HEATING Subject Page HEATING 333 Bleeding Air From Heater Core 333 Heater Control Switch B 333 Remove 333 Install. 334 Heater Unit . 334 Remove ... 334 Install .. : 335 Heater Fan Motor Assembly 335 Remove 335 Install. 335 PROBLEM SOLVING AND DIAGNOSIS ..... 336 AIR CONDITIONING .. 336 GENERAL INFORMATION . 336 Refrigerant Circuit 336 SERVICE OPERATIONS Compressor Belt Tension & Adjustment 336 Adjust... 4 337 Compressor. 337 Refrigerant (A/C) Lines 337 Remove 337 Install 337 Condenser 338 Remove . 338 Install 338 Air-conditioner Controls .. 338 PROBLEM SOLVING & DIAGNOSIS snnone 338 Heater Vacuum Hosing Diagram. 339 Air Conditioning & Heater Wiring Diagrams 339 HEATING BLEEDING AIR FROMHEATER CORE 1. Disconnect the heater core outlet hose at the heater control valve connection. 2. Any trapped air should be allowed to flow out. Connect the hose to the heater control valve, when a continuous flow of coolant is obtained from the hose. & AIR CONDITIONING HEATER CONTROL SWITCH Heater Control §) Fan Switch Electrical Connections Fan Speed JAdjustments. ~~ Hed Adjustment Controls, Bo010 Remove 1. Disconnect the battery. 2, Remove the lower trim panel, by removing the three upper and three lower retaining screws. (HJ, HX & HZ Only- Remove the ash tray.) Per 3.HQ Only: From the right hand side air outlet assembly, disconnect the air ducting. 4. Remove the light switch knob, by depressing the release tab on top of the switch unit while pulling the knob outwards, also remove the cigarette lighter. 5. HQ Only: Remove the scre ing the instrument cluster facia and remove the facia. For further assistance look in appropriate section of this chapter. 6. Remove the screw retaining the control cable to the switch lever and remove cable. 7. Remove the screws retaining the control assembly to the instrument panel. 8. [fairconditioning is fitted, release the wiring loom retaining clips from the air duct (right hand side). 9. Disconnect the wiring connections, and vacuum hoses from the back of the assembly, it is advisable to label connections for easier installation. 10. Remove the control unit from vehicle. ret 333HEATING & AIR CONDITIONING and instrument compartment. 6. Remove the left hand side air outlet and then remove the centre air duct. 7. HJ, HX & HZ: Remove the lower left dash panel. (Also check “Instrument Panel”in “Body Chapter”) (a) Remove the glove box door by removing screws from hinges Install 1. Connect he heater /airconditioner wiringloom connectors and any vacuum hoses, insert assembly into position and replace the retaining screws. 2. airconditioning is fitted, fitthe wiring loom retainingclips to the air duct (right hand side). 3, Replace the control cable to the lever and tighten the screw retaining the control cable to the switch lever and remove _(b) Remove centre console as described earlier. cable. (©) Remove 6 screws at top of glove box compartment and 4. HQ Only: Replace the instrument cluster facia and either end of lower left dash panel. tighten retaining screws. For further assistance look in (d) Lift lower dash panel from vehicle. appropriate section of this chapter. 8. Remove the screws retaining the distribution duct to the 5. Replace the light switch knob, by pushing the switch into heater housing, then remove the distribution duct. the unit unt the retaining pin clips into place. 9. Remove the screw and wing nuts securing the demist duct, 6.HQ Only: From the right hand side air outlet assembly, _ then remove the screws securing the air inlet duct. reconnect the air ducting. 10, Disconnect the vacuum hose and remove assembly from 7. Replace the lower trim panel, tighten the three upper and vehicle. three lower retaining screws. (HJ, HX & HZ Only- 11. From inside the engine bay remove the screws retaining Remove the ash tray.) the heater housing, then remove the two nuts from the 8, Reconnect the battery. housing inside the cabin. 12, Remove the assembly and rest gently on the interior floor, HEATERUNIT then disconnect the vacuum hoses and the temperature door Remove control cable and remove the assembly from the vehicle and 1. Drain coolant from the radiator by removing the lower _ place on clean bench. radiator hose. Dismantle 2, Disconnect the coolant hoses from the heater core and“ 1. Remove the seal for the heater housing to the body. wiring from heater fan, 2, Remove the three screws securing the temperature door 3, Remove the lower right dash trim panel, by removing the cam retaining plate, then remove the retaining plate and cam six retaining screws. assembly. 4, From the right side air duct release the wiring hamess __3. Remove the three screws securing the heater core support retaining clip, then remove the right hand side air duct, plate, then remove the core and temperature door support 5, Remove the right hand side instrument compartment door assembly. 4, Remove the four screws securing the heater core clamp ee ar waeand remove the heater core. 5, From the mode and demist doors remove the link pin for the vacuum actuator connector link. 6. Remove the duct assembly closing panel, by removing the seven retaining screws, then remove the nuts securing the vacuum actuator. Assembly 1 Replace the vacuum actuator and tighten the retaining nut, then replace the duct assembly closing panel and tighten the retaining screws. 2. Replace the pin for the vacuum actuator connector link to the mode and demist doors. 3. Replace the heater core, then replace the four screws securing the heater core clamp. 4, Replace the core and temperature door support assembly, then tighten the three support plate retaining screws. 5. Replace the cam assembly and the retaining plate, then install the three retaining screws loosely. 6. Rotate the cam base plate so that when the cam is rotated its full travel, the temperature door seals fully at both openings, then tighten the three retaining screws. 7. Replace the seal for the heater housing to the body. Install 1. Replace the assembly into the vehicle, then reconnect the temperature door control cable and the vacuum hoses. 2. Liftthe assembly into position, then replace and tighten the nuts from inside the vehicle and the screws from inside the engine compartment. 3. Install the demist duct andairinlet duct into the vehicle then connectthe vacuum hose and tighten the retainingscrewsand wing nuts 4, Replace the distribution duct, then install and tighten the retaining screws. 5. Replace the centre air duct and the left hand side air outlet. 6. Replace the right hand side instrument compartment and compartment door. 7. Replace the right hand side air duct then reconnect the wiring hamess retaining clip. 8. Replace the closing panel, then tighten the six retaining screws. Dueting to fop Duct and Center Outlet Heater Housing Ho08 Vent Control Shaft HEATING & AIR CONDITIONING. ee este fi 9. Reconnect the coolant hoses to the heater core and fan wiring connector. 10. Top up radiator with specified coolant. Specified Coolant: 6cyl Engines: HN2043 eg. Tectaloy VPlus+ ‘V8 Engines: HN2043 eg. Tectaloy VPlus+ 11. Bleed the heater system of any air locks, as described earlier in this chapter. 12. Check the operation of the heater. HEATERFANMOTORASSEMBLY fan Motor | End and Brushes Fan Motor ‘Shaft and Armature 1. Lift the bonnet, disconnect the cooling hose for the blower ‘motor, then disconnect the electrical connections from the blower motor. 2-Remove the screws securing the blower motor, then remove the air inlet assembly. 3. Then remove the fan attaching nut securing ito the motor shaft, then remove the blower motor ensuring the fan remains in the housing. 4, Remove the fan through the motormounting opening inthe blowerhousing, Install 1. Replace the fan into the blower housing, then replace the blower motor into position. 2. Replace the fan attaching nut to the motor shaft and tighten. 3. Replace the air inlet assembly, then replace and tighten the blower motor retaining screws. 4, Reconnect the electrical connections to the blower motor and then reconnect the cooling hose to the blower motor. 335HEATING & AIR CONDITIONING Problems and Diagno HEATING TROUBLE DIAGNOSIS GUIDE Condition- Insufficient, Erratic, No Heator Demist CAUSE: Low radiator coolant due to coolant leaks. ACTION: Check supply tank cap pressure. Replace if below minimum pressure. Fill to level. Pressure test for engine cooling system and heater system leaks. Service as required. CAUSE: Low radiator coolant due to engine overheating. ACTION: Remove bugs, leaves, etc. from radiator or condenser fins. Check for: Loose drive belt, sticking thermo- stat, incorrect ignition timing, water pump impeller damage, and restricted cooling system. Service as required. CAUSE: Loose drive belt. ACTION: Replace if cracked or wor and/or adjust belt tension. CAUSE: Thermostat. ACTION: Check coolant temperature at supply tank. If under 77 degrees Celsius replace thermostat CAUSE: Plugged or partially plugged heater core. ACTION: Clean and backflush engine cooling system and heater core. CAUSE: Loosely or improperly adjusted control cables. ACTION: Adjust to specifications. CAUSE: Airflow control doors sticking or blinding. ACTION: Check if doors and door cables respond properly to movements of Control Knobs. Repair sticking or binding door as required. CAUSE: Kinked, clogged, collapsed, soft, swollen, or de- composed engine cooling system or heater system hoses. ACTION: Replace damaged hoses and backflush engine cooling system, then heater system, until all particles have been removed. CAUSE: Blocked air inlet. ACTION: Check cowl air inlet for leaves, foreign material, cic, Remove as required. Condition - Too Much Heat ery of Cerca A corto) Pea aris Meine) CAUSE: Sticking water valve. ACTION: Check if valve and valve cable respond properly to movements of Control Knob, Repair sticking or binding door as required. TEST LOOSE MOTOR FAN TEST ‘Tum on the fan switch, ifonly a hum is heard, the fan is loose on the motor. BLOWER SWITCH TEST Substitute a blower switch for the suspected switch. PLUGGEDHEATERCORETEST Make certain the control knob is set at “HOT”. Temporarily remove the outlet hose from the heater core (the hose may be detached from the heater in engine compartment), whilst the engine is running. HEATER WATER VALVE TESTS Prior to testing, check for proper coolant level, coolant temperature, and drive belt tension. Also check for coolant leaks or plugged hoses or heater core. Correct any defects before proceeding with the tests. AIR CONDITIONING GENERALINFORMATION The following information provides basic service operations for the air conditioning system, including the compressor. REFRIGERANT CIRCUIT The refrigerant circuit below is schematic of the major components. ‘A compressor, condenser, expansion tube, evaporator, and an accumulator. ‘Theengine RPMishigher onairconditioned modelssoasnot to drop to low at idle during system operation, When the ignition is tuned off and the air conditioning has been operating, a faint sound of liquid flowing for 30-60 seconds ‘maybe heard. Thisis the refrigerant in the system continuing, to flow until high side and low side pressures equalize. SERVICE OPERATIONS COMPRESSOR BELT TENSION & ADJUSTMENT Inspect the condition of the air compressor belt. COMPRESSOR DRIVE BELT TENSION 336HEATING & AIR CONDITIONING Condenser i ‘Thermal Switch REFRIGATION CIRCUIT Receiver De-Hydrator ° Low pressure liquid ~ . Low pressure vapour POA Vave High pressure quia = High pressure vapour Ho0s1 NEW USED 1. Install new compressor and fit drive belt. Torque compres- 140 +/- 5 Ibs. "95 4/-5 Ibs. sor mounting bolts to specification, * Belt deflection in Ibs. when a force is applied in the area _2, Adjust drive belt to specification. Install refrigerant hoses, shown in diagram. and connect clutch wire. ADJUST. 3. Charge the air conditioning system. 6eyl. Using a ring spanner or socket, loosen off the compressor idler pulley assembly. Pull on the idler pulley to tighten the belt, tighten the compressor idler pulley nut. Torque idler pulley nut to 20-30 Ib. ft. when the correct tension has been achieved. ‘V8 Engine: Using a ring spanner or socket, loosen off the compressor idlerpulley assembly. Pullontheidlerpulley totightenthe belt, tighten the compressor idler pulley nut. Torque idler pulley nut to 20-30 Ib. ft. when the correct tension has been achieved. COMPRESSOR * Where a failure has occurred that may have resulted in foreign material in the system, the system must be flushed using Refrigerant R-12. * All compressor removal and install operations, except belt replacement, can be performed only after the unit has been discharged. Storage of compressor The port protection plate should be fitted to keep compressor free from moisture and foreign material if it is necessary to store a serviced compressor. Remove 1 Discharge the air conditioning service system, and remove refrigerant lines from compressor. 2. Loosen compressor mounting bolts, belt adjuster, remove diive belt and disconnect electrical connector. 3.Remove compressor mounting bolts and remove compres- sor from the vehicle, Install REFRIGERANT (A/C) LINES Removal 1, Discharge the refrigerant from A/C system following recommended EPA procedure, observing safety precau- tions. 2. Remove the A/C line using a back-up spanner on each fitting Install 1. Install new A/C line with protective caps installed. 2, Using new O-rings lubricated with clean refrigerant oil, connect the A/C line into the system. Use two wrenches when tightening the fittings to specification. 3. To check for leaks, evacuate and charge the refrigerant system following the recommended procedures and safety precautions. EVAPORATORASSEMBLY Remove 1, Discharge refrigerant from air conditioning system and remove the heater assembly as described previously. 2. Disconnectthe line forthe P.O.A.S.T valvetothe compres- sor, then remove the expansion valve to receiver pipe which also connects the valve to dehydrator. 3. From the blower housing mounting frame remove the four retaining screws. 4, Disconnect the electrical connections from the resistor and the blower motor, then remove the evaporator assembly. Install L. Replace the evaporator assembly into the vehicle and connect the electrical connections. 2. Replace and tighten the blow housing mounting frame 337HEATING & AIR CONDITIONING screws. 3. Reconnect the pipe from the expansion valve to the receiver pipe and the dehydrator, then reconnect the line for the P.O.A.S.T valve to the compressor. 4, Replace the heater assembly as described previously and charge air conditioning system. CONDENSER Remove 1, Discharge the refrigerant system and remove the radiator grille and front bumper bar as described in Body chapter. 2. Disconnect and cap both the inlet and outlet refrigerant lines. 3. Remove the screws securing the radiator into position, then remove the radiator backwards, then lift out the con- denser from the vehicle. Install 1. Install the condenser into the vehicle. 2. Replace the radiator into position and replace the retaining bolts, then the inlet and outlet lines using new “O” ring seals. 3.Reconnect the refrigerant pipeson the righthandside of the condenser using new oil condenser line ‘O” ringsand replace the screws securing the right hand side condenser bracket. 4, Replace the radiator grille (as described in body chapter) then replace the front bumper (as described in body chapter). 5. Evacuate and charge the system with refrigerant. AIR CONDITIONER CONTROLS See Heater controls earlier in this chapter. PROBLEMDIAGNOSIS COMPRESSOR DIAGNOSIS. Problem: Oil Leaks Remedy: Inspect for leaks. Oil leaks do not necessarily indicate leaking refrigerant, check for oil leaks around the following components: - Shaft seal, leak test see area between clutch and compres- sor. - Hose fittings. - Compressor housing. ‘Thoroughly clean around compressor and components with detergent and hot water, starting detection procedures. Fol- low supplier instructions for the proper techniques tobe used for ‘ELECTRONIC’ Leak Detectors. Another useful test is a soap bubble test. Apply a soapy mixture around all joints or possible leak areas, start air conditioner and turn on to high operation, check for bubbles. If bubbles are found at any section or joint where the soapy solution was applied it will indicate a leak requiring repair. Problem: Bearing Noise Remedy: Carry out the following procedure: Remove belt. Disengage clutch. Rotate rotor pulley by hand. Listen for bearing noise. Feel for hard spots. If excessive, repair or replace compressor. * All compressors have operating noise, thi mistaken for a faulty compressor. Problem: Suspect bearing or seal failure, Remedy: Discharge the system, disengage clutch, rotate front plate by hand. While rotating, if severe rough spots or ‘catches’ ate felt, repair or replace the compressor. Problem: Compressor noise. Remedy: Visual inspection of: Broken or loose bolts at compressor and engine fixing points - replace and/or torque bolts to specifications. Loose or bent engine crankshaft pulley - repair or replace. Broken bracket and/or compressor body mounting - replace broken component. Oil level - insufficient oil can cause unusual noise, Drive belt not at correct tension. Generator bearing noisy - replace. Water pump bearing noisy - replace. Loose engine mounting bolts - re-torque. Low refrigerant charge. Low charge can be determined by ow suction pressure together with low head pressure. should not be COMPRESSOR CLUTCHDIAGNOSIS Problem: Field coil is broken. Remedy: Repair lead or replace field coil. Problem: Electrical current not correct. Remedy: Check electrical current for volts and amps. ‘Amp reading : 2.86 Volt reading: 2. If the amp reading is high the problem will most likely be a short within the field coil. If no amperage reading the problem could be an open circuit in the winding. An intermittent or poor system ground results in lower voltage at the clutch, This will cause clutch slip which may be diagnosed as belt slip. Check for tight fitof coil retaining SPECIFICATIONS COMPRESSOR Make: Frigidaire ‘Type: 6 Cylinder axial Rotation: Clockwise Displacement: 108 cu. in. COMPRESSOR CLUTCH COIL Resistance: 4.18-4.38 ohms (at 80° F), Current Draw: 2.86 amps @ 12 V (at 80° F). CAPACITIES Refrigerant capacity: 3.25 Ibs. Compressor oil: 525 Viscosity. Oil Capacity: 10 ozs. DRIVE BELT TENSION New: 1404/-5 Ibs. Used: 9541-5 Ibs. * Drive belt considered used after 10 minutes of operation. 3220HEATING & AIR CONDITIONING Heater Vacuum Hosing Check Valve = == == hafemvac = g Conditioning] ask Q sare] irr eI Relay Oo o He 2 omed Air Conditioning and Heater Wiring Diagram swith Ss aS hatomwae 339