING AMPLIFIER A: GO TO NEXT STEP.
2. REPLACE AIR MIX CONTROL SERVO MOTOR HINT: Since the servo motor cannot be tested when it is removed from the vehicle, replace the servo motor with a normal one and check that the condition returns to normal. OK : Same problem does not occur. NG: REPAIR OR REPLACE AIR CONDITIONING HARNESS OK: SYSTEM IS OK

1. CHECK DTC Clear the DTC (see «CHECK MODE PROCEDURE»(ref-265087-S04618455462007092000000) ). Read the DTC (see «CHECK MODE PROCEDURE»(ref-265087-S04618455462007092000000) ). Result RESULT REFERENCE Result Proceed to DTC (B1499/99) is output A (see «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000) ) DTC (B1499/99) is not output B B: SYSTEM IS OK A: Go to «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000)

HINT

1. Use these procedures to troubleshoot the air conditioning system.
2. *: Use the intelligent tester.

1. VEHICLE BROUGHT TO WORKSHOP
2. CUSTOMER PROBLEM ANALYSIS AND SYMPTOM CHECK
3. INSPECT BATTERY VOLTAGE Standard voltage: 11 to 14 V If the voltage is below 11 V, recharge or replace the battery before proceeding.
4. CHECK CAN COMMUNICATION SYSTEM* Use the intelligent tester to check if the CAN communication system is functioning. Result RESULT REFERENCE Result Proceed to CAN DTC is not output A CAN DTC is output B B: Go to «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000) A: GO TO NEXT STEP.
5. CHECK DTC* Check for DTCs and write down any DTCs that are output. Clear the DTCs. Recheck for DTCs. Based on the DTCs output above, try to cause output of the air conditioning system DTC by simulating the operation indicated by the DTC. Result RESULT REFERENCE Result Proceed to DTC is not output A DTC is output B B: Go to step 8 A: GO TO NEXT STEP.
6. REFER TO «PROBLEM SYMPTOMS TABLE»(ref-265087-S41324774392007092000000) . Result RESULT REFERENCE Result Proceed to Fault is not listed in problem symptoms table A Fault is listed in problem symptoms table B B: Go to step 8 A: GO TO NEXT STEP.
7. OVERALL ANALYSIS AND TROUBLESHOOTING* «DATA LIST / ACTIVE TEST»(ref-265087-S12689001982007092000000) «TERMINALS OF ECU»(ref-265087-S00584358842007092000000)
8. ADJUST, REPAIR OR REPLACE
9. CONFIRMATION TEST END

HINT

1. Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary.
2. Inspect the fuses and relays related to this system before inspecting the suspected areas below.

Air conditioning system

PROBLEM SYMPTOMS CHART

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Scheme 237

Scheme 238

1. CHECK AIR CONDITIONING AMPLIFIER Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. AIR CONDITIONING AMPLIFIER ECU TERMINALS VOLTAGE AND RESISTANCE SPECIFICATION Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition S5-3 (E36-7) - GND (E36-24) B - W-B Power supply for pressure sensor Ignition switch ON 4.5 to 5.5 V CANH (E36-8) - GND (E36-24) V - W-B Hi-level CAN bus line Ignition switch ON Pulse generation (Scheme 235)CANL (E36-9) - GND (E36-24) W - W-B Lo-level CAN bus line Ignition switch ON Pulse generation (Scheme 236)SG-3 (E36-23) - Body ground B - Body ground Ground for evaporator temperature sensor Always Below 1 PRE (E36-12) - SG-2 (E36-10) L - G Air conditioning pressure sensor signal Refrigerant pressure: normal 0.76 to 4.74 V PRE (E36-12) - SG-2 (E36-10) L - G Air conditioning pressure sensor signal Refrigerant pressure: Abnormal (less than 0.196 MPa [2.0 kgf/cm 2, 28 psi] Below 0.76 V PRE (E36-12) - SG-2 (E36-10) L - G Air conditioning pressure sensor signal Refrigerant pressure: Abnormal (more than 3.14 MPa [32 kgf/cm 2, 455 psi]) 4.74 V or more SG-2 (E36-10) - Body ground B - Body ground Ground for pressure sensor Always Below 1 SOL+ (E36-13) - GND (E36-24) GR - W-B A/C compressor operation signal Engine idling Pulse generation (Scheme 237)Heater control (blower switch): 1 A/C switch ON IG+ (E36-14) - GND (E36-24) Y - W-B Power source (IG) Ignition switch ON 10 to 14 V SBLW (E36-21) - GND (E36-24) GR - W-B Blower motor ON signal Ignition switch ON 10 to 14 V --> Below 1 V Heater control (blower switch): 0 --> 1 TE (E36-22) - SG-3 (E36-23) W - B Evaporator temperature sensor signal Ignition switch ON 1 to 1.3 V Temperature near evaporator: 15°C (59°F) GND (E36-24) - Body ground W-B - Body ground Ground for main power supply Always Below 1 A/C (E36-27) - GND (E36-24) P - W-B A/C switch signal Ignition switch ON Below 1 V --> 10 to 14 V A/C switch OFF --> ON LED (E36-28) - Body ground GR - Body ground A/C switch indicator signal Engine idling 10 to 14 V --> Below 4 V A/C switch ON Heater control (blower switch): 0 --> 1 LOCK (E36-3)* - SG-2 (E36-10) W - G Compressor lock sensor signal Ignition switch ON A/C switch ON Magnetic clutch ON Pulse generation (Scheme 238)MGC (E36-15)* - GND (E36-24) V - W-B Magnetic clutch relay signal Ignition switch ON Magnetic clutch OFF 10 to 14 V MGC (E36-15)* - GND (E36-24) W - B Magnetic clutch relay signal Ignition switch ON Magnetic clutch ON Below 1 V HINT: *: for 2GR-FE Using an oscilloscope, check WAVEFORM 1. CAN communication signal ITEM AND CONTENT REFERENCE (WAVEFORM 1) Item Content Symbols (Terminal No.) CANH (E36-8) - GND (E36-24) Tool Setting 1 V/DIV., 10 msec./DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Using an oscilloscope, check WAVEFORM 2. CAN communication signal ITEM AND CONTENT REFERENCE (WAVEFORM 2) Item Content Symbols (Terminal No.) CANL (E36-9) - GND (E36-24) Tool Setting 1 V/DIV., 10 msec./DIV. Condition Ignition switch ON HINT: The waveform varies depending on the CAN communication signal. Using an oscilloscope, check WAVEFORM 3. A/C Compressor* operation signal ITEM AND CONTENT REFERENCE (WAVEFORM 3) Item Content Symbols (Terminal No.) SOL+ (E36-13) - GND (E36-24) Tool Setting 5 V/DIV., 500 msec./DIV. Condition Engine idling, Blower switch LO, A/C switch ON HINT: *: Compressor and pulley for 2AZ-FE, compressor and magnetic clutch for 2GR-FE Using an oscilloscope, check WAVEFORM 4. Compressor lock sensor signal* ITEM AND CONTENT REFERENCE (WAVEFORM 4) Item Content Symbols (Terminal No.) LOCK (E36-3)* - SG-2 (E36-10) Tool Setting 500 mV/DIV., 20 msec./DIV. Condition Ignition switch ON, A/C switch ON, Magnetic clutch ON HINT: *: for 2GR-FE

Scheme 239

1. DESCRIPTION Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform troubleshooting.
2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. DLC3 TERMINALS VOLTAGE AND RESISTANCE SPECIFICATION Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG(5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1 SG (5) - Body ground Signal ground Always Below 1 BAT (16) - Body ground Battery positive Always 10 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Ignition switch LOCK* 54 to 69 CANH (6) - CG (4) HIGH-level CAN bus line Ignition switch LOCK* 200 or higher CANH (6) - BAT (16) HIGH-level CAN bus line Ignition switch LOCK: Go to next step* 1 M or higher CANL (14) - CG (4) LOW-level CAN bus line Ignition switch LOCK* 200 or higher CANL (14) - BAT (16) LOW-level CAN bus line Ignition switch LOCK* 1 M or higher If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. NOTE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the ignition switch, other switches or doors. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the ignition switch ON and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual.

Scheme 240

1. CHECK DTC Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details.
2. CLEAR DTC Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Clear the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details.

Scheme 241

1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Read the DATA LIST by following the prompts on the tester. Air conditioning amplifier DATA LIST DETAIL 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 circuit: -23.3°C (-9.94°F) Short circuit: 65.95°C (150.71°F) COOLANT TEMP Engine coolant temperature / Min.: 1.3°C (34.34°F) Max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed after engine warmed up - AMBI TEMP Adjusted ambient temperature / Min.: -30.8°C (-23.44°F) Max.: 50.8°C (123.44°F) - - EVAP FIN TEMP Evaporator temperature sensor / Min.: -29.7°C (-21.46°F) Max.: 59.6°C (139.28°F) Actual evaporator temperature is displayed Open circuit: -29.7°C (-21.46°F) Short circuit: 59.6°C (139.28°F) REG PRESS SENS Regulator pressure sensor / Min.: 0 MPaG Max.: 3.187 MPaG Actual regulator pressure is displayed - REG CTRL CURRNT Regulator control current / Min.: 0 A Max.: 0.997 A Value changes between 0 A and 0.997 A in accordance with compressor and magnetic clutch operation - DESTINATION Destination / DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Destinations displayed - #CODES Number of trouble codes / Min.: 0, Max.: 255 Number of DTCs displayed
2. PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. Connect the intelligent tester (with CAN VIM) to the DLC3. Turn the ignition switch ON and turn the intelligent tester ON. Perform the ACTIVE TEST by following the prompts on the tester. Air conditioning amplifier ACTIVE TEST DETAIL Item Test Details / Display (Range) Diagnostic Note A/C COMPRESSOR*1 A/C Compressor OFF, ON - A/C MAG CLUTCH*2 Magnetic clutch relay / OFF, ON Operating sound can be heard HINT: *1: for 2AZ-FE *2: for 2GR-FE

HINT

When the air conditioning system functions properly, DTC B1400/00 is output.

Air Conditioning system

DIAGNOSTIC TROUBLE CODE CHART

HINT

*1: DTC B1422/22 (Compressor Lock Sensor Circuit) is indicated only for a currently occurring malfunction for 2GR-FE.

*2: Compressor and Pulley for 2AZ-FE, Compressor and Magnetic Clutch for 2GR-FE

1. CHECK DTC Clear the DTC (see «DTC CHECK / CLEAR»(ref-265087-S33552389282007092000000) ). Read the DTC (see «DTC CHECK / CLEAR»(ref-265087-S33552389282007092000000) ). Result RESULT REFERENCE Result Proceed to DTC (B1499/99) is output A (see «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000) ) DTC (B1499/99) is not output B B: SYSTEM IS OK A: Go to «CAN COMMUNICATION SYSTEM»(ref-265056-S25724441792007092000000)

ON-VEHICLE INSPECTION

1. INSPECT COOLER CONDENSER ASSEMBLY If the fins of the cooler condenser are dirty, clean them with water. Dry the fins with compressed air. NOTE: Do not damage the fins of the condenser. If a fin of the cooler condenser is bent, straighten it using a screwdriver or pliers.
2. CHECK CONDENSER FOR LEAKAGE OF REFRIGERANT Using a halogen leak detector, check the pipe joints for gas leakage. If gas leakage is detected in a joint, check the torque of the joint.

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE FRONT BUMPER COVER Remove front bumper cover (see «REMOVAL»(ref-265092-S20173643722007092000000) ).
4. DISCONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the bolt and disconnect the cooler refrigerant discharge hose from the cooler condenser. Remove the O-ring from the cooler refrigerant discharge hose. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
5. DISCONNECT COOLER REFRIGERANT LIQUID PIPE Remove the bolt and disconnect the cooler refrigerant liquid pipe from the cooler condenser. Remove the O-ring from the cooler refrigerant liquid pipe. NOTE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering them.
6. REMOVE RADIATOR SUPPORT UPPER BRACKET Remove the 2 bolts and 2 brackets.
7. REMOVE NO. 2 FAN SHROUD Remove the 2 bolts and fan shroud.
8. REMOVE COOLER CONDENSER ASSEMBLY Remove the cooler condenser.
9. REMOVE COOLER DRYER Using a 14 mm socket hexagon wrench, remove the cap from the modulator. Remove the O-ring from the cap. Using pliers, remove the cooler dryer.

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

1. INSTALL COOLER DRYER Using pliers, install the cooler dryer. Apply a sufficient amount of compressor oil to the contact surfaces of a new O-ring and the cap. Compressor oil: ND-OIL 8 or equivalent Install the O-ring to the cap. Using a 14 mm socket hexagon wrench, install the cap to the modulator. Torque: 2.9 N*m (29 kgf*cm, 25 in.*lbf)
2. INSTALL COOLER CONDENSER ASSEMBLY Install the cooler condenser.
3. INSTALL NO. 2 FAN SHROUD Install the fan shroud with the 2 bolts. Torque: 10.5 N*m (107 kgf*cm, 8 ft.*lbf)
4. INSTALL RADIATOR SUPPORT UPPER BRACKET Install the 2 brackets with the 2 bolts. Torque: 45 N*m (459 kgf*cm, 33 ft.*lbf)
5. INSTALL COOLER REFRIGERANT LIQUID PIPE Remove the attached vinyl tape from the pipe and the connecting part of the cooler condenser. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the pipe joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the cooler refrigerant liquid pipe. Install the cooler refrigerant liquid pipe on the cooler condenser with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
6. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE Remove the attached vinyl tape from the hose and the connecting part of the cooler condenser. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint. Compressor oil: ND-OIL 8 or equivalent Install the O-ring on the cooler refrigerant discharge hose. Install the cooler refrigerant discharge hose on the cooler condenser with the bolt. Torque: 9.8 N*m (100 kgf*cm, 7 ft.*lbf)
7. ADJUST HOOD SUB-ASSEMBLY (See «ADJUSTMENT»(ref-265086-S26898599612007092000000) )
8. INSTALL FRONT BUMPER COVER Install the front bumper cover (see «FRONT BUMPER»(ref-265092-S26759249342007092000000) ).
9. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
10. CHARGE REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
11. WARM UP ENGINE (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )
12. CHECK FOR LEAKAGE OF REFRIGERANT (See «REPLACEMENT»(ref-265087-S42514689952007092000000) )

Scheme 258

Scheme 259

1. REMOVE LOWER INSTRUMENT PANEL Remove the lower instrument panel (see REMOVAL under «LOWER INSTRUMENT PANEL»(ref-265064-S41277272842007092000000) ).
2. REMOVE ROOM TEMPERATURE SENSOR Disconnect the duct. Disconnect the connector. Detach the claws and remove the sensor.

Scheme 260

1. INSPECT ROOM TEMPERATURE SENSOR Measure the resistance of the sensor. Standard resistance TERMINALS RESISTANCE SPECIFICATION Tester Connection Condition Specified Condition 1 - 2 10°C (50°F) 3.00 to 3.73 k 1 - 2 15°C (59°F) 2.45 to 2.88 k 1 - 2 20°C (68°F) 1.95 to 2.30 k 1 - 2 25°C (77°F) 1.60 to 1.80 k 1 - 2 30°C (86°F) 1.28 to 1.47 k 1 - 2 35°C (95°F) 1.00 to 1.22 k 1 - 2 40°C (104°F) 0.80 to 1.00 k 1 - 2 45°C (113°F) 0.65 to 0.85 k 1 - 2 50°C (122°F) 0.50 to 0.70 k 1 - 2 55°C (131°F) 0.44 to 0.60 k 1 - 2 60°C (140°F) 0.36 to 0.50 k NOTE: Touching the sensor even slightly may change the resistance value. Hold the connector of the sensor. When measuring the resistance, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (Scheme 260) If the result is not as specified, replace the room temperature sensor.