16 - Section HA - Heater & Air Conditioner Net

HEATER &
AIR CONDITIONER
SECnONHA
CONTENTS
AIR FLOW AND COMPONENT LAYOUT - Manual Air Conditioner HA- 2
DOOR CONTROL - Manual Air Conditioner HA- 5
HEATER ELECTRICAL CIRCUIT - Manual Air Conditioner HA- 7
PRECAUTIONS HA- 8
PRECAUTIONS FOR REFRIGERANT CONNECTION HA- 10
PREPARATION HA- 11
EVACUATING, CHARGING AND CHECKING HA- 20
DESCRIPTION - Manual Air Conditioner HA- 34
SERVICE PROCEDURES HA- 38
AIC PERFORMANCE TEST HA- 44
COMPRESSOR OIL - For MJS170 (HITACHI make) HA- 52
COMPRESSOR - Model MJS170 (HITACHI make) HA- 54
AIC ELECTRICAL CIRCUIT - Manual Air Conditioner HA- 62
TROUBLE DIAGNOSES - Manual Air Conditioner HA- 64
DESCRIPTION - Auto Air Conditioner HA- 95
DOOR CONTROL - Auto Air Conditioner HA-107
AIC ELECTRICAL CIRCUIT - Auto Air Conditioner HA-110
TROUBLE DIAGNOSES - Auto Air Conditioner HA-112
SERVICE DATA AND SPECIFICATIONS (S.O.S.) HA-168
When you read wiring diagrams:
Read GI section, "HOW TO READ WIRING DIAGRAMS".
See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW to FOLLOW FLOW CHART
IN TROUBLE DiAGNOSES".
AIR FLOW AND COMPONENT LAYOUT - Manual Air Conditioner
Air Flow
Ventilation
Temperature
control lever
Foot and Dafroster
CD To ventilator
@ To floor
@ To defroster
Defroster
.... ; Air passed through heater core
~ ; Mixed eire '-+<;=J)
<::==J : Air not passed through heater core
Outside air
Outside air
BI-Ievel
SHA604C
HA-2
Air Flow (Cont'd)
AIR DISTRIBUTION RATIOS
VENT
B/L FOOT FlO OEF
-;
:J

fJ
<W
...1
1_
I
I
I
I
I
I I
I
I I
I
I I
OEF
VENT
I
170 I
I
I
I 1 1
I
1 I
I I 1
50
I
I
I
I I
35
1
I I
I
FOOT
1
I
I 1
I
I 1
1
I I
I
1 I
I
I I
1
I 1
0%
SAT266C
HA.3
Component Layout
Side defroster duct
Side vent duct
Heater unit
Cooling unit
Intake unit
SHA605C
HA-4
DOOR CONTROL - Manual Air Conditioner
SHA606C

Intake
door motor
Control Rod Adjustment
MODE DOOR
1. Move side link by hand and hold mode door in VENT mode.
2. Install mode door motor on heater unit and connect it to
harness.
3. Turn ignition switch to ACC.
4. Turn VENT switch ON.
5. Attach mode door rod to side link rod holder.
6. Check that when DEF position is selected, only DEF door is
at full-open position, and when VENT position is selected,
only VENT door is at full-open position.
INTAKE DOOR
1. Install intake door motor on intake unit.
2. Connect intake door motor harness connector.
4. Turn REC switch ON.
5. Install intake door lever.
6. Set intake door rod in REC position and fasten intake door
rod to holder on intake door lever.
7. Check that intake door operates properly when RECswitch
is turned ON and OFF.
Intake unit
Intake
door
Intake door rod
Intake
door lever
Holder
SHA607C
HA-5
Air mix door
DOOR CONTROL - Manual Air Conditioner
Control Rod Adjustment (Cont'd)
AIR MIX DOOR
1. Connect harness to air mix door motor and set temperature
control lever at full-cold position.
2. Set air mix doors I and II at full-eold position and fasten door
rod.
3. Check that when temperature control lever is at full-eold,
both doors are at full-cold position, and when temperature
control lever is at full-hot, both doors are at full-hot position.
SHA608C
WATER COCK CONTROL CABLE
Clamp cable at full-close position when air mix doors I and II are
at full-cold position, and full-open position when air mix doors I
and II are at full-hot position.
HA6
HEATER ELECTRICAL CIRCUIT - Manual Air Conditioner
Wiring Diagram
R.H. DRIVE MODEL
SWITCH UNIT
,,0----------_
INTAKE
DOOR
MOTOR
'ILLUMINATION
INDICATOR
REC INDICATOR
r n
=A/C SWITCH
'0 0
=REC SWITCH
12 0 0
-r-r-" . __. __. __
FUSE BLOCK
(Refer to "'POWER SUPPLY ROUTING"
in El section.)

OR
@ff]
"'
"'
B/R MODE
. DOOR
B/R MOTOR
U,
OR
a
@

OR
"W
@
@r------ ----,
@i I GNJTI ON SWITCH I'
ACe or ON
BLOWER
MOTOR
,
,.
-.
""
c s,
- .
.
,-
-,
-<
-",
0'
-.
CONTROL AMP.

B1E8IRhMI'h@

""WWNNNWNNNW_______
1111111111111111111111
EE E

0
@
""I
'"
OR/B
r ,
L...-R/l'
L-G/R
"
j'---

-
-
y GROUND
(Main harness)
CONNECT
rf--
vw
".
I
r-t
l
/
R

'.
.... ,..l:I1D
"
L/R
., ..
>
>
"' ".
J M!l3
MO'
MOl
@>lMJ

BLOWER BLOWER BLOWER
RELAY-3 RELAY-2 RELAY-I RESiSTOR
BOO
HA-7
SHA690C
PRECAUTIONS
Gloves
Goggles
PRECAUTIONS FOR THE HANDLING OF REFRIGERANT
Always wear eye protection when working around the
system.
Always be careful that refrigerant does not come in contact
with your skin.
Keep refrigerant containers stored below 40C (104F) and
never drop from high places.
Work in well-ventilated area because refrigerant gas evap-
orates qUickly and breathing may become difficult due to
the lack of oxygen.
Keep refrigerant away from open flames because poison-
r- ous gas will be produced if it burns.
Do not increase can temperature beyond 40C (104F) in
charging.
Do not heat refrigerant container with an open flame. There
is a danger that container will explode.
CAUTION:
Do not use steam to clean surface of condenser or evapo-
rator. Be sure to use cold water or compressed air.
Compressed air must never be used to clean a dirty line.
RHA261B
Avoid Open Flame
RHA2628
No Direct Heat
on Container
Do not release refrigerant into the atmosphere.
HA-8
O.K.
l!J
N.G. \J
SHA919A
PRECAUTIONS
Do not use manifold gauge whose press point shape Is
different from that shown. Otherwise, Insufficient evacuat-
ing may occur.
Do not over-tighten service valve cap.
Do not allow refrigerant to rush out. Otherwise, compressor
011 will be discharged along with refrigerant.
HA-9
PRECAUTIONS FOR REFRIGERANT CONNECTION
WARNING:
Gradually loosen discharge side hose fitting, and remove it
after remaining pressure has been released.
CAUTION:
When replacing or cleaning refrigerant cycle components,
observe the following.
Do not leave compressor on Its side or upside down for
more than 10 minutes, as compressor oil will enter low
pressure chamber.
When connecting tubes, always use a torque wrench.
SHA896A
After disconnecting tubes, plug all openings immediately to
prevent entrance of dirt and moisture.
Plug
$HA058
Always replace used O-rings.
When connecting tube, apply compressor oil to portion
shown in illustration. Be careful not to apply 011 to threaded
portion.
O-ring must be closely attached to Inflated portion of tube.
Apply Oring
compressor oil.
SHA897A
u n ; O ~ ~ N u t
~ ~
o
Qf!l}
em
I ~
~
-@L
SHA898A
After inserting tube into union until O-ring is no longer
visible, tighten nut to specified torque.
After connecting line, conduct leak test and make sure that
there Is no leakage from connections. If a gas leaking point
Is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.
MJS170 model
"; Special tool or commercial equivalent
PREPARATION
SPECIAL SERVICE TOOLS
Tool name
Description
Tool number
Clutch disc wrench Removing shaft nut and clutch disc
KV99412302'
~
Clutch disc puller Removing clutch disc
KV994C5780
,
Shaft handle socket Rotating compressor shaft
KV99412329'
W
Shaft seal remover Removing and installing shaft seal
KV99403043
o:Y
Shaft seal installer
KV99403042
-:
Shaft seal pilot Installing shaft seal
KV99403041'
.:
Allen socket Removi og rear cover
KV99412330'
~
Cylinder head remover Removing rear cylinder head
KV994C5785'
~
HA-11
Tool name
Tool number
Description
PREPARATION
Oil separator kit
KV994A9690
KV992C5079
Adapter connector A
CD KV992C5081
Adapter connector B
KV992C5082
Charge nozzle
KV994C1552
Blind cover set
KV994C4548
Blind cover
CD KV994C4531
Gasket
KV994C4532
Gasket (Useless)
@ KV994C4533
Gasket (Useless)
@ KV994C4534
Bolt
@ KV994C4559
CD
A @ @
~ ~ i j ~
10.391 10.39) 10.611 to.511
~
Unit: mm (in)
HA-12
Separating oil from refrigerant
Using separate oil
Charging refrigerant into compressor
Blind cover
RECOMMENDED TOOLS
PREPARATION
Service Tools
Tool name
Manifold gauge
(3-valve type)
Charging hose
(Four)
Charge valve
Adapter valve
Thermometer
Vacuum pump
Joint adapter
(T-type)
Description
RHA570B
RHAS72B
RHA573B
RHA575B
RHA576B
HA-13
Discharging, evacuating and charging
refrigerant
Discharging, evacuating and checking
refrigerant
Discharging and charging refrigerant
Evacuating and charging
Checking temperature
Evacuating refrigerant
Charging refrigerant
Tool name
Gas leak detector
Description
PREPARATION
Service Tools (Cont'd)
Charging refrigerant leaks
Charging cylinder
Weight scale
\
~ ~
~ ~
RHA579B
Checking amount of refrigerant and
charging refrigerant
Checking amount of refrigerant
For details of such handling methods, refer to the Instruction
Manual attached to each of the service tools.
HA-14
PREPARATION
HANDLING METHOD AND STRUCTURE
Manifold gauge
The manifold gauge is used to measure the operating pressure
accurately in the high pressure and low pressure lines of the
refrigerating system.
The high pressure gauge measures from -101.3 kPa (-1,013
mbar, -760 mmHg, -29.92 inHg) to 2,942 kPa (29.4 bar, 30
kg/em', 427 psi), and the low pressure gauge measures gener-
ally from -101.3 kPa (-1,013 mbar, -760 mmHg, -29.92 inHg) to
1,471 kPa (14.7 bar, 15 kg/em', 213 psi).
CAUTION:
When installing the gauge to the refrigerating system, use
utmost care not to mistake high pressure and low pressure
line connections. (Wrong connections will lead to a dam-
aged gauge.)
Before evacuating, confirm that the gauge has a negative
pressure scale. (If not, the gauge will be damaged.)
RHA580B
Vacuum
valve cock
C
Inner valve
incorporated
Center joint (AI:
Use for evacuating,
High pressure side joint (B):
Connect to high pressure side service valve
of refrigerating system.
Low pressure side joint (e):
Connect to low pressure side service valve
of refrigerating system.
Refrigerant joint (0):
Use for charging refrigerant.
Low pressure
compound gauge
Charging hose
1. Completely lighten the high pressure valve, low pressure
valve and vacuum pump valve cocks of the gauge manifold.
2. Connect the charging hoses to the high and low pressure
lines.
3. Connect the charging hose fitted with a valve core to the
refrigerant canister.
4. Connect the charging hose to the vacuum pump.
The high and low pressure hoses are color coded to prevent
wrong connection.
High pressure line hose Red
Low pressure line hose Yellow
Refrigerant canister hose Blue or green (with valve core)
Vacuum pump hose Blue or green
Bulge
Hose
(straight end)
CAUTION:
Check each hose for cracks. If found, discard the hose.
Do not use any hose if bulges are found.
Check the rubber packing. If any deterioration or cracks are
found, replace it with a new one.
Packing
RHA5818
HA15
PREPARATION
Handle is fully turned clockwise.
Charging hose
connecting POrt
Disc
Refrigerant
flows out.
Handle
Needle
Packing
Service
canister
Refrigerant
flow stops.
Charge valve
The charge valve is used to charge the refrigerant into the
system from the service canister through the gauge manifold.
Attach this valve to the head of a service canister by screwing
it on. Then turn the handle clockwise to pierce the canister to
allow the refrigerant to flow into the refrigerating system.
CAUTION:
Check the packing for any sign of deterioration or cracks. If any
abnormalities are found, replace it with a new one.
1. Turn the charge valve handle counterclockwise to fully
retract the needle, and then attach the charge valve to the
service canister. Note that leakage will occur if the charge
valve is attached to the canister without retracting the
needle.
2. Securely fit the charge valve to the head of the service
canister by turning it. Then turn the handle slowly clockwise
to make a hole in the canister with the needle.
3. Turn the handle counterclockwise to retract the needle, and
the refrigerant will flow into the gauge manifold through the
hole. To stop the flow of the refrigerant, turn the handle
clockwise to close the hole with the needle.
RHA5828
RHA5848
Charge valve
Refrigerant
Connecting T-joint adapter
Blue (green) The T-joint adapter is used to connect two refrigerant canisters
so that air purging and the accompanying discharge of refrig-
erant into the atmosphere can be eliminated when recharging
the refrigerant. If only one service canister is sufficient to
charge the refrigeration system, do not use this T-joint adapter.
1. Turn the handle of each charge valve fully counterclock-
wise, and attach the valve to a refrigerant canister.
2. Connect the T-joint adapter to both charge valves so that
two refrigerant canisters are connected as shown.
3. Connect the charging hose with valve core to the T-joint
r- adapter. Connect the valve core end of the charging hose to
the manifold gauge.
If more than three service canisters are needed for charging,
use a cross joint adapter to connect four service canisters.
HA16
PREPARATION
Installing the adapter valve
Install the adapter valve to each of the high pressure and low
pressure service valves so that air purging from the charging
hose can be omitted. This also ensures that refrigerant leakage
upon disconnection of the hose can be prevented.
1. Before connecting the adapter valve to the on-vehicle
service valve, turn the adapter valve handle fully counter-
clockwise to retract the pin.
CAUTION:
Check the packing for any sign of deterioration or cracks. If any
abnormality is found, replace the packing with new.
2. Connect the charging hose to the adapter valve.
Turning the handle clockwise will cause the on-vehicle service
valve pin to be pushed open by the adapter valve pin, thus
opening the refrigerant passage.
Turning the handle counterclockwise will close the passage.
Before removing the adapter valve from the on-vehicle service
valve, be sure to fully turn the handle counterclockwise to shut
off the refrigerant passage.
Vacuum pump
The vacuum pump is used to purge air and moisture from the
inside of the refrigeration system by evacuation, thereby ensur-
ing proper functioning of the air conditioner system.
Check the vacuum pump to see that the vacuum pump capacity
is greater than -100.0 kPa (-1,000 mbar, -750 mmHg, -29.53
inHg).
RHA587B
Vacuum pump performance check procedure
1. Connect the vacuum gauge to the system.
2. Run the vacuum pump, and check to see that the needle
pointers of the gauge manifold and vacuum gauge move
smoothly, indicating a similar value.
3. After running the vacuum pump for two or three minutes,
read the vacuum gauge. The measured value indicates the
vacuum pump capacity.
LO HI
Hose
Connecting nipple
Valve
(close)
Vacuum gauge
Oto-101.3kPa
(0 to -1,013 mbar,
oto -760 mmHg,
oto -29.92 inHg)
Gauge manifold
Hose
Vacuum
pump
RHA588B
Gas sampli n9 adapter
Detecting section
Power pilot lamp
Power/sensitivity selector switch
L.E.D. lever meter
Gas leak detector
The gas leak detector is used to check whether the refrigeration
system is leaking. The detector is available in two types; halide
torch or electrical. The features of these gas leak detectors are
listed on the next page.
RHA5898
HA-17
PREPARATION
Type Detection ability Features
Low price
Halide torch 200 g (7.05 oz)/year (thin green)
Low sensitivity
Less safe because of the use of flame
for detection
Easy handling
Discharge type
3 - 50 g (0.11 - 1.76 oz)/year
Medium sensitivity
(Suction type) Each point needs two or more
seconds for detection.
Electrical
Positive ion
High sensitivity
emission type 2 g (0.07 oz)/year
High price
(Suction type)
Warm-up time is needed because a
heater is incorporated.
1 kg (2 Ib)/month; if 13.3 kPa Can be used easily in refrigerant
Other simple checking method: (133 rnbar, 100 mmHg, 3.94 inHg) charging operation.
Change in vacuum when evacuating change in vacuum is detected in 10 Detection ability is very low with
minutes. vacuum gauge in gauge manifold.
Leakage inspection of a refrigeration system needs a
sensitivity greater than 20 g (0.71 oz)/year.
The actual amount of leak is estimated at 5 to 10 times the
detected amount.
Insufficient cooling may be felt if leakage exceeds 150 to
200 g (5.29 to 7.05 oz),
Gauze
Water
tank
Wet and dry bulb
hydrometer
Etched-stem
type
thermometer
RHA590B
Temperature gauge
Use to check the air conditioner performance. An etched stem
type thermometer may be used. A hygrometer must also be
used because the air conditioner performance depends on the
humidity.
n
Weight scaleRHA591B
Scale
Measure the weight of the refrigerant to determine how much
the refrigerant is charged.
HA-18
PREPARATION
Charging cylinder
The charging cylinder is used to correctly measure the amount
of refrigerant to be charged.
Features
With the charging cylinder, the operator can measure
correctly the amount of refrigerant to be charged into the
system.
Change in the refrigerant volume due to a change in
temperature and pressure can be supplemented, and this
ensures correct charging of refrigerant.
CAUTIONS:
Never attempt to carry the charging cylinder containing
refrigerant.
Do not put the charging cylinder In a hot place. If the
temperature and pressure of the refrigerant In the cylinder
Increase, the safety valve will be pushed open and the
refrigerant will be released Into the atmosphere.
Do not expose the cylinder to the direct sunlight.
Do not over-charge the refrigerant so that It exceeds the
maximum limit of the cylinder.
Do not charge the cylinder with more refrigerant than Is
needed.
Scale
cover Refrigerant
container
RHA674B
Sight
glass
Pressure gauge
Vent valve
no--1'"il
HA19
EVACUATING, CHARGING AND CHECKING
Refrigerant Charging Procedure
WORK PROCEDURE
orkingoperationdepends uponthe
erformanee of the pump and the
eather.
In serviceAIC system Replace parts or repair.
New AIC system Install the AIC system.
!
Install the servicetools.
J.
Evacuating
Run pump for over 5 minutes.
!
N.G,
Checking airtightness
'I
Repair.
I
Shut off the high and low
pressure valves of the manifold
gauge, and leave system as it is
for 5 to 10 minutes.
! O.K.
I
Evacuating*l
I Run curnp for over 20 minutes.
1
Charging
Chargeapprox. 200 g (7.05 oz)
refrigerant from low pressure
side (with engine shut off).
J.
N.G.
I Preliminary refrigerant leak check
J. O.K.
Charging
Chargea specified amount of
refrigerant from low pressure
side. Keep engine speed below
1,500 rpm.
!
N.G.
Checki ng refrigerant leaks
J. O.K.
Checking amount of refrigerant
Start engine, and check after
increasing engine speed to 1,500
*1: W
to 2,000 rpm.
p
!
w
Check operation of AlC system.
I
!
Remove service tools.
Use care not to allow refrigerant
to leak out when removing.
Make sure that ,refrigerant remain-
ingin service canister isnot leaking.
,
HA.20
Refrigerant Charging Procedure (Cont'd)
SETTING OF SERVICE TOOLS
Make sure that the service tools are set as indicated below and
that no refrigerant is leaking.
Charging
hose
(yellow/
green)
Connect
refrigerant
container
(charging cylinder).
\ Charging hose (red)
Charging hose (green)
Charging hose Ivetlowl__

Vacuum pump
Adapter valve
Connect service I
-- valve low and high.
--------------=--

service valve

service valve

"l-tvoe joint adapter
Connect
manifold
gauge.
Refrigerant
Connect
manifold
gauge.
HA-21
Refrigerant
container
'1, If a 13.6 kg (30 Ib)
container of refrigerant is
used a weight scale will
be needed.
This scale is to determine
the amount of refrigerant
that is used.
*2: Transfer refrigerant from
a 13.6 kg (30 lbl con-
tainer to a charging
cylinder, and measure the
amount of refrigerant.
RHA5928
Seal
Evacuation
Why evacuation is needed
When installing a car air conditioner, it is essential to com-
pletely remove air and water from the inside of the refrigeration
system beforehand. This process is called evacuation. If the air
conditioner is operated without completely removing these
substances, the following abnormalities may result.
Poor cooling due to reduction in the thermal exchange rate
in condenser
Moisture recirculating together with the refrigerant through
the refrigeration system freezes at the port of the cold
expansion valve. This impedes the normal refrigerant flow,
thus lowering the cooling efficiency.
The refrigerant reacts with water chemically, generating
corrosive hydrochloric acid thus causing corrosion to the
refrigeration system components.
CAUTION:
When installing an air conditioner in the vehicle, the pipes
must be connected as the final stage of the operation. The
seal caps of the pipes and other components must not be
removed unlll their removal is required for connection.
Before installing any air conditioner component that has
been stored in a cool location to a vehicle that has been
exposed to the hot sun, leave the component as it is for
some time in a hot location with its seal cap unremoved.
This step is necessary to prevent condensation of moisture
AHA5'38 inside the cold component.
'- ---'.c:..::J Thoroughly remove moisture from the refrigeration system
betore charging the refrigerant.
kPlI Irnbar, mmHg, inHgl
1 ~ ~ t , t - - 1 _
760, (Atomospheric pressure)
29.921
J
1
Vacuum L=;'T=;=;=;:::::;:::::'-r--;;-r-,--i--
010.0.01
'00
(2121
RHA594B
Relation between boiling point of water and atmospheric
pressure
Water boils at 100C (212F) under normal atmospheric pres-
sure. The boiling point lowers with the atmospheric pressure.
This characteristic of water is utilized to purge it from the
system. The pressure inside the refrigeration system is lowered
by a vacuum pump so that water can evaporate at a normal
temperature. The water vapor is then discharged to the outside
together with the air.
HA-22
Evacuation (Cont'd)
Vacuum pump
The degree of evacuation greatly affects the cooling capacity of
the air conditioner and the service life of the refrigeration
system components. However, use of a vacuum pump having
insufficient capacity results in prolonged evacuation. It is nec-
essary to use a vacuum pump with a sufficiently large capacity
and also to maintain the pump to ensure its original pumping
capacity.
EVACUATION PROCEDURE
,----------,
Charging of I
refrigerant I
. I
L ~
0'"
,0
Leave as is for
. ~ .,j
ON
-0
-0
i
mo
5 to 10 minutes.
o
O.K.
mo
~ o O
~ E
. . . ~ tA
1O .... ~ o ~ m
5 eg moO BCD;
I
~ 0._
o!
0'0
> 0._
wEE
wEE
N.G.
ll:::::j
Repair.
I
RHA5958
Low pressure
gauge
Compressor
High pressure gauge
To condenser
High pressure valve
[open]
Vacuum pump valve
RHA596B
1. Completely tighten the low pressure and high pressure
adapter valves.
Tightening of the valves opens the service canister valve.
2. Open the high and low pressure valves and vacuum pump
valve of the gauge manifold.
3. Run the vacuum pump.
7
RHA5978
4. Perform evacuation for more than five minutes to stabilize
the vacuum inside the system. Check to ensure that the low
pressure gauge indicates -98.6 to -101.3 kPa (-986 to -1 ,013
mbar, -740 to -760 mmHg, -29.13 to -29.92 inHg).
5. Shut off the high and low pressure valves and vacuum
pump valve of the gauge manifold.
HA-23
Evacuation (Cont'd)
CHECKING AIRTIGHTNESS
1. Shut off the high and low pressure valves and vacuum
pump valve of the gauge manifold. and leave the system as
it is for 5 to 10 minutes.
2. Make sure that the needle of the low pressure gauge will
not move back toward the atmospheric pressure side
(gauge pressure 0).
If any reverse movement is noted, it indicates poor system
airtightness. Service the system until airtightness is complete.
If pressure changes approx. 13.3 kPa (133 mbar, 100 mmHg,
3.94 inHg) in 10 minutes, the refrigerant in the system will be
exhausted in about one month.
To high
pressure
service
valve
High pressure
valve cock
[HI) Iclosel
RHA5988
To
vacuum
pump
To low
pressure
service
valve
High pressure =:8:=
gauge
Low pressure
valve cock
[LOI Iclcsel
Vacuum pump valve
cock (close)
MAINTENANCE
If inadequate airtightness is detected, check and service the
following portions:
Leak from pipe joints Leak from gauge manifold
Contaminated, damaged, or de-
formed O-ring
No oil applied when connecting
pipe
Excessive or insufficient tighten-
ing of pipe joint
Malfunctioning hose
Improper installation of gauge
Malfunctioning valve
Malfunctioning packing
EVACUATION
If no abnormality is found during the airtightness check, perform
evacuation again for more than 20 minutes.
1. Run the vacuum pump.
2. Open the high and low pressure valve and vacuum pump
3. Evacuate for more than 20 minutes.
4. Close the high and low pressure valves and vacuum pump
HA-24
Charging Refrigerant
Procedure
I"
(Run engine at
1,500 rpm or less.)
O.K.
r::>
Refrigerant charging I
~ .
(Shut off engine.)
,--,
I I
I 5 I
: ~ b
I ~ I v
I I
I I
L__...J
N.G.
Repair. I N.G.
RHA599B
PRELIMINARY CHARGING PROCEDURE
This operation is performed to check the refrigerant leakage
and to protect the compressor.
1. Turn the charge valve handle to open a hole in the service
canister to allow the refrigerant to flow through the gauge
manifold.
2. Open the low pressure valve of the gauge manifold, and
charge the refrigerant into the system from the low pres-
sure side.
3. After charging approx. 200 g (7.05oz) of refrigerant, shut off
the low pressure valve.
CAUTION:
The refrigerant charging operation must be performed after
shutting off the engine. If the compressor Is operated with
an insufficient amount of refrigerant, the compressor may
seize up due to a lack of return of the compressor oil.
Do not shake nor hold the refrigerant canister upside down.
RHA600B
Vacuum pump
Compressor
High pressure gauge
~ 1 r $ ~ -
To conaenser
Low pressure gauge
Service canister
charge valve open
Service canister
(Half the amount
of a canister
capacitv)
HA-25
Gas leak detector
To pipe joint
RHA6018
Charging Refrigerant (Cont'd)
PRELIMINARY CHECK FOR REFRIGERANT LEAKS
1. Make sure that the gauge manifold valve is closed.
2. Check for refrigerant leak from each connector in the
system using the leak detector.
At this point, the pressure in the system is not high. Only large
amounts of refrigerant leak due to loose pipe joints, etc. can be
detected.
Weight
scale
RHA602B
CHARGING REFRIGERANT
1. Make sure that the valves of the gauge manifold are closed.
2. Start the engine, and run the compressor.
3. Slowly open the low pressure valve of the gauge manifold.
4. Charge the specified amount of refrigerant.
The charged amount of refrigerant can be determined by
subtracting the weight of the canister measured after charging
from its weight measured before charging.
WARNING:
Never attempt to open the high pressure valve while the engine
is running. If opened, the pressure in the refrigerant canister
will increase, thus causing an explosion.
CHARGING REFRIGERANT WITHOUT USING T-JOINT
ADAPTER
If the service canister used for charging is empty, replace the
canister with a new one, and proceed as follows:
1. Make sure by shaking the canister that no refrigerant is left
inside.
2. Shut off all the valves of the gauge manifold.
3. Disconnect the charge valve from the emptied canister, and
attach it to a new service canister.
4. Run the vacuum pump, and open the vacuum valve (center)
of the gauge manifold to purge air from the inside of the
hose.
5. Run the vacuum pump for approx. 30 seconds.
6. Shut off the vacuum valve (center) and stop the vacuum
pump.
7. Unseal the new canister, and open the charge valve.
8. Open the low pressure valve to charge the refrigerant into
the system.
HA-26
Charging Refrigerant - Charging cylinder
WORK PROCEDURE
RHA6758
" " " ~
""'nifold
~ .
RHA6748
Sight glass
---,=="-Outlet
valve
(slowly
openl
Inlet valve (slowiy open)
RHA6778
Install the charging cylinder correctly to the vehicle.
Refer to "SETTING OF SERVICETOOLS" in "Refrigerant Charg-
ing Procedure".
PRELIMINARY CHARGING OF REFRIGERANT-1
1. Make sure that the inlet and outlet valves of the charging
cylinder are closed.
2. Slowly open the outlet valve of a refrigerant container [13.6
kg (30 Ib)].
3. Slowly open the inlet valve of the charging cylinder.
The refrigerant will flow into the sight glass of the charging
cylinder as the valve is opened.
HA-27
RHA678B
I
1 ~ ~ s i 9 h t
tjl9
1ass
Vent valve
(slowly open)
Charging Refrigerant - Charging cylinder (Cont'd)
,---------------, 4. Slowly open the upper vent valve to release pressure from
the charging cylinder. While doing so, continue charging
until the required amount of refrigerant is reached.
The refrigerant volume changes with the temperature and
pressure. It is necessary to charge refrigerant with a little more
than the required amount (indicated on the sight glass).
Refer to the CAUTION label attached on the vehicle, or to the
Service Manual.
5. Close the inlet valve and upper vent valve of the charging
cylinder.
..,J.l... I
II
RHA679B
6. Turn on the heater switch (the charging cylinder is provided
with a heater.)
The refrigerant charging time can be reduced by heating the
refrigerant to increase its pressure. In this case, do not allow
the pressure in the cylinder to rise higher than 1,030 kPa (10.30
bar, 10.5 kg/em', 150 psi). (If pressure rises above this level,
turn off the heater.)
The pressure in the charging cylinder can be measured by the
upper pressure gauge.
EVACUATION AND AIRTIGHTNESS CHECK
Refer to "EVACUATION" and "CHECKING AIRTIGHTNESS" in
"Evacuation" .
SETTING OF FLOW METER
1. Rotate the charging cylinder main body until the scale for
R12 is at the correct position on the sight glass.
2. Read the charging cylinder pressure gauge.
3. Rotate the charging cylinder so that the scale of the
charging cylinder agrees with the pressure value indicated
on the pressure gauge.
4. Open the outlet valve of the charging cylinder.
RHA680B
HA-28
Sight
glass
Referigerant level
before charging
-ISpeCified amount
of charge
Refrigerant level
after charging
Charging Refrigerant - Charging cylinder (Cont'd)
~ - - - - - - - - - - - - - , CALCULATING CHARGING AMOUNT OF REFRIGERANT
1. Record the amount of refrigerant in the sight glass before
charging.
2. Subtract the required amount of refrigerant (charge quan-
tity specified for the vehicle) from the amount of refrigerant
recorded in step 1. Charge refrigerant into the system until
the remaining value equals to the value indicated on the
sight glass.
Example:
Level in sight glass: 3 Ib 8 oz
Charge specification (from Service Manual) 2.0 - 2.4 lb.
Calculate charge quantity into Ib and oz as follows: 1 Ib = 160z,
and 0.1 Ib = 1.6 oz, 50 that 2.0 Ib = 32 oz, 2.4 Ib = 32 + (4 x
1.6) = 32 + 6.4 = 38.4, round off to 38. Therefore our charge
quantity will be between 32 and 38 OZ, or 2 Ib 0 oz to 2 Ib 6 oz.
Subtract 2 Ib 6 oz from the level in the sight glass (3 Ib 8 oz) =
1 Ib 2 oz.
This will be our ending point.
RHA681B
LISight
glass
RHA6828
PRELIMINARY CHARGING OF REFRIGERANT-2
1. Slowly open the high pressure side valve of the manifold
gauge to charge refrigerant from the high pressure side.
2. Close the high pressure valve after charging approx. 200 g
(7.05 oz) refrigerant.
CAUTION:
The refrigerant in the charging cylinder is kept in the liquid
state, so the refrigerant should be charged from high pressure
side. Do not start the engine with the high pressure valve kept
open.
PRELIMINARY CHECK FOR REFRIGERANT LEAKS
Refer to "PRELIMINARY CHECK FOR REFRIGERANT LEAKS"
in "Charging Refrigerant".
CHARGING REFRIGERANT
1. Slowly open the high pressure valve of the manifold gauge,
and charge the calculated amount of refrigerant in "CAL-
CULATING CHARGING AMOUNT OF REFRIGERANT".
CAUTION:
The refrigerant In the charging cylinder is kept in the liqUid
state, so the refrigerant should be charged from high pressure
side. Do not start the engine with the high pressure valve kept
open.
2. Close the high pressure valve of the manifold gauge.
3. Make sure that the calculated amount of refrigerant is in the
sight glass.
4. Close the charging cylinder outlet valve.
5. Turn off the heater if it is on (when using heater equipped
type).
HA-29
Inspection for Refrigerant Leaks
WORK PROCEDURE
-----,
1---1
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........,
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:
!!.g-55 )
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-
---......--
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L___-l
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Inspection for refrigerant leaks
-I
N.G.
Repair. k"'
,-
I
I
I
I
I
I
L_
RHA603B
To facilitate inspection for refrigerant leaks, establish the
following conditions:
Start the engine.
Run the air conditioner.
Set the blower fan control to MAX.
Set the temperature control to FULL COLD.
Run the refrigerant system for more than 5 minutes after
setting the above-mentioned conditions (to circulate the
refrigerant through the system).
Pressurein high
pressure line
Refrigerant leaks should be checked immediately aller stopping
the engine, beginning with the high pressure line, using a gas
leak tester. This Is because the pressure In the high pressure
line drops gradually aller the refrigerant circulation stops while
the pressure in the low pressure line rises gradually as shown
in the graph. Leaks can be detected easily when pressure Is
high.
t
Compressor stops.
Time
RHA6048
HA-30
WORK PROCEDURE
Confirmation of Amount of Charged Refrigerant
The amount of refrigerant charged into the system can be
observed through the sight glass by watching the flow of the
refrigerant and by reading the high pressure and low pressure
manifold gauges under the following conditions:
CONDITIONS
Door window: Open
AIC switch: ON (Manual Air Conditioner)
Auto switch: ON (Auto Air Conditioner)
TEMP. setting: Max. COLD
(Manual Air Conditioner)
: D(Auto Air Conditioner)
FAN speed: 4 (Manual Air Conditioner)
HI (Auto Air Conditioner)
Check sight glass after a lapse of about five minutes.
Engine speed: Approx. 1,500 rpm
After warming up engine, adjust intake air temperature to 30 to 35C (86 to 95F).
Wait until high pressure is stabilized at approx. 1,471 kPa (14.7 bar, 15 kg/em', 213 psi)."1
*1: Cover the entire condenser until the required pressure is indicated.
Check the sight"glass of the refrigerant system.*2
Touch the high and low pressure pipes of the sys-
tem to get an idea of the temperature.
*2: Refer to sight glass inspection.
Check to see whether the refrigerant is free of
N.G.
If white clouding or air bubbles are found:
white clouding and bubbles.
O.K.
Charge refrigerant until white clouding or bubbles
disappear.
Wait for some time to al-
low the refrigerant to sta-
bilize after charging, then
check the condition
through the sight glass.
Charged amount of refrigerant is O.K.
I
Charge again with approx. 150 g (5.29 oz) of refrig-
erant.
HA-31
Confirmation of Amount of Charged Refrigerant (Cont'd)
charge
Appropriate Refrigerant is insufficient Almost no refrigerant
Overcharged, or air in sys-
tem
Check item
Temperature of high and High pressure side is hot High pressure side is No difference is felt be- High pressure side is very
low pressure pipes while low pressure side is warm and low pressure tween high and low pres- hot.
cold. side is somewhat cold. sure sides.
Flow of refrigerant viewed Mostly transparent. Bubbles are always flow- Nothing is visible. If overcharged, no bubbles
through sight glass Occasionally some bub- ing. Refrigerant is cloudy. are seen. If there is air in
bles are seen when en- the system, large bubbles
gine rpm is increased or are seen.
decreased.
[ ]
r
1
r 1 J 1
/. "\

".
-J
"y
, .
rID ITIr rtD
Pressure Normal high pressure: Both high and low pres- High pressure value is Both high and low pres-
1,373 - 1,765 kPa sure values are insuffi- very small. sure values are excessive.
(13.7 - 17.7 bar, cient.
14 - 18 kg/cm
2
,
199 - 256 psi)
Normal low pressure:
147 - 294 kPa
(1.47 - 2.94 bar,
1.53 kg/cm
2
,
21 - 43 psi)
Action to take Air bubbles may. be gener- Add refrigerant after Check the refrigerant Stop the compressor and
aled when the receiver checki ng for leaks. system. extract excessive refriger-
drier strainer Is clogged, ant. If air is found, perform
or when the expansion evacuation, then charge
valve Is opened exces- the specified amount of
sively. refrigerant.
a. The bubbles seen through the sight glass are
influenced by the ambient temperature. Since
the bubbles are hard to see in comparatively
low temperatures below 20'C (68F), it is
possible that a slightly larger amount of re-
frigerant would be filled if supplied according
to the sight glass.
When the STY (for the aulo air conditioning
system) activates at an ambient temperature of
less than 20'C (68'F), bubbles can sometimes be
seen through the sight glass. However, the
amount of refrigerant is correct if the following
conditions are met:
(1) The air vent temperature is less than 7'C
(4S'F) as per the performance chart (HA-
28).
(2) Bubbles disappear under the following
conditions:
Door windows: Closed
Auto switch: ON
TEMP. selling: 40
FAN speed: HI
REC. switch: ON
Check sight glass after a lapse of about five
minutes.
Recheck the amount when It exceeds 20C
(68'F). At higher temperatures the bubbles
are easy to see.
b. When the screen in the receiver drier Is
clogged, the bubbles will appear even if the
amount of refrigerant is normal. In this case,
the outlet side pipe of the receiver drier
becomes considerably cold.
HA-32
Recovery Procedure
REMOVAL OF REFRIGERANT CHARGING DEVICE
1. Completely loosen the adapter valves of the low pressure
and high pressure Jines.
The inner valve of the adapter valve will prevent the
refrigerant from leaking out.
2. Remove both the high-pressure and low-pressure side
adapter valves from the on-vehicle service valve.
If adapter valve is not used for charging, proceed as follows to
minimize the refrigerant discharge into the atmosphere.
3. Loosen the nut of the low pressure charging hose while
pressing it against the service valve to prevent refrigerant
leakage.
4. After loosening the nut. quickly remove the charge valve
from the service valve.
5. Wait until the high pressure gauge indication drops to
below 981 kPa (9.8 bar, 10 kg/cm
2
, 142 psi), then similarly
disconnect the high pressure charging hose.
Reference
Weight of canister
+charge valve
9 (OZ)
500
(17.64)
400
114.11)
300
(10.59)
200
(7.05)
100
(3.53)
560
119.75)
400g
(14.110z1
canister
3009 (10.58 oz)
250 9 canister
340 (8.82 oz) canister
(11.99)
200 9 (7.05 oz) canister
DISPOSAL OF RESIDUAL REFRIGERANT
Securely shut off each of the charge valves, adapter valves and
manifold gauge valves to prevent the residual refrigerant from
leaking out. Keep these valves in a safe location for the next
charging.
The amount of refrigerant remaining In a service canister can
be estimated from the Table shown here. It is recommended
that a label be attached indicating the remaining amount In the
canister.
o 100 200 300 400 9 (oz)
(0) (3.53) (7.05){10.58}(14.111
Canister content
RHA6088
HA-33
DESCRIPTION - Manual Air Conditioner
Control Switches
SWITCHES AND THEIR CONTROL FUNCTIONS
~
Indicator illuminates
Air outlet Intake air Compressor
A/C ~
A/C 0
~
~
ON-'
"i
VENT *3 *1*4
:; B/l *5
*'*4
Mode
.J
FOOT *5
*'*4
S
FlO *5
ON'
~
OEF FRE *'*4
~ 0
~
REC*2 ON'
*1: Compressor is operated by thermo control amp. and E.C.C.S. control unit.
*2: Depending on mode switch position.
*3: When vent mode isselected, REC switch function isas in the following chart:
*4: Depending on Ale switch position.
*5: Depending on REC switch position.
i ~
REC
ON OFF
A/C
ON REC REC/FRE
SW
OFF REC FRE
SHA267C
HA-34
Specifications
AIR MIX DOOR MOTOR
The air mix door motor is attached to the heater unit. It rotates,
opening the air mix door to the position set by the temperature
control lever.
Motor rotation is conveyed through shafts and linkages. The air
mix door position is fed back to the control amplifier by the
Potentio Balance Resistor (P.B.R.) built into the air mix door
motor.
Air mix door motor operation
~
~
P. B. R.
(Hot
sl de)
1 2
Air mix door Direction of
operation lever movement
Clockwise IToward
<:B e
COLD ....HOT
passenger
compartment)
e e
STOP STOP
Counterclockwise
e <:B
HOT ....COLD IToward engine
compartment)
SHA637C
Characteristics of P.B.R.
(knl
3
ol---------------"'t-
OOOL
HA-35
HOT
82.6"C
(Ill F)
SHA270C
Specifications (Cont'd)
MODE DOOR MOTOR
When a mode switch is selected, the position switch built into it
reads the corresponding mode to determine the direction of
motor rotation. As soon as the desired mode is set, the position
switch stops the motor.
To control amp.
SHA638C
HA-36
INTAKE DOOR MOTOR
The intake door motor is installed on the side portion of the
intake unit. Using a rod and link it opens and closes the intake
door. When the REC switch is ON (OFF), the ground line of the
intake door motor is switched from terminal @ to @ (@ to
@ ). This causes the motor to start because the position switch
contacts built into it are now set to the current flow position.
The contacts turn along with the motor. When they reach the
non-current flow position, the motor will stop. The motor always
turns in the same direction. (FRE-->REC-->REC/FREC)
Ignition switch
ACC
Intake
,
} - - - . ~
33J-
dO
_0-a
c
~ ~ < O C I
To
control
unit
SHA284C
HA-37
SERVICE PROCEDURES
Acceleration Cut System
This system is controlled by the E.C.C.S. control unit.
When the engine is heavily overloaded, the compressor is
turned off for several seconds to reduce overloading.
Water Cock Control System
The water cock is connected to the air mix doors with a cable.
When the air mix doors are at the full-cold position, the water
cock is fully closed, and when the air mix doors are at the
full-hot position, the water cock is fully opened.
HA-38
SERVICE PROCEDURES
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the receiver
drier, through the evaporator, and back to the compressor.
Refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.
FREEZE PROTECTION (For manual air conditioner)
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specified point, the thermo
control amplifier allows compressor operation.
FREEZE PROTECTION (For auto air conditioner)
When the A/C is switched on, the compressor runs continuously, and the evaporator pressure is
controlled by a suction throttle valve (S.TV.) to prevent freeze up.
REFRIGERANT SYSTEM PROTECTION
Low-pressure switch
The refrigerant system is protected against excessively low pressures by the low-pressure switch,
located on the receiver drier. If the system pressure falls below the specifications, the low-pressure
switch opens to interrupt compressor operation.
Fusible plug
Opens at temperature above 105'C (221'F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace the receiver drier.
Pressure relief valve
The refrigerant system is also protected by a pressure relief valve, located on the end of the high
pressure flexible hose near the compressor. When the pressure of refrigerant in the system increases to
an abnormal level [more than 3,727 kPa (37.3 bar, 38 kg/cm
2
, 540 psi)], the release port on the pressure
relief valve automatically opens and releases refrigerant into the atmosphere.
Pressure relief
valve
rr==="\1
Compressor
Outside air L - ~ ~ - - - - - ' - U
High-pressure
= gas
ETIl High-pressure
liquid
Low-pressure
~ liquid
(Jill]] Low-pressure
gas
Receiver drier
Low-pressure switch
U
Expansion valve
HA-39
Blower motor
Suction throttle valve
(for Auto A/Cl
SHA463C
SERVICE PROCEDURES
Refrigerant Lines
FOR AUSTRALIA
20
(1.0 -2.0,
10 _ 20 7
(1.0 - 2.0,
7-14)
- 25
(1.5 2.5,
11 18)
Cooling unit

(2.0 3.0, 14 22)
Low-pressure
(Suction) service
valve
20
(1.0 - 2.0, 7 14)
High-pressure
(Discharge) service
valve
15 -19
(1.5 - 1.9, 11 14)

(2.0 3.0, 14 - 22)
10-20
(1.0 2.0, 7 14)
10-20
(1.0 2.0, 7 14)
25
(1.5-2.5, 11 - 18)
25
(1.5 2.5, 11 - 18)
: Nsm (kg-m, ft-Ib)
Receiver drier
SHA613C
HA-40
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
L.H.D. MODEL FOR EUROPE
10 -20
11.02.0,
7 -141
10 20
11.0 -2.0.
7 -141
15-25
11.5 - 2.5,
11 -181

(1.0 -2.0,
7 -141
15 -25
(1.5 - 2.5,
11 - 181
10 -20
(1.0 '2.0,
7 -141
Low-pressure
(Suction) servicevalve
High-pressure
(Discharge) service valve
14 - 18 (1.4 -1.8, 10 - 131
20 - 29 (2.0 - 3.0. 14 . 221
Cooling unit

11.5 - 1.9,
11 - 14)
20 - 29 (2.0 - 3.0,
14 - 22)
N'm (kg-m.lt-Ibl
HA-41
SHA527C
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
R.H.D. MODEL FOR EUROPE
10-20
(1.0 2.0,
7
10 20
(1.0 2.0,-
7 14)
15-25
(1.5 2.5,
11 18)
10-20
(1.0 - 2.0, 7 14)
15-25
(1.5 2.5, 11 18)
Cooling unit

(2.0 3.0, 14 22)
10-20
(1.0-2.0, 7 14)
High-pressure
(Discharge) service
valve
15 -19
(1.5 - 1.9, 11 14)
Low-pressure
(Suction) service
valve

(2.0 3.0, 14 - 22)

(2.0 3.0, 14 22)
10-20
(1.0 2.0, 7 - 14)
15 25
(1.5 2.5, 11 - 18)
Receiver drier
: Nsrn (kg-m, fl-Ib)
SHA718C
HA-42
SERVICE PROCEDURES
Compressor Mounting
SHA614C
Compressor
68 (5.1 - 6.9, 37 - SO)
, sl 54 (4A. 5,5, 32 - 40)

(l so 68 (5,1 - 6.9, 37 SO)
\
'2

31 (3,2, 7" \
Idler pulley -.I r
SO. 68 (5.1 6.9,37 SO)
Nsm (kg-m, ftlbl
Belt Tension
Refer to section MA.
Fast Idle Control Device (F.I.C.D.)
Refer to section EF & EC.
HA-43
AIC PERFORMANCE TEST
Performance Chart
TEST CONDITION - For Manual Air Conditioner
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well venti-
lated place)
Doors: Closed
Door windows: Open
Hood: Open
TEMP. lever position: Max. COLD
Mode switch: .; (Ventilation) set
REC switch: dl:> (Recirculation) set
FAN lever position: Max. position
Engine speed: 1,500 rpm
Time required before starting testing after air conditioner
starts operating: More than 10 minutes
TEST READING
For Australia
Recirculating-towdischarge air temperature table
Inside air (Recirculating air)
at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature
'C ('F)
% 'C ('F)
20 (68) 6.5 - 7.2 (44 - 45)
50 - 60
25 (77) 11.0 - 12.0 (52 - 54)
30 (86) 15.6 - 16.8 (60 - 62)
35 (95) 20.3 - 21.6 (69 - 71)
20 (68) 7.2 - 7.9 (45 - 46)
60 - 70
25 (77) 12.0 - 12.9 (54 - 55)
30 (86) 16.8 - 17.9 (62 - 64)
35 (95) 21.6 - 22.9 (71 - 73)
Ambient air temperature-la-compressor pressure table
Ambient air
Relative humidity
High-pressure (Discharge side) Low-pressure (Suction side)
Air temperature
kPa (bar, kg/em', psi) kPa (bar, kg/em', psi)
% 'C ('F)
20 (68)
1,079 - 1,324 (10.79 - 13.24, 105.9 - 129.5 (1.059 - 1.295,
11.0 - 13.5, 156 - 192) 1.08 - 1.32, 15.4 - 18.8)
25 (77)
1,196 -1,461 (11.96 -14.61, 146.1 - 178.5 (1.461 - 1.785,
12.2 - 14.9, 173 - 212) 1.49 - 1.82, 21.2 - 25.9)
30 (86)
1,373 - 1,687 (13.73 - 16.87, 187.3 - 228.5 (1.873 - 2.285,
14.0 - 17.2, 199 - 245) 1.91 - 2.33, 27.2 - 33.1)
50 - 70
35 (95)
1,589 - 1,942 (15.89 - 19.02, 229.5 - 280.5 (2.295 - 2.805,
16.2 - 19.8, 230 - 282) 2.34 - 2.86, 33.3 - 40.7)
40 (104)
1,804 - 2,197 (18.04 - 21.97, 269.7 - 329.5 (2.697 - 3.295,
18.4 - 22.4, 262 - 319) 2.75 - 3.36, 39.1 - 47.8)
45 (113)
1,991 - 2,442 (19.91 - 24.42, 308.9 - 377.6 (3.089 - 3.776,
20.3 - 24.9, 289 - 354) 3.15 - 3.85, 44.8 - 54.7)
HA44
Doors:
Door windows:
Hood:
Performance Chart (Cont'd)
TEST CONDITION - For Auto Air Conditioner
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well venti-
lated place)
Closed
Open
Open
(ij'\ Set up ACTIVE-TEST with CONSULT and set each
~ component as follows:
Mode door: VENT
Intake door: REC
Air mix door: Full-cold
Compressor: ON
Blower motor: 12V
@Set up self-diagnosis STEP 2 and set code No. "66".
HA-45
VG30DETT engine L.H.D. model
air temperature table
'C ('F)
% 'C ('F)
20 (68) 7.0 - 7.8 (45 - 46)
25 (77) 11.6 - 12.7 (53 - 55)
50 - 60 30 (86) 16.5 - 17.7 (62 - 64)
35 (95) 21.3 - 22.7 (70 - 73)
40 (104) . 26.2 - 27.8 (79 - 82)
20 (68) 7.8 - 8.7 (46 - 48)
25 (77) 12.7 - 13.8 (55 - 57)
60 - 70 30 (86) 17.7 - 18.9 (64 - 66)
35 (95) 22.7 - 24.1 (73 - 75)
40 (104) 27.8 - 29.6 (82 - 85)
Ambient air temperature-Io-compressor pressure table
Ambient air
% 'C ('F)
20 (68)
785 - 961 (7.85 - 9.61, 68.6 - 103.0 (0.666 - 1.030,
8.0 - 9.8, 114 - 139) 0.70 - 1.05, 10.0 - 14.9)
25 (77)
912 -1,108 (9.12 -11.08, 118.7 -150.0 (1.187 - 1.500,
9.3 - 11.3, 132 -161) 1.21 - 1.53, 17.2 - 21.8)
30 (86)
1,128 -1,383 (11.28 -13.83, 167.7 - 205.0 (1.677 - 2.050,
11.5-14.1,164-201) 1.71 - 2.09, 24.3 - 29.7)
50 - 70
35 (95)
1,353 - 1,657 (13.53 - 16.57. 213.8 - 260.9 (2.138 - 2.609,
13.8 - 16.9, 196 - 240) 2.18 - 2.66, 31.0 - 37.8)
40 (104)
1,579 - 1,922 (15.79 - 19.22, 258.9 - 315.8 (2.589 - 3.158,
16.1 - 19.6, 229 - 279) 2.64 - 3.22, 37.5 - 45.8)
45 (113)
1,795 - 2,207 (17.95 - 22.07, 304.0 - 372.7 (3.040 - 3.727,
18.3 - 22.5, 260 - 320) 3.10 - 3.80, 44.1 - 64.0)
HA-46
VG30DETT ENGINE R.H.D. MODEL
Recirculating-la-discharge air temperature table
'C CF)
% 'C ('F)
20 (68) 7.0 - 7.8 (45 - 46)
25 (77) 10.2 - 11.4 (50 - 53)
50 - 60 30 (86) 15.2 - 16.5 (59 - 62)
35 (95) 20.4 - 21.5 (69 - 71)
40 (104) 25.4 - 26.7 (78 - 80)
20 (68) 7.8 - 8.6 (46 - 47)
25 (77) 11.4 - 12.4 (53 - 54)
60 - 70 30 (86) 16.5 - 17.6 (62 - 64)
35 (95) 21.5 - 22.8 (71 - 73)
40 (104) 26.7 - 28.0 (80 - 82)
Ambient air lemperalure-to-compressor pressure table
Ambient air
% 'C CF)
20 (68)
1,098 - 1,353 (10.98 - 13.53, 122.6 -152.0 (1.226 - 1.520,
11.2 - 13.8, 159 - 196) 1.25 - 1.55, 17.8 - 22.0)
25 (77)
1,265 - 1,559 (12.65 - 15.59, 156.9 - 194.2 (1.569 - 1.942,
12.9 - 15.9, 183 - 226) 1.60 - 1.98, 22.8 - 28.2)
30 (86)
1,451 - 1,785 (14.51 - 17.85, 185.4 - 226.5 (1.854 - 2.265,
14.8 - 18.2, 210 - 259) 1.89 - 2.31, 26.9 - 32.8)
50 - 70
35 (95)
1,608 - 1,981 (16.08 - 19.81, 220.7 - 269.7 (2.207 - 2.697,
16.4 - 20.2, 233 - 287) 2.25 - 2.75,32.0 - 39.1)
40 (104)
1,765 - 2,158 (17.65 - 21.58, 247.1 - 313.8 (2.471 - 3.138,
18.0 - 22.0, 256 - 313) 2.52 - 3.20, 35.8 - 45.5)
45 (113)
1,942 - 2,373 (19.42 - 23.73, 274.6 - 362.9 (2.746 - 3.629,
19.8 - 24.2, 282 - 344) 2.80 - 3.70, 39.8 - 52.6)
HA-47
Performance Test Diagnoses
Characteristics revealed by the manifold gauge In the following table, the portion marked on each
readings for the air conditioning system are gauge scale indicates the range which shows that
shown in the following table. the air conditioning system is in good order.
For how to do the performance test, refer to the This range is described in Performance Chart.
item "Performance Chart".
Condition
IINSUFFICIENT REFRIGERANT CHARGE
Probable cause Corrective action
Insufficient cooling.
Bubbles appear in sight
glass.
Refrigerant is low, or
leaking slightly.
1. Leak test.
2. Repai r leak.
3. Charge system.
Evacuate, as necessary,
and recharge system.
AC352A
IALMOST NO REFRIGERANT
No coolingaction. Serious refrigerant leak.
A lot of bubbles or some-
thing like mist appears in
sight glass.
Stop compressor Imme-
diately.
1. Leak test.
2. Discharge system.
3. Repair leak(s).
4. Replace receiver drier
if necessary.
5. Check oil level.
6. Evacuate and
recharge system.
MALFUNCTIONING EXPANSION VALVE
Slight cooling.
Sweat or frosting on ex-
pansion valve inlet.
AC354A
Expansion valve restricts
refrigerant flow.
Expansion valve is
clogged.
Expansion valve is in-
operative.
Valve stuck closed.
Thermal bulb has
lost charge.
If valve inlet reveals
sweat or frost:
2. Remove valve and
clean it. Replace it if
necessary.
3. Evacuate system.
4. Charge system.
If valve does not operate:
2. Replace valve.
3. Evacuate and charge
system.
Performance Test Diagnoses (Cont'd)
Condition Probable cause Corrective action
AC355A
AC356A
Sweat on suction line.
No cooling.
Sweat or frosting on suc-
tion line.
Expansion valve allows
too much refrigerant
through evaporator.
expansion
valve.
Check valve for opera-
tion. If suction side does
not show a pressure de-
crease, replace valve.
2. Replace valve.
system.
IMALFUNCTIONING SUCTION THROTTLE VALVE
Frosted evaporator.
Suction throttle valve is
inoperative.
Suction throttle valve
restricts refrigerant flow.
2. Replace valve.
system.
2. Replace valve.
system.
AC358A
HA-49
Condition
MALFUNCTIONING CONDENSER
AC361A
HIGHPRESSURE LINE BLOCKED
AC362A
MALFUNCTIONING COMPRESSOR
AC363A
No cooling action: engine
may overheat.
Bubbles appear in sight
glass of drier.
Suction line is very hot.
Frosted high-pressure
liquid line.
HA-50
Probable cause
Usually a malfunctioning
condenser.
Drier clogged, or restric-
tion in high-pressure
line.
Internal problem in com-
pressor, or damaged
gasket and valve.
Corrective action
Check fan belt and
fluid coupling
Check radiator fan rno-
tor.
Check condenser for
dirt accumulation.
Check engine cooling
system for overheat-
ing.
Check for refrigerant
overcharging.
If pressure remains high
in spite of all above ac-
tions taken, remove and
Inspect the condenser for
possible oil clcgging.
2. Remove receiver drier
or strainer and
replace it.
system.
1~ Discharge system.
2. Remove and check
compressor.
3. Repair or replace
compressor.
4. Check oil level.
5. Replace receiver
drier.
system.
Condition
TOO MUCH OIL IN SYSTEM (Excessive)
Probable cause Corrective action
AC364A
I AIR IN SYSTEM
AC359A
I MOISTURE IN SYSTEM
AC360A
Insufficient c o o l i n g ~
Sight glass shows occa-
sional bubbles.
After short operation,
suction side may show
vacuum pressure read-
ing. During this condi-
tion, discharge air will
be warm. As a warning
of this, reading vibrates
around 39 kPa (0.39 bar,
004 kg/em', 6 psi).
HA-S1
Too much oil circulates
with refrigerant, causing
the cooling capacity of
the system to be
reduced.
Air mixed with refriger-
ant in system.
Drier is saturated with
moisture. Moisture has
frozen in expansion
valve. Refrigerant flow is
restricted.
Refer to COMPRESSOR
OIL for correcting oil
level.
2. Replace receiver
drier.
system.
2. Replace receiver drier
(twice if necessary).
3. Evacuate system com-
pletely. (Repeat 3D-
minutes evacuating
three times.)
4. Recharge system.
COMPRESSOR OIL - For MJS170 (HITACHI make) _
Checking and Adjusting
The 011 used to lubricate the compressor is circulating with the
refrigerant.
Whenever replacing any component of the system or a large
amount of gas leakage occurs, add 011 to maintain the original
amount of oil.
Total amount of oil in the system:
150 m(5.3 Imp II oz)
a-ring
I.
0
-rin
g
B O ~ 1 t
I0KV992C5081
. .
Low-pressure side
(Suction)
SHA702
1. Connect oil separator KV994A9690 between compressor
discharge side and condenser.
2. Evacuate and charge the system.
3. Operate compressor at engine idling with air conditioner
set for maximum cooling and high fan speed.
4. Stop compressor operation after 10 minutes.
CAUTION:
Never allow engine speed to exceed idling speed.
Do not continue compressor operation for more than 10 min-
utes.
5. Disconnect oil separator and connect refrigerant line to
original positions.
6. Disconnect low flexible hose from compressor suction
valve.
7. Add new oil from compressor suction port.
Amount of oil to be added:
120 m(4.2 Imp II oz)
About 30 m(1.1 Imp II oz) of 011 remains unremoved in the
system.
8. After adding oil, rotate compressor clutch by hand 5 to 10
turns.
9. Connect refrigerant line and evacuate and charge system.
10. Conduct leak test and performance test.
11. Gradually loosen drain cap of oil separator to release
residual pressure. Remove cap and drain oil.
12. To prevent formation of rust and intrusion of moisture or
dust, perform the following before placing oil separator kit
into storage.
1) Cap each opening of flexible hose and double union se-
curely.
2) Cap oi I separator, evacuate it from service valve, and
charge refrigerant.
When oil contains chips or other foreign material. Alter air
conditioner system has been lIushed with refrigerant replace
receiver drier. Then pour In 150 m(5.3 Imp II oz) of 011 into air
conditioner system.
HA-52
COMPRESSOR OIL - For MJS170 (HITACHI make) _
IF OIL SEPARATOR IS NOT AVAILABLE
Add oil accordance with the table below.
: Remove compressor all as follows.
Condition
Amount of oil to be added
m(lmp fI oz)
1. Remove all oil from new and old
compressors...
Replacement of compressor 2. Charge new compressor with the
same amount of oil as was in the old
compressor.
Replacement of front cooling unit 70 (2.5)
Replacement of rear cooling unit 15 (0.5)
Replacement of cool box 10 (0.4)
Replacement of receiver drier (liquid tank) 10 (0.4)
There is no sign of oil leakage from
10 (0.4)
condenser.
Replacement of condenser
There are evidences of a large amount
of oi I leakage from condenser.
60 (2.1)
There is no sign of oil leakage. Oil need not be added.
Replacement of flexible hose or pipe
60 (2.1)
of oil leakage.
There is no sign of oil leakage. Oil need not be added.
Gas leakage
of oil leakage.
60 (2.1)
.
1. With the compressor upside down, cern-
pletely drain the 011 through the suction port
(from the embossed letter "s" mark side).
2. When the 011 stops flowing out, rotate the
clutch hub two or three times to completely
drain the 011.
HA53
COMPRESSOR - Model MJS170 (HITACHI make)
Precautions
Plug all openings to prevent moisture and foreign mailer
from entering.
Do not leave compressor on its side or upside down for
more than 10 minutes.
When replacing or repairing compressor, check compres-
sor oil level in system.
When replacing with a new compressor, drain specified 011
from new compressor. Refer to COMPRESSOR OIL.
Be sure there is no oil or dirt on frictional surface of clutch
disc and pulley.
When replacing compressor clutch, be careful not to
scratch shaft or bend pulley.
When replacing compressor clutch assembly, do not forget
BREAK-IN OPERATION.
When storing a compressor, be sure to fill It with refrigerant
to prevent rust formation. Add refrigerant at the low-
pressure side and purge air at the high-pressure side,
while rotating shaft by hand.
When Installing shaft seal, O-ring and gaskets, apply com-
pressor oil sparingly to the contact surface. Do not reuse
them.
After replacement or repairs, conduct a Leak Test.
HA-54
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KV99412302
AC133A
Compressor Clutch
REMOVAL
When removing shaft nut, hold clutch disc with clutch disc
wrench.
Clutch disc
Pulley Coil
SHA7038
Using clutch disc puller, clutch disc can be removed easily
INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the drive plate and pulley should be replaced.
Pulley
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
slippage, both the pulley and drive plate should be replaced.
The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
Coil
Check coil for loose connection or cracked insulation.
HA-56
Compressor Clutch (Cont'd)
ADJUSTMENT
When assembling clutch disc, adjust disc-to-pulley clear-
ance with shims.
BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengaging
the clutch about thirty times. Break-in operation raises the level
of transmitted torque.
0.50.8
(o.o2O0.Q311
7

810.241
4 (0.161
20 (0.781
Use thk:kneu gauge by
machining it asshown.
Unit: mm Hnl
SHA839
Shaft Seal
REMOVAL
Before disassembling, be sure to measure the amount of
oil. After assembling, charge with the same amount of new
oil.
KV99400043
Pulling case
Outer seal rubber
SHA634C
With Tool KV99403043, remove shaft seal by hooking the
pulling case.
INSPECTION
Check the outer seal rubber for scars and hardening.
HA-57
Shaft Seal (Cont'd)
Check the seal lips for scars and wear.
Dust lip
Seal lip
(Rubber)
Seal lip
(Teflon)
SHA635C
KV99403041
KV99403042
SHA636C
INSTALLATION
When installing shaft seal;
1) Cap shaft seal pilot to the top end of compressor shaft.
2) Using shaft seal installer, insert shaft seat.
\KV99412330
Cylinder Head, Valve and Cylinder
REMOVAL (Rear)
Using Allen socket, remove rear cover.
Using cylinder head remover, remove rear cylinder head.
KV994C5785
SHA909A
INSPECTION
Check suction valve plate and cylinder head for sings of
damage.
HA-58
Cylinder Head, Valve and Cylinder (Cont'd)
REMOVAL (Front)
With the front facing downward, support compressor shell.
Using a plastic mallet, tap at the rear end of the shell flange,
driving shell straight downward.
Detach front cover from cylinder assembly.
INSPECTION
Check suction valve plate and cylinder head for signs of
damage.
Check to make sure contact surfaces of cylinders, compres-
sor shaft and compressor shell are free from any sign of
scratches.
SHA043A
Refrigerant passage
(low-pressure)
Refrigerant passage
(low-pressure)
Suction slot
SHA276A
INSTALLATION
1. Front cover must be installed so that the cutout portions of
front cover and shell are aligned.
For this purpose, install front cover on cylinder head so that
angle between threaded hole in front cover and low-
pressure side refrigerant passage in cylinder head is about
60.
Suction slit
Refrigerant passage
(low-pressure side)
Cylinder Head, Valve and Cylinder (Cont'd)
2. When installing shell on cylinder. adjust position of shell so
that suction inlet of shell opens in the same direction as
suction slit of cylinder visible in suction inlet by removing
suction valve.
SHA383B
Suction inlet
~ : Suctlcn stit
~
. I I ,
Shoe disc
. . .
Cylinder
When installing suction cover to rear cover, align knock pin.
Rear cover
SHA274A
Rear cover fixing bolt
/
Rear cover
SHA275A
Using Allen socket, install rear cover.
HA-60
COMPRESSOR- Model MJS170 <.H.IT... A_C... H... I_.m_a_.ke;.c} _
Leak Test
Charge refrigerant from suction side and evacuate air from
discharge side. Then conduct leak test.
"'"---'-. KV994C4532
KV994C4531
Suction port
SHA907A
HA61
A/CELECTRICAL CIRCUIT - Manual Air Conditioner
Wiring Diagram
-
I
-
T
II
I
r--
rnai n harness)
BLOWER
RiQT II
CONNECTOR @\W1
,
J 0
in EL section.)
-I
A I 61:: G/W
.__
@
ROUTING"
-+
u -r 46 L/W
L/R
I A 4F L/R
,------1--10 P/8
FUSE BLOCK
(Refer to "POWER SUPPLY

! or ON
.
(Eng i ne room
harness)
(A I ternator
@hB{rneSSIW/,-@@-w/,.
@@
ALTERNATOR tE1 J11

BODY GROUND
@
..J
LOW-
PRESSURE
SWIICH
BODY A/C
GROUND RELAY
RADIATOR
FAN
MOTOR
RADIATOR
FAN
RELAY
I IGNITION SWITCHI
ON or START
"
O/w
o[
'"
I
LOCK
LAY BOX)
to "POWER
w_
r ROUTING"
E3
section. )
(Eng i ne room harness)
[ill
@
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II
In!
I II
II
.;1-'.
,
11:"-
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o ""'t'I t'lC
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.,9
I
@,-,==,--=,---J---,
7 FUSIBLE LINK HOLDER
BATTERY
FUSE B
(l n RE
(Refer
SUPPL
in EL
HA-62
AIC ELECTRICAL CIRCUIT - Manual Air Conditioner
Wiring Diagram (Conl'd)
SWI TCH UN] T
SHA692C
THERMISTOR
FAN
SWITCH
G) :AfT mode'
C!J:MIT model
THERMO
CONTROL
AMP.
INDICATOR
7 REG INDICATOR
,,0------
=A/C SWITCH
, 0>-----0
=REC SWITCH
r a 0)-----0
:=f ILLUMINATION
,,0-----------
, 0>--------,

W . AIR MIX
, 0' DOOR MOTOR
W 11 M
W
er-neee:
MOTOR
'/'
u,
oe
a
'('j BR 0 INTAKE
G/W DOOR MOTOR
o
CONTROL AMP ,
e e
-,
..
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-,
,-
-0
-,
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HA-63
TROUBLE DIAGNOSES - Manual Air Conditioner
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair HA-65
Symptom Chart HA-66
Preliminary Check HA-67
PRELIMINARY CHECK 1
(Intake door is not set at "FRESH" in DEF mode) HA-67
PRELIMINARY CHECK 2
(A/C does not blow cold air) HA-68
PRELIMINARY CHECK 3
(Magnet clutch does not engage in FOOT & DEF or DEF mode) HA-69
PRELIMINARY CHECK 4
(Air outlet does not change) HA-70
PRELIMINARY CHECK 5
(Noise) HA-71
PRELIMINARY CHECK 6
(Insufficient heating) HA-72
Main Power Supply and Ground Circuit check HA-73
Circuit Diagram for Quick Pinpoint Check HA-74
Harness Layout for AIC system HA75
Diagnostic Procedure 1
(Blower motor does not rotate) HA-77
(Intake door does not change in VENT, BIL or FOOT modes) HA-81
(Magnet clutch does not engage when A/C switch and fan switch are ON) HA-82
, (Illumination or control panel indicators do not come on) HA-86
(Temperature of air outlet does not change) HA-90
Electrical Component Inspection HA-92
HA-64
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW
CHECK IN
<Reference item
LISTEN TO CUSTOMER
COMPLAINTS AND CONFIRM.
INVESTIGATE ITEMS RE-
LATED TO EACH SYMPTOM.
Symptom Chart
(See pageHA-66.)
ELIMINATE GOOD SYSTEM(S)/
PART(S).
Preliminary Check
(See pageHA-67 - 72.)
ELIMINATE GOOD PART(S)/
HARNESS(ES)/CONNECTOR(S)
ELECTRICALLY.
Electrical Com-
ponents Inspection
(See pages HA-92 - 94.)
Harness Layout for
A/C System (See
pages HA-75 - 76.)
Main Power Supply
and Ground Circuit
Check
(See pageHA-73.)
O.K_
Malfunctioning
partes)
REPAIR/
REPLACE.
Malfunctionin9
harness(es)/
connector(s)
CHECK MAIN POWER SUPPLY
AND GROUND CIRCUITS.
------'
Diagnostic Proce-
dure(s) (Seepages
HA-77 - 91.)
Circuit Diagram
for Quick Pin-
point Check (See
pageHA-74.)
L _
N.G.
CHECK OUT
HA-65
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Preliminary Check
PRELIMINARY CHECK 1
Intake door is not set at "FRESH" in DEF mode.
Is intake door in "Fresh" posi-
No
" I Go to Diagnostic Procedure 3.
"I
tion when REC switch is turned
from ON to OFF in VENT, BIL,
FOOT or FOOT & DEF modes
with ignition switch at ACe and
fan speed at 4?
(Intake door must be at RECI
FRE position when VENT mode
is selected.)
(Can you hear air moving from
the intake unit? Or open glove
box and check intake door oper-
etten which is located behind
the glove box")
!yes
Is intake door in "REC" position
No
" I Go to Diagnostic Procedure 3.
I
when REC switch is turned from
OFF to ON in VENT. BIL, FOOT
or FOOT & DEF modes with igni-
tion switch at ACe and fan
speed at4?
ation which is located behind
the glove box)
~ Yes
Is intake door in "Fresh" posi-
No
Replace control amp. built-into
tion when DEF mode is heater unit.
selected?
atlon which is located behind
the glove box")
~ Yes
!INSPECTION END
HA-67
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
AIC does not blow cold air.
DOES AIR FLOW FROM VENTS? N.G. IS BLOWER MOTOR OPERATING
Condition NORMALLY?
Ignition switch, Ale switch, and
Yes
1No
fan switch are ON.
e Mode switch is in VENT mode CHECK BLOWER
and temperature lever is in full MOTOR OPERATION.
cold position Go to Diagnostic Pro-
O.K.
cedure 1.
CHECK COMPRESSOR BELT
N.G.
CHECK COMPRESSOR OPERA- CHECK VENTILATOR DUCT FOR
TENSION. TION. AIR LEAKS.
Refer to MA section
O.K. O.K. N.G.
!N.G.
OK
..
Adjust or replace CHECK REFRIGERATION CYCLE IRepair air leaks.
I
compressor belt. PRESSUREWITH MANIFOLD
GAUGE CONNECTED.
Refer to Performance Chart.
!N.G.
O.K.
CHECK REFRIGERANT. Go to Performance CHECK THERMO CONTROL AMP.
Connect manifold gauge then Test Diagnoses.
O.K. N.G.
check system pressure.
! N.G.
O.K.
CHECK FOR REFRIG- Go to Diagnostic Procedure 6. Replace thermo con-
ERANT LEAKS. trot amp.
Go to Diagnostic Procedure 4. CHECK FOR EVAPORATOR COIL
FREEZE UP.
Remove intake unit and check if
evaporator freezes.
HA.68
PRELIMINARY CHECK 3
Magnet clutch does not engage in FOOT" DEF or DEF modes.
Perform PRELIMINARY CHECK 2 and 4 before referring to the following flow chart.
With engine running, does mag-
No
Go to Diagnostic Procadure 4.
net clutch engage normally
when Ale switch and fan switch
are ON?
1 Ves
Push AIC switch and turn AIC
system OFF. Make sure that
magnet switch is disengaged.
1
With engine running, does mag-
No
Replace control amp. bullt-lnto
net clutch engage normally heater unit.
when FOOT & DEF or DEF
switch and fan switch are ON?
1 Ves
INSPECTIONEND
HA-69
PRELIMINARY CHECK 4
Air outlet does not change.
Go to Diagnostic Procedure 2
DOES AIR COME OUT FROM EACH DUCT NORMALLY WHEN EACH MODE _ ___l
SWITCH IS SELECTED WITH IGNITION SWITCH AT ACC? I

Air outlet
..;
VENT
:;
FOOT & VENT
Mode
..J
FOOT & DEF
S
FOOT & DEF
DEF
AIR DISTRIBUTION RATIOS
VENT S/L FOOT "0
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y
I INSPECTION END
HA-70
PRELIMINARY CHECK 5
Noise
Check where noise comes
from.
~ ~ ~ ~
Blower motor Expansion valve Compressor Refrigerant line I
I Belt
1 1 1
I
Replace blower Replace expan- Replace com-
motor. sian valve. pressor.
!
!
The line is fixed directly to The line is not fixed.
I
the body.
1
Fix the line with rubber or Fix the line tightly.
I
some vibration absorbing
material.
I
! !
The belt vibration is intense. Side of belt is worn out.
1
Readjust belt tension. The pulley center does not
Refer to ENGiNE MAINTE- match.
NANCE in MA section. Readjust the pulley center.
HA-71
PRELIMINARY CHECK 6
Insufficient heating
DOES AIR FLOW FROM FOOT
N.G.
CHECK BLOWER MOTOR OPER-
AREA? ATION.
Condition: Go to Diagnostic Procedura 1.
Ignition switch and fan switch
are ON.
a Mode switch is in FOOT mode
and temperature lever is in
full hot position.
~ O . K .
CHECK AIR MIX DOOR OPERA-
TION.
Go to Diagnostic Procedure 6.
HA-72
Main Power Supply and Ground Circuit Check
POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in section EL and AIC
ELECTRICAL CIRCUIT.
CONTROL AMP. REMOVAL
1. Remove driver side instrument lower lid.
2. Remove vent duct.
3. Remove control amp. with harness connected.
Voltmeter terminal
Voltage
Ei)
e
@
Approximately. 12V
@
Body ground
..
Check body ground CIrCUIt for control amp. WIth Igmtlon switch
OFF.
1. Disconnect control amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check continuity between terminal No. @ and body
ground.
CONTROL AMP. CHECK
1. Disconnect control amp. harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ or No. @I and
body ground.
Control amp. harnessconnector
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.
Harness Layout for AIC System
ENGINE COMPARTMENT
Compressor
connector
- " ~ ~ ~
Air conditioner
(--_I- relay
~ ~
~ ..... .i: .--,--
Low-pressure switch
I
SHA615C
HA-75
Harness Layout for AIC System (Cont'd)
PASSENGER COMPARTMENT
II
II
Air conditioner switch unit
connector
Rear of fuse block
Mode door motor connector @
Blower motor
relay connector
Intermediate
connector@
Control amp. connector
Mode door
motor connector
Intake door ~
motor connector
,-
\
c
BlOW;' ,elay-3T
Blower connector
relay-2
connector @
_____\-Blower relay-1
connector ---_
Blower motor
connecto,@
SHA616C
HA-76
INCiDENT
Fan fails to rotate
2 Fan does not rotate at speed 1.
Flow
chart No.
II]
SYMPTOM: Blower motor does not rotate.
Perform PRELIMINARY CHECK 2 before referring to the
following flow chart.
3
Fan does not rotate at speed 2.
Check if blower motor rotates

4 Fan does not rotate at speed 3.
@]
properly at each fan speed.
Conduct checks as per flow

5
Fan does not rotate at speed 4.
chart.
m

@]

m
CHECK POWER SUPPLY FOR
c @
Blower motor harness connector
@)

BLOWER MOTOR.
(Go to next page.)
Disconnect blower motor har-

ness connector.
N.G.
Check fuses at fuse block.
LIR
Do approximately 12 volts exist (Refer to "POWER SUPPLY
00

between blower motor harness ROUTING" in EL section and
terminal No. @ and body AlC ELECTRICAL CIRCUIT.)
ground?
iii

SHA316C

Check circuit continuity between
N.G.
Reconnect blower motor har-
blower motor harness terminal ness connector.
iii
Blower motor harness connector
No. @ and body ground.
@)

CHECK BLOWER MOTOR.
[ill
(Refer to Electrical Components
L
Inspection.)
00

Replace blower motor.
Oonnnuitv should exist.

SHA317C
[;]
[;]
Resistor harness
CHECK BLOWER MOTOR CIR-
N.G.
Disconnect blower motor and
connector

CUlT BETWEEN BLOWERMO- resistor harness connectors.
TOR AND RESISTOR.
!
Do approximately 12 volts exist
Ii]
Note
L
[Y]
between resistor harness termi-
Check. circuit continuity between
nal No. @ and body ground?
blower motor harness terminal
+
No. @ and resistor terminal
O.K.
No. @.

SHA318C
A
Ii] Resistor harness
(Go to next page.)
Blower motor harness
Note:
connector@) connector
If the result Is N.G. after checking circuit continuity, repair harness or

connector.
L
L
TID
SHA319C
. HA-77
Diagnostic Procedure 1 (Cont' d)
Gil
Switch unit harness

@
connector@)

1Bffi=EBJ
CHECK RESISTOR AFTER DIS-
VIR
CONNECTING IT.

TV1
QR/B
Inspection.)
+
O.K.
IN.G.
00
Replace resis-
tor.
SHA320C
iii
Switch unit harness
Reconnect resistor harness con-
connector-@ nector.
rillS
3
01 111 i
VIR
Gil
lDIET
CHECK FAN SWITCH CIRCUIT.
)
BR
NJ
Do normal volts exist between
iii
+
switch unit harness connector
N.G.
Do approx. 5 volts exist between
terminal?
control panel terminals No.
00

Flow
Terminal No.
Normal
and No. (j})?
chart No.
voltage
O.K.
SHA321C (Fan SW
lOB e
(Apprcx.l
position)
[!J
Control amp. harnessconnector
2V
ICJI

3V
lB
1416
I

@ (j})
.lil'
171 I
I1J (3) 4V Replace fan switch.
L
rw
V'
TV[
.-..
5V
)
<!-"!
[!J
1
0 K
Fan switch
CHECK CONTROL AMP. HAR-
N.G.
Replace control amp.
NESS TERMINAL VOLTAGE.

- Do approximately 12 volts or 0
SHA322C
volts exist between control amp.
harness terminals No. @ , @ ,
@ or @ and body ground?
Flow
FanSW
chart
Terminal
operation
No.
No.
ON OFF
@ OV
Approx.
12V
@ OV
APprox.
12V
I1J
@ OV
Approx.
12V
@
OV
APprox.
12V
1
0 K
I Replace blower motor.
HA-78
m
Switch unit harness
connector
SYMPTOM: Air outlet does not change.
1EfH:E1B
YIR
Perform PRELIMINARY CHECK 4 and Main Power Supply

and Ground Circuit Check before referring to the following
PIB
m
flow chart.
ClIIIIItT -
CHECK MODE DOOR MOTOR
N.G.
Disconnect switch unit harness
)
[\[]
POSITION SWITCH. connector.
00

Measure voltage between switch
ISl 1 unit harness connector termi-
nals No. and (jJ) .
SHA323C
Mode
Terminal No.
Voltage
between switch unit harness
ISl Switch unit switch
EEl e
(Apprcx.I
connector terminal No. and
harness connector
VENT 5V
(jJ),
001 EM
BIL 4V N.G.
1
0 K
FOOT

(jJ)
3V
FlO 2V Replace
BR YIR
00
OEF OV
switch unit.
-
iii ...
00
OK

between control amp. harness
SHA324C
connectors No. and (jJ).
iii
N.G.
1
0 K
C\ZJ
Repair har-

ness or con-
""""'"
nector.

y

! Replace control amp.
I
I!l
Control amp.
harness connector Measure voltage between con-
N.G.
IRepair harness or connector.
I SHA325C
trot amp. harness connector ter-
I!l
minals No. and (jJ).
C\ZJ
Mode
Terminal No.
Voltage

switch
EEl e
IApprox.1
VENT 5V
YI]
""""'"
BIL 4V
PlB
)
(jJ) FOOT 3V
m=w
FlO 2V
DEF OV
Control amp.
1
0 K
harness connector
fj
SHA326C
I Repair harness or connector.
I
CHECK BODY GROUND CIR-
N.G.
fj
Mode door
CUlT FOR MODE DOOR MOTOR.
motor harness
Does continuity exist between
connector
I I I
I
1I I
I

mode door motor harness con-
II eo
nector terminal No. @ and IXII
body ground?
B
[ill
1
0 K
---'
...
00

(Go to next page.)
SHA327C
Diagnostic Procedure 2 (Cont'd)
iii
iii
,
Check circuit continuity between N.G.. 1Repair harness or connector.
I
--
each terminal on control amp.
r \ORControl amp.
! harne.. connector eJ
and modedoor motor.
B/R 00
Terminal No.
i B:ia 2524 erF
I 27 za ,
Control Mode door
Continuity
I _____
: GY GY
amp. motor
I W/Li iY/G I

I I I I
LID

I I I I
I
I I I
@ @and@
, ,
I
I
... ___I... .!.____'-
Yes
-"-- @ @
@
@and@

--....---... ----
i :?::?::
LO.K.
tel o
[!1

CHECK FOROUTPUTOF CON- N.G. I Replace control amp.
I
TROL AMP.
Mode door motor
connector @ between control amp. harness
terminals No. and when
SHA328C
mode is switched from "VENT"
to "DEF" or when mode is
[!1
Control amp. switched from "DEF" to
harness connector
"VENT"?
! IEtEffiIW]
Terminal
Mode door motor
No.
) joy GY
MOde Direction

door of linkage
00 [YJ
operation rotation
8 8
Stop Stop
VENT- Counter-
'--:!....-...!f--'
8 EEl
DEF clockwise
SHA329C
EEl 8
DEF-
Clockwise
VENT
lO.K.
IReplace mode door motor.
HA-80
Intake door motor
harness connector @
GIW
SYMPTOM: Intake door does not change In VENT, S/L, or FOOT
modes.
Perform PRELIMINARY CHECK 1, and Main Power Supply
and Ground Circuit Check before referring to the following
flow chart.
+
ov
5V
8
Replace con-
trol amp.
Terminal
No. Voltage
IApp",x.1
N.G.
Ale switch
Check the voltage between con-
trol panel harness connector
terminals No. @ and if]) .
Disconnect control panel con-
nector.
Switchpressed
Switchfree
N.G.
N.G. Check intake door motor power
supply circuit continuity.
OV 12V
Terminal voltage
(ApproJ<.t
ov 12V 12V
12V 12V OV
12V
O.K.
Select VENT mode and check
the voltage between intake door
motor harness terminals No.
@!, @, @ and body ground.
CHECK POWERSUPPLY FOR
INTAKE DOOR MOTOR.
Disconnect intake door motor
harness connector.
between intake door motor har-
ness terminal No. @ and body
ground?
_____1
AlC REC
Mod.
switch switch
VIR
ON ON REC
ON OFF
REel
FRE
OFF OFF FRE
WI.
Intake door motor
harness connector

tM OOel----..
SHA331C
Switch unit
harness connector @
SHA330C
I I 0
J.G II I I I
ClRET
)
00
-
[Y]
......
I
Replace intake door motor.

Switch unit

N.G.. 1Replace control panel.
Continuity
REC switch between terminal
No.@and if])
control panel terminals No. @
and if]).
Switch pressed Yes
Switch free No
I 1., Itl
I I I 12
N.G. - I Repair harness or connector.
Replace control amp.
control panel harness terminal I
No. @ (if])) and control amp.
harness terminal No. @ (if]) ).
1
0 K
WI.
Switch unit harness
connector@
VIR

I..w 12'
Control amp.
harness. connector
SHA334C
HA.81
(Go to next page.)

m
Compressor harness Diagnostic Procedure 4
connector@
SYMPTOM: Magnet clutch does not engage with AIC switch and

fan switch are ON.
Perform PRELIMINARY CHECK 2 before referring to the

Ale switch
G
rn
tiD
ON
+
m
O.K.
I Check magnet clutch coil. CHECK POWER SUPPLY FOR
COMPRESSOR.
lNG
Disconnect compressor harness

SHA335C connector.
Replace magnet clutch.
Ii)
Ale relay harness
between compressor harness
Refer to COMPRESSOR-
connector@)
Ale switch
Model MJS170 (HITACHI make).
ON connector terminal No. @l and

body ground?
aJIIOl:T
1Vl
Ii)

Ii]
)
CHECK AIC RELAY OPERATION.
N.G.
00

Do approximately 12 volts exist AIC RELAY.

between Ale relay harness con- Disconnect Ale relay.
tiD

-"
nector No. @ and Do approximately 12 volts exist
body ground? between Ale relay harness ter-
SHA336C
minals No. @, i and body
O.K.
(!)
Ale relay harness
ground?
connector
Compressor harness
1
0 K N.G.
connector @)

m
Disconnect Ale relay harness
connector.
-
IV
G
00
TITI
(!)
Note
CHECK POWER SUPPLY CIR-
Check circuit continuity between CUlT AND FUSE AT FUSE
AIC relay harness connector BLOCK.
terminal No. @ and compres- (Refer to "POWER SUPPLY
SHA337C
sor harness connector terminal ROUTING" in EL section and
Ii]
Ale relay harness
NO.@. AIC ELECTRICAL CIRCUIT.)
connector

GIW
CHECK AIC RELAY AFTER DIS- N.G.. 1 Replace AIC relay.
." ..."
[YJ
IV
CONNECTING IT.

00
Inspection.)

SHA338C
I Reconnect AIC relay.
!
Note:
If the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-82
CiI
Low-pressure switch
CiI

iii
harness connector
+
is
CHECK COIL SIDE CIRCUIT OF
N.G.
AIC RELAY. Ale relay harness connector
00 approximately 12 volts exist terminal No. and low-
LG/B
between low-pressure switch pressure switch harness con-
[YJ
harness connector terminal No. nector termi nal No. @.
+
@ and body ground?
00
[!I
1
0 K
III
Note
00 approximately 12 volts exist

N.G.
SHA339C
between E.G.C.S. control unit low-pressure switch harness
iii
Ale relay harness Low-pressure switch
harness terminal No. @ and connector terminal No. and
connector harness connector body ground? E.C.C.S. control unit' harness

O.K.
connector terminal No. @.
lO.K.
Note
LG/B
CHECK LOW-PRESSURE
LG/B
SWITCH.
TIl]
Inspection.)
!N.G.
SHA340C
Replace low-pressure switch;
[!I
E.C.C.S. control unit
connector
0
II
ClUNIT

Do approximately 8 to 9 volts
N.G.
CHECK E.C.C.S. CONTROL
Ale switch00
exist between E.C.C.S. control UNIT.
OFF unit harness connector terminal (Refer to EF & EC section.)
OR
TVT
No. @ and body ground?
+ !O.K.
-=--=-
For terminal arrangement, refer to
Disconnect thermo control amp.
Circuit Diagramfor Quick Pinpoint Check.
harness connector.
SHA341C

III

Low-pressure
switch connector (Go to next page.)
@)
II ClUNIT CllNNiECTIIR II
Note:
If the result is H.G. after checking circuit repair harness or
E.C.C.S. control 9
connector.
unit connector
OR
OR
For terminal
[ill
arrangement
refer to Circuit -'----'-
Diagramfor Quick Pinpoint Check. SHA342C
0
II
CONNECTUR II is
E.C.C.S.control 46 AIC switch
unit connector 00
S8 [Y]

Circuit Diagram for Quick Pinpoint Check.
SHA343C
HA-83
IJ
-. 00 Thermocontrol

amp. harness
IJ I
Note
connector@
II CGRC:; II!Wa
thermo control amp. harness
E.C.C.S. control connector terminal No. @ and
unit connector
E.C.C.S. control unit harness
s.
LI.
connector terminal No. @ .
For terminal arrange-
TQ1
LOK ment, refer to Circuit
II
Diagram for Quick

N.G.
Pinpoint Check. CHECK POWERSUPPLY FOR CHECK POWERSUPPLY CIR-
SHA344C
TEHRMO CONTROL AMP. CUlT AND FUSE AT FUSE
II
Thermo control amp.
Do approximately 12 volts exist BLOCK.
harness connector
between thermo control amp. (Refer to "POWER SUPPLY

harness connector terminal No. ROUTING" in EL section and
@ and body ground? AIC ELECTRICAL CIRCUIT.)
[JZJ
II
LO.K.
+ -
Is the voltage between thermo
N.G.. 1Replace thermo control amp.
control amp. harness connector

terminal No. and body
;.
ground approximately OV?
SHA345C
1
0 K
Note
II Thermo control amp.
Check continuity between
harness connector
thermo control amp. harness
0

connector terminal No. @ and
4'
NJ
terminal No. @.
WI.
LO.K.
iii
CHECK AIC SWITCH OF SWITCH

N.G.
Disconnect switch unit connec-
UNIT. tor.
-e-
Check the voltage between
SHA346C switch unit harness connector
terminals No. and @
II Thermo control amp. Control amp.
Terminal
harness connector harness connector
No.
Voltage
'E5
@
REC switch
0
r
@

(Approx.)
IIXIXI
I II
_III
'81 II
Switchpressed
EB 8
ov
Switchfree 5V
WI.
WI.
LOX.
rID
00
I Replace control amp.
SHA347C
iii
Switch unit
(Go to next page.)
harness connector@
[ffi]? rni
VIR Note:
If the result is H.G. after checking circuit continuity, repair harness or
connector.
-.:r
)
R
1Vl
00

SHA348C
HA-84
r
iii Switch unit harness
iii ~
connector
Checkcircuit continuity between
N.G.
Replace switch unit.
I
~ lEE ?
11'
VIR
I
terminal No. and (j]) .
-.
eJ
R
Continuity
between
00
LID
A/Cswitch
terminal No.
and (j])
~
Switch pressed Yes
SHA349C
Switch free No
l!1 Switch unit
I!'I
,p.K.
harness connector
Note
~
terminal No. ((j]) and can-
A I VIR
trol amp. harnessconnector tar-
I
[ili8
~
minal No. ((j]).
I
I
!'.K.
I
I
LID
IReplace control amp.
I
I
I
L.::.-
Note:
" the resu"
Is N.G. aHer checking circuit continuity, repair harness a
connector.
r------
I
I
I
~
Control amp.
harness connector
SHA350C
HA-85
SYMPTOM: Illumination or control panel indicators do not come
on.
Perform Main Power Supply and Ground Circuit Check
before referring to the following flow chart.
Turn ignition switch and lighting switch ON.
~
CHECK ILLUMINATION AND INDICATORS.
Turn AIC, REC and fan ON.
Rotary VENT, BIL, FOOT, F/D and DEF switches in or-
der.
Check for incidents and follow the repairing methods
as shown.
INCIDENT
ILL
Howto repair
Control
AIC REC
panel
X 0 0
Go to DIAGNOSTIC
PROCEDURE s-t.
0 X 0
Go to DIAGNOSTIC
PROCEDURE 5-2_
0 0 X
Go to DIAGNOSTIC
PROCEDURE 5-3.
0 X X
Go to DIAGNOSTIC
PROCEDURE 5-4.
0: Illumination or indicator comes on.
X: Illumination or indicator does not come on.
HA-86
DIAGNOSTIC PROCEDURE 5-1
Switch unit
harness connector
Switch unit
CHECK THE OTHER ILLUMINA-
TION SYSTEMS EXCEPT FOR
AIC SYSTEM.
Do the other illuminations come
on with ignition switch and light-
ing switch ON?
~ O K .
Turn ignition switch and lighting
switch OFF.
CHECK ILLUMINATION BULB.
Remove switch unit and discon-
nect harness connectors. Re-
move illumination bulb(s) and
check them.
N.G. CHECK ILLUMINATION SYSTEM.
Refer to IIluminatibn/Wiring Dia-
gram in EL section.
N.G.. 1Replace illumination bulbts),
SHA352C
ILLUMINATION WITH LIGHTING
SWITCH ON.
between switch unit connector
harness terminal No. CD and
body ground?
CHECK TIME CONTROL SYS-
TEM.
Refer to TIME CONTROL SYS-
TEM in EL section.
HA-87
N.G.
ILLUMINATION SYSTEM.
Refer to Illumination/Wiring Dia-
gram in EL section.
m
DIAGNOSTIC PROCEDURE 52
, L/R
N.G.
Switch
CHECK MAGNET CLUTCHOP- . I Go to Diagnollic Procadure 4.
I

unit
ERATION.
I I I connector
-
@
Does magnet clutch operate nor-
ED
GNi TQl
mally when engine is ON and
AlC switch, fan switch are ON?

m
!OK
Ohmmeter should show some resistance when
test leads ant connected as shown; it should
Checkcircuit continuity of
show open circuit when test leads are rewrsed.
L.E.D.
SHA354C

Replace switch unit.
. I Go to Diagnollic Procadure 3.

Check circuil continuity of
L.E.D.
DIAGNOSTIC PROCEDURE 53
N.G. I
CHECK INTAKE DOOROPERA-
TION.
Does intake door operate nor-
mally when engine is ON and
AIC switch, fan swilch are ON?
m
Switch
fiW I I I. I I unit
I 4) 17 I I connector
@
Ohmmeter should show some resistance when

test leads are connected as shown; it should
show open circu it when test leads reversed.
SHA355C
Replace control panel.
HA-88
PI Switch unit harness connector @
DIAGNOSTIC PROCEDURE 5-4
Turn ignition switch and lighting
switch OFF.
Disconnect switch unit harness
connector.
1!1 Control amp. harness connector
II I [9\- 2m ~ i 5
TQl

SWITCH UNIT
body ground?
r;) ! OK
=
SHA357C
CUIT FOR CONTROL AMP.
Does continuityexist between
terminal No. @ and body
ground?
lO.K.
T
IReplace control amp.
HA-89
m
Control panel harness
SYMPTOM: Temperature of air outlet does not change.
connector
m
Y/R
CHECK TEMPERATURE CON-
N.G.
Disconnect control amp. harness
1E:EtHm
.......
)
TROL LEVER. connector.
Measure voltage between con-
p
00
trot panel harness connector
II
1
terminals No. and (jJ).
Check if approximately 5 volts
Temp.
Terminal
exist between control panel har-
control
No.
Voltage
ness connector terminals No. @
5HA521C
lever
G)
e
lapprox.)
and (jJ).
Full hot
@
5V
1
o
.
K
. I5J
Control amp. harness connector N.G.
[1t
Full cold OV
@
Replace con-
Y/R
.......
O.K.
trol amp.
a1tffim
)
I5J
00
Measure voltage between con- (Go to next page.)
p
lli
trol amp. harness connector ter-
minals No. and (jJ) .
I", D
Temp.
Terminal
SHA522C control
No.
Voltage
lever
G)
e
(approx.l
[!J Control amp. is
Full hot 5V
@
connectors Full cold OV
mffi!Bmm:lim [!J
1
0 K
1:
N.G.
a: <:J >- <:J
Check continuity between each Repair harness or connector.
GIW w-;:Z a:I
terminal of control amp. and air

mix door motor.
[ill
Terminal No.
'"
Airmix
Control
Continuity
Air mix door motor connector SHA523C
door
amp.
motor
1!1
lw
Control amp. harness

connector
[1t
.......
':I lJ'
Y"
IDl
)
lz lz

it @
G/Y
00
.
BRIY
1!1
1
0 K
CHECK FOR CONTROL AMP. N.G-". I Replace control amp.
[j[]
OUTPUT.
Check if 12 volts exist between
SHA524C
terminals No. @ and @ when
II
temp. control lever is moved.
Control panel harness
-,
[1t
ED
Terminal Air mix
connector@
No. door motor Direction of
OK
Airmix
linkage
Replace air mix door motor.
00 il=tJi
Y/R

door
rotation
operation
BR e e
Stop Stop
e
(!)
Cold--+Hot
Counter-
clockwise
00
1YJ
G)
e
Hot--+Cold Clockwise
+ c
""--"
SHA525C
HA-90
II
~ i 5
II ~
Check If approximately 5 volts N.G. I Replace control amp.
l
~ B A
exist between control amp. har-
ness connector terminals No. @
~
and@.
VIA
Control amp. harness
connector
l
O
.
K
.
~
1]]
Repair harness or connector.
~
SHA526C
HA-91
710
1,140
460
270
o
2
3
4
OFF
Switch position
Electrical Components Inspection
FAN SWITCH
Check resistance between terminals at each switch position.
Resistance between terminals No. @ and @
(Approx. (I)
SHA618C
Air condltloner '
switch unit
SHA359C
\
Resistor
o
[ SHA.,9C
BLOWER MOTOR
Confirm smooth rotation of the blower motor.
Ensure that there are no foreign particles inside the intake
unit.
BLOWER RESISTOR
Check continuity between terminals.
SHA620C
HA-92
Air conditioner
switch unit
=
Electrical Components Inspection (Cont'd)
! AIC SWITCH
Check continuity between terminals at each switch position.
Switch condition Terminal No. Continuity
While Ale switch is pushed

@ Yes
While REC switch is pushed @ @ Yes
SHA618C
Switch unit connector @
OOi5~ EEHJ:I
11 ~
Ale switch I
I
I
I
,
,-----
SHA362C
LOW-PRESSURE SWITCH
High-pressure side line pressure
Operation Continuity
kPa (bar, kg/em', psi)
196 (1.96, 2.0, 28) Turn OFF Does not exist
206 (2.06, 2.1,30) Turn ON Exist
RELAY
Check circuit continuity between terminals by supplying 12 volts
to coil side terminal of relay.
RHA675A
HA-93
Air conditioner
switch unit
=
SHA618C
Switch position
VENT
BtL
FOOT
FOOT/DEF
Resistance between terminals
No. and No.
(Q)
o
270
460
1,140
$HA364C
DEF 710
THERMO CONTROL AMP.
1. Run engine and operate AIC system.
2. Connect the voltmeter from harness side.
3. Check thermo control amp. operation shown in the table.
Thermo control
Voltage Evaporator outlet air temperature
amp.
'C ("F)
operation
(Approx.)
Decreasing to 3.0 (37) Turn OFF 12V
Increasing to 4.5 (40) Turn ON OV
HA-94
DESCRIPTION - Auto Air Conditioner
Features
OUTLET AIR TEMPERATURE CONTROL (Air mix door control)
When the desired temperature is set on the control panel, the automatic temperature control system
determines both the head and foot target temperatures, as well as target upper (VENT and DEF) and
lower (FOOT) outlet air temperatures. This computation is accomplished in relation to the desired
temperature, and outside conditions (ambient temperature and sunload). The automatic temperature
control system then controls the air mix door position so that the outlet air temperatures meet target'
. outlet air temperatures.
A summary of the automatic temperature control system is as follows:
1. The upper and lower air temperatures are independently controlled to provide a comfortable ride.
2. Optimum outlet air temperatures can be set to the passenger's preference.
3. Outlet air temperature feedback control through duct sensors permits a "potentiometerless" air mix
door design. It requires no adjustment, increases service life and improves performance reliability.
FAN SPEED CONTROL
The A.T.G. system continuously regulates fan speed according to the difference between the target
temperature and the temperatures detected at the upper and lower in-vehicle sensors. The greater the
difference between the temperatures the higher the blower speed. If the cabin sunload or ambient
temperature is high, fan speed will be increased.
INTAKE DOOR CONTROL
The A.T.G. system adjusts the intake door position once every sixty seconds. The system is programmed
to take in outside air as much as possible.
OUTLET DOOR CONTROL
The A.T.G. system controls distribution of air through the VENT, DEFand FOOToutlets based on the cabin
sunload, ambient temperature and the set temperature.
COMPRESSOR MAGNET CLUTCH CONTROL
The A.T.G. system automatically shuts off the compressor at temperatures lower than OOG (32F).
SELF-DIAGNOSTIC SYSTEM
The A.T.G. system contains an on-board diagnostic system which can be used to check the A.T.G. system
sensors and motors and any trouble data stored in the memory.
Pushing the "AUTO" and "OFF" switches at the same time for more than 5 seconds will give the
self-diagnostic mode. There are 4 kinds of self-diagnostic systems (STEP 1 to STEP4). Each step can be
accessed by pushing the "AUTO" switch. The functions of each step are as follows:
STEP 1 - Monitor diagnosis
STEP 2 - Actuator test
STEP 3 - Ghange of difference between upper and lower target temperature
STEP 4 - Readout of trouble data memory
. Target temperature
When a temperature for the cabin is set using the TEMP. SET switch, the A.T.G. system calculates an
initial target temperature based on information from the various A.T.G. system sensors. This target
temperature is continuously updated to bring the cabin temperature to the set temperature in the most
comfortable way possible for the occupants. (The program for this was made after careful study of
comfort levels related to car interiors).
HA-95
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Specifications
AUTO AMPLIFIER
The auto amplifier has a built-in microcomputer which pro-
cesses information from the A.T.e. system sensors. Signals are
sent from the auto amplifier to activate the A.T.e. system
depending upon the information sent by these sensors and the
set temperature selected on the switch panel.
The A.T.e. system's self-diagnostic capabilities are built into
the auto amplifier.
I Ambient temp. s e n s o f " ~
Mode door motor Venti J star door I
p. B. R. (Potent I 0
balance Reslstorl
H
Floor door
I
I In-vehicle sensor
r
buT l d-j n mode
(Upper)
door motor
L-j Defroster door I
I In-vehicle sensor
r
(Lower)
\ Ai r mix door motor
I
(1)1
I
(I)
I
Air mix door
I Duct sensor
~
AutomatIc
(De froster)
ampl i fler
I AI r- mix door motor
,
Air mix door (IT) I eM I er-e-
ccmeueer-r
I
(]J)
I
I Duct sensor
r
(Vent i I atc!"')
I
Intake door motor Intake door
I Duct sensor
r
(F J cor-J
\ Fan
control ampl ifier Blower motor
I
I
Sunload sensor
I--
I Compressor
I
I
(Magnet crutch)
Thermal transmitter ~
ewater- temp.}
1
Temperature
set switch
SHA255C
HA-97
AIR MIX DOOR I and II MOTORS
Component and related parts
Auto amplifier
Air mix door motors
In-vehicle sensors (upper and lower)
Duct sensors (vent, floor, defroster)
Ambient sensor
sunload sensor
SHA273C
Operation of air mix door I and II motors
Air mix door I
~
~
"Direction of lever
movement" is as
viewed from arrow P
I
Heater
unit
p. [JtJ
I
Motor
@ Air mix door I Direction of

@
@ and II operation lever movement
8 EEl
COLD-+HOT *Clockwise
8 8 STOP STOP
EEl 8 HOT-+ COLD *Counterclockwise
'.
~
~
Air mix door IJ
43 42
SHA274C
System operation
The air mix door motors are attached to the bottom of the heater
unit. The motors rotate, moving a lever system which varies the
air mix door position to heat or cool the inlet air. Outlet air
temperature is measured by the duct sensors, signals from
which are sent to the auto amplifier which uses them to modify
the air mix door position to achieve the current target temper-
ature.
It takes about 1 minute to stabilize duct air temperature.
When ambient temperature is below SoC (41F) or above
60C (140F), air mix door position is fixed.
HA-98
MODE DOOR MOTOR
Auto amplifier
Mode door motor with potential ballast resister (P.B.R.)
Lower in-vehicle sensor
Ambient sensor
Sunload sensor
~
\
SHA275C
Mode door motor operation
Mode door motor operation
70
48
47
><1
73 72
72 48 73
@

Mode door Direction of
operation
side link rotation
e
i) V E N T ~ D E F Clockwise
o e
STOP
STOP
i)
e
D E F ~ V E N T
Counterclockwise
SHA276C
System operation
The mode door motor is attached to the heater unit. The motor
operates a cam assembly which moves the air outlet doors. The
auto amplifier controls air distribution to the VENT, DEF and
FOOT outlets. Outlet door position is conveyed to the auto
amplifier by the P.B.R. built into the mode door motor.
The auto amplifier computes air outlet conditions according to
ambient temperature, set temperature and sunload. When
thermal loads are great, the air outlet computation is addition-
ally influenced by the foot area temperature. The air outlet
positions are smoothly adjusted in response to changes in
ambient temperatures.
When the set temperature is decreased or when the sunload is
increased, the air flow volume from the vent outlets is in-
creased.
HA-99
INTAKE DOOR MOTOR
Auto amplifier
Intake door motor
Upper in-vehicle sensor
Vent duct sensor
Ambient sensor
Sunload sensor
Intake door operation
@ (@
Intake door Direction of
operation lever rotation
e EB
REC -+ FRE Counterclockwise
e e
STOP STOP
EB e FRE -+ REC Clockwise
69
Intake door operation
~
~
SHA278C
System operation
The intake door motor is attached to the air intake unit. Intake
door position is controlled approximately once every minute,
according to the difference between target and actual vent air
temperatures. When the actual outlet air temperature is higher
than the target vent air temperature, the intake door will
gradually shift toward the recirculation-air side. When the outlet
air temperature reaches the target outlet air temperature, the
intake door will gradually shift toward the fresh air side.
However, when the ambient temperature is lower than 20C
(68F), 100% fresh air is taken is regardless of outlet air
temperatures.
When the compressor is "OFF" the auto amplifier sets the
intake door at the "FRESH" position except when the "RECIRC"
switch is "ON".
HA-100
DESCRIPTION .- Auto Air Conditioner
TEMPERATURE SENSORS
:3
8
~
82
AmbIent temperature sensor
3
2
61
326062
60
~
~
~
~
25
~
79
27
81
F[oQr (duct) sensor Lower In-vehicle sensor
Defroster ( d u c ~ sensor Vent <duct) sensor
SHA256C
Sun load sensor
/
SUNLOAD SENSOR
The sunload sensor is located on the right defroster grille. It
detects sunload entering through the windshield by means of a
photo diode and converts it into a current value which is then
input into the auto amplifier.
SHA292C
HA-101
FAN CONTROL AMPLIFIER
The fan control amplifier is located on the cooling unit. It amplifies the base current flowing from the auto
amplifier to change the blower speed.
ACC
ACC
:f.
:f.
J
M Blower
motor
Fan control
ampl ifier
66
r------
---,
Auto amp J if i er
I
I
I
C I
Outputislgnal
:>
I
~
Micro-
I 3665
computer
process 36
I
circuit
V
I
I
I
I
I
L ______
65
_-.J
"::"
I
SHA257C
HA-102
System Operation
SWITCH PANEL
To
illumination
control
c J r-cu 1t SHA265C
Switch panel
Display
L-----------{12

Iv'C switches
{
AUTO ECON DEF
Switch
OFF HI UP
output
2 2
signals
REC LO DOWN
3 3
{
Signa!PAII
4
Swl tch SignaJIIBP
Input
5
signals
Signa I NCn
6
Ground
Control Unit
{
14
Power
15
supply
16
Buzzer
contro I
7
signals
8
'""""0'{
9
control
signals
10
II
System operation
Except for illumination lamp terminals @ and @, the switch panel is operated by signals emitted from
the control unit. There are three categories of signals.
1) Power and ground signals
2) Indicators (VFD and LED) and buzzer control signals
3) Switch input and output signals
The control unit always sends three different signals to the switch panel on three lines 0, @, and @.
For example, when the "Auto" switch is pushed, signal "A" returns to the control unit on line No. G)' And
when the "Econ" switch is pushed, signal "8" returns to the control unit on line No. G).
Similarly for the other switches; the control unit recognizes which signal returns on which line, and then
identifies which switch is pushed.
HA-103
System Operation (Cont'd)
AMBIENT TEMPERATURE INPUT PROCESS
For A.T.e. system operation an accurate ambient sensor signal
is necessary. The auto amplifier contains a circuit to ensure
accurate measurement of increases in ambient temperature.
Sudden increase in temperature of 16e (61F) or more, which
may be detected after encountering heavy traffic after a period
of high speed cruising, are processed through a delay circuit.
The delay circuit processes any temperature increase in incre-
ments of O.06e (O.11F) every 12 seconds and, in this way, the
A.T.e. system is protected from any sudden changes in ambient
sensor signal due to low air flow around the sensor.
Temperature decreases are not processed through the time
delay circuit.
Example:
In the case of a signal stop after high-speed cruising, the
ambient temperature will rises suddenly.
The ambient temperature input process functions at this time to
prevent unpleasant air conditioning system changes.
SHA245C
3 6 9
Time (mln.I
111.81 -----
213.6) -----------
e
i!l
iL 315.4) ------------------,
'L. :
,
,
,
,
,
,
,
,
,
,
,
,
,
o

12 sec.
o

10.11
\&HC'
kW (kcal/h, BTU/hl/m'
[kW (kcel/b, BTU/hI/so ftl
.t: 42,273)]
,go 0.7681660.2.6191 _
5 [8.26 (7.102.2B.182)] :
,
0.384 (330, 1,309) ---- I
{4.13 (3.551. 14.091)] ! :
, ,
SUNLOAD INPUT PROCESS
The sunload input circuit in the auto amplifier also features a
time delay to prevent abrupt A.T.e. system changes. This
feature operates under rapid increases and decreases in
sunload.
Example:
When entering a tunnel the sunload will change SUddenly. The
sunload input process system functions at this time to prevent
unpleasant air conditioning system changes.
o 1 2 3
Time Imln.)
SHA246C
HA-104
Fixed resistor
SENSOR INPUT PROCESS
A fixed resistor is built into the auto amplifier. 12V DC is
converted to 5V DC by the constant voltage circuit where it is
then applied to the ground line of the auto amplifier by the fixed
resistor and sensors. The auto amplifier monitors the voltage
between each sensor and the fixed resistor. The resistance of
each sensor varies according to temperature.
Accordingly, the voltage at each sensor varies according to the
temperature. The voltage signal is processed by the auto
amplifier for A.T.C. system operation.
,
,
I
I
I
,
I
I
I
I
I
I
I
I
,
- J
of sensor
voltage
Auto amplifier
r------------- -------,
I I
I I
I I
I I
I
I
I
I
I
I
I
I
L _
I
I
I
I
I
I
,
Each sensor
I
I
I
I
I
I
I
I
,
SHA247C
STARTING FAN SPEED AND OUTLET DOOR CONTROL
Component parts
Starting fan speed and outlet door control components are:
Auto amplifier
. Fan control amplifier
In-vehicle sensors (Upper and Lower)
Duct sensor (Defroster, Venti lator and Floor)
Ambient sensor
sunload sensor
Thermal transmitter (Engine coolant temperature sensor)
System operation
Fan speed control
At a set temperature of 25C (7rF), when the upper compartment temperature is below 21C (70F)
and the outlet duct temperature is lower than 35C (95F), the fan starts at minimum flow rate. As the
discharge air temperature increases, the air flow rate increases to bring the compartment
temperature to the target level as quickly as possible.
When the ambient temperature is above 40C (104F), fan air flow rate is at full volume.
As interior temperature begins to reach the target temperature, fan speed decreases.
Under heavy sunload conditions, fan speed is increased to maintain uniform interior temperature. Fan
speed also increases if the set temperature is decreased.
Outlet door control
At a set temperature of 25C (77F), when the upper in-vehicle temperature is lower than 21C (70F)
and all of the outlet air temperatures are lower than 35C (95F), the system starts with the minimum
airflow rate in the defroster mode. When defroster duct temperature rises above 35C (95F), the air
outlet mode changes from the defroster mode to the DEF/FOOT mode. When floor duct temperature
exceeds 40C (104F), the starting fan speed control and outlet door control mode is replaced by the
normal automatic control mode. When the upper in-vehicle temperature is far greater than the lower
in-vehicle temperature because of a large sunload, the system starts with the ventilator mode, which
is replaced by the automatic control mode as the coolant temperature and outlet air temperature
increases.
HA-105
Starting fan speed and outlet door control specifications
Automatic fan speed control
5.5V
Outlet is '@
fixed in FOOT/DEF.
4V '
Outlet is fixed in DEF.
oT
L

5 ....
1 : 1 = r - ~
6 f G'--.'------;/---------+-----.
Outlet is fixed in VENT.
4 1'----,:-:----',
Time
(J)2' When both upper and lower in-vehicle temperatures are much higher than set temperature.
: When upper jn-vebjcle temperature is higher than set temperature.
@ : When upper in-vehicle temperature is lower than set temperature.
@ VG30DE engine model
When DEF duct temperature rises above 35C (95"FI
VG30DE engine model
When DEF duct temperature rises above approximately 20 C (68
0
F)
(Exact temperature depends on ambient ternperature.I
@ VG30DE engine model
When FLOOR duct temperature rises above 40C (104 F)
VG30DETT engine model
When FLOOR duct temperature rises above approximately 36 C (97 F)
(Exact temperature depends on ambient temperature.)
When water temperature rises above 40C (104 F) and difference between outlet air temperature and target temperature is
lower than SoC (9 F).
SHA290C
-1 (30) 1 (34)
MAGNET CLUTCH CONTROL
The auto amplifier controls compressor operation by the ambi-
ent temperature and signals from the E.C.C.S. unit.
The auto amplifier will turn the compressor 'ON" or "OFF" as
determined by a signal detected by the ambient temperature
sensor.
ON
OFF
_1 J
I I
Ambient temperature C (0 F)
SHA291C
HA-106
DOOR CONTROL - Auto Air Conditioner
6. Attach mode door rod to side link rod holder.
7. Check mode door operates when position is changed with
CONSULT or when code No. 6X is changed to others.
3X 4X 5X 6X
Code No.
Mode door
DEF HEAT BtL VENT
position
INTAKE DOOR
1. Install intake door motor on intake unit.
2. Connect intake door motor to harness.
4. Set up "ACTIVE TEST" mode with CONSULT or set up
self-diagnosis STEP 2.
5. Set INTAKE DOOR position as in the following table.
6X
Code No.
VENT
MODE DOOR POSITION
Control Rod Adjustment
MODE DOOR
1. Move side link by hand and hold mode door in VENT mode.
2. Install mode door motor on heater unit and connect it to
harness.
4. Set up "ACTIVE TEST" mode with CONSULT or set up
self-diagnosis STEP 2.
5. Set MODE DOOR position as in the following table.
SHA307C
Mode door motor
Intake door rod
6. Install intake door lever.
7. Set intake door rod in REC position and fasten intake door
rod to holder intake door lever.
8. Check intake door operates properly when position is
changed with CONSULT or when code No. 6X is changed to
others.
Intake
door lever
Holder
Intake unit
Intake
door
SHA308C
INTAKE DOOR POSITION
REC
Code No.
6X
@
3X 4X 5X 6X
Code No.
Intake door
Outside air
Partial out-
Recirculation
position side air
HA-107
Control Rod Adjustment (Cont'd)
AIR MIX DOOR
1. Connect harness to air mix door motors I and II and set
temperature control lever at full-cold position.
2. Set air mix doors I and II at full-cold position and fasten door
rod.
3. Check that when temperature control lever is at full-cold.
both doors are at full-cold position. and when temperature
control lever is at full-hot, both doors are at full-hot position.
SHA366C
WATER COCK CONTROL CABLE
Clamp cable at full-close position when air mix door II is at
full-cold position. and full-open position when air mix door II is
at full-hot position.
HA-108
NOTE
HA-109
AIC ELECTRICAL CIRCUIT - Auto Air Conditioner
Wiring Diagram
L.H. DRIVE MODEL
AUTO AMP.
@i fi(
BODY -=- -=
GROUND BODY
GROUND
..r m
DOOR MOTOR MODE DOOR
MOTOR
I
II
... ... ......... "'C1UU 111''''

II

l-L/R
,- L
(
3-Y/L
4-Y/G
5-Y/8
t ._,n
1-G/B
e-G/T
t-G/R
ID-G/W
11- Ii
12-R/Y
13-G/R
1'- OR
tS-BR/Y
16- 8R
17- BR./W
lnatlon
{ ystem
:1
@)
(Ma i n harness)
E:W/L
./,
./'
W/'
(
(@)
,/1
()

i,
(

(Sub-harness)
(
,/,
.L
R/L R/L
@
C2 . W/R W/R
, ,
I II
Ilw
....e

@)m (lHmJ
W/R
FOOT DUCT
SENSOR

IN-VEHICLE
SENSOR-LWR
I
To ilium
control 5
CHECK
CONNECTOR
@I
o ."
OEF DUCT
SENSOR

DOOR I
MOTOR

DOOR II
MOTOR
VENT
DUCT L..:::=:::::...
SENSOR

SWITCH UNIT
HA-110
AIC ELECTRICAL CIRCUIT - Auto Air Conditioner
Wiring Diagram (Cont'd)
FR
FUSE BLOCK
Un RELAY SO>O
(Refer to "'POWER
SUPPLY ROUTI NG"
In EL eece l cn. )
(Engine
room
harness)
IGNITION SWITCH
ON or START
NNECTOR
: AlT model
@ : MIT model
tn
c
!'J
in EL aect t cno
BATTERY FUSIBLE LINK HOLDER

I
RADIATOR
FAN SUB U
RELA Y
"'

(Bro'M"))
@
rO-LG/B
'I.)- OR
LOW-
PRESSURE
SWITCH
O
"==+0+=1-1-1- B/R,-l===--
G/W
RELAY
w -+-=<D"
FUSE BLOCK CRefer to pFOWER SUPPLY RQUTING*
ir-
BULB
I
I IGNITION SWITCH rI GNI TI ON SWI TCH
CHECK
,
ACe or ON ON or START
RELAY
;
TOR
I BATTERY
- '"
,
- "
CO

'-
BLOWER
L

RELAY
"
u+
5.
L_
r-r-
I 1L W cD 0 '" :I: c _J
-
-;r ... ';' .., ':' C\I ';'
CONNECTOR
1I1I1 I
BR
B
CONNEC
g@ @)g @).tg, @ @)
rn 01,,00
THERMAL F. 1. C. D. I ATOR
TRANSMITTER SOLENOID RAO
VALVE

harness)
@)

0
".
C
L
.c
- ,
"'
,
- w
, - OR !OJ
@] " -
L -
r--
33 - R
I
.. -
"
oj
"
"
wL;__@
....
z
"
-'
o
'"
....
z
o
o
a
"
u
u
w
u,
w
o
"
L

!O
(Eng i ne room harness)
(Me i n harness)
I
BR
R"
CBody mID

BODY
GROUND
SHA694C
HA111
TROUBLE DIAGNOSES - Auto Air Conditioner
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair HA-114
Symptom Chart HA-115
Self-diagnosis HA-117
CHECKING PROCEDURE HA-119
STEP 1: MONITOR DIAGNOSIS HA-121
STEP 2: ACTUATOR TEST HA-121
STEP 3: AUXILIARY MECHANISM , HA-122
STEP 4: READOUT OF TROUBLE DATA STORED IN MEMORY HA-123
Consult HA-124
Preliminary Check HA-125
PRELIMINARY CHECK 1
PRELIMINARY CHECK 2
(Intake door does not change) , HA-126
PRELIMINARY CHECK 3
(Insufficient cooling) HA-127
PRELIMINARY CHECK 4
(Insufficient heating) HA-129
PRELIMINARY CHECK 5
(Blower motor operation is malfunctioning) HA-130
PRELIMINARY CHECK 6
(Magnet clutch does not engage) HA-131
PRELIMINARY CHECK 7
(Discharged air temperature does not change) HA-132
PRELIMINARY CHECK 8
(Noise) HA-132
Main Power Supply and Ground Circuit Check HA-133
Harness Layout for AIC System HA-134
Circuit Diagram for Quick Pinpoint Check HA-136
(SYMPTOM: Self-diagnosis detects intermittent short or open circuit in each
sensor circuit) " HA-137
(SYMPTOM: Ambient sensor circuit is open) HA-138
(SYMPTOM: Ambient sensor circuit is shorted) HA-139
(SYMPTOM: Upper in-vehicle sensor circuit is open) HA-140
(SYMPTOM: Upper in-vehicle sensor circuit is shorted) HA-141
(SYMPTOM: Lower in-vehicle sensor circuit is open) HA-142
(SYMPTOM: Lower in-vehicle sensor circuit is shorted) HA-143
(SYMPTOM: Del. duct sensor circuit is open) HA-144
(SYMPTOM: Del. duct sensor circuit is shorted) HA-145
(SYMPTOM: Vent duct sensor circuit is open) HA-146
(SYMPTOM: Vent duct sensor circuit is shorted) HA-147
HA-112
Contents (Cont'd)
(SYMPTOM: Floor duct sensor circuit is open) HA-148
(SYMPTOM: Floor duct sensor circuit is shorted) HA-149
(SYMPTOM: Sunload sensor circuit is shorted) HA-150
(SYMPTOM: Air mix door does not operate normally) HA-151
(SYMPTOM: Intake door does not operate normally) HA-152
(SYMPTOM: Mode door does not operate normally) HA-153
(SYMPTOM: Mode door does not move at all) HA-154
(SYMPTOM: Magnet clutch does not engage) HA-155
(SYMPTOM: Air conditioner control switch panel illumination does not come on) HA-157
(SYMPTOM: Set temperature and ambient temperature do not appear on
display window) HA-158
(SYMPTOM: When air conditioner switch is operated it does not beep) HA-159
(SYMPTOM: Figures of set temperature and ambient temperature do not appear
on the display window and indicator lamp (L.E.D.) does not come on) HA-160
(SYMPTOM: Switches do not work) HA-161
(SYMPTOM: Blower motor operation is malfunctioning) HA-162
Electrical Components Inspection HA-165
HA-113
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW
CHECK IN <Reference item
LISTEN TO CUSTOMER COMPLAINTS AND
CONFIRM.
INVESTIGATE ITEMS YOU
SHOULD CARRY OUT
RELATED TO EACH SYMPTOM.
r-t-r- ....J
Symptom Chart
Main Power Supply and
Ground Circuit Check
(See page HA-133.)
Preliminary Check
(See pages HA-125 -132.)
Electrical Com-
ponents Inspection
Self-diagnosis and CONSULT
Harness Layout
for AIC System
Malfunctioning
partts)
REPAIRI
REPLACE.
----'
INSPECT EACH
COMPONENT.
---'
CHECK MAIN POWER
SUPPLY AND GROUND
CIRCUIT.
No
Malfunctioning
harness(es)/
connectorls)
ELIMINATE GOOD PART(S)/
HARNESS(ES)/CONNECTOR(S)
ELECTRICALLY.
ELIMINATING GOOD
PARTS/SYSTEMS
r---:""'--....J
Diagnostic Proce-
dure(s) (See pages
HA-137 - 164.)
Circuit Diagram
for Quick Pin-
point Check (See
page HA-136.)
r---------------+
I
I
I
I
I
I
I
t
I
I
I
I
I
I
I
I
I
I
I
I
I
I
1
1
I
I
L________________ FINAL CHECK
N.G. '-----______ _ ---'
DELETE TROUBLE DATA STORED IN
MEMORY.
DELETE WITH CONSULT.
OR REMOVE BATTERY
GROUND CABLE OR FUSE.
O.K.
CHECK OUT
HA-114
Symptom Chart
DIAGNOSTIC TABLE
Symptom Possible cause Diagnostic procedure
Air outlet does not Mode door motor not operating correctly Proceed to Preliminary check 1, then to Diag-
change Inaccurate sensor input nestle procedures 17 and 18 if air mix door is
No output to mode door motor from auto am- malfunctioning.
plifier
Intake door does not Intake door motor or mechanism malfunc- Proceed to Preliminary check 2, if intake door
change tioning is malfunctioning, go to Diagnostic Procedure
Inaccurate sensor input 16.
No output to intake door motor from auto
amplifier
Insufficient cooling Compressor clutch not engaged Proceed to Preliminary check 3. If air mix
Air mix door motors not working properly doors do not operate properly, go to Diagnos-
Condenser fan inoperative tic procedure 15.
Low freon level
Check compressor clutch operation and freon
level of system.
Discharged air temper- Air mix doors do not operate correctly Proceed to Prellminary check 7.
ature does not change Incorrect sensor input
Noise Compressor belt tension Proceed to Preliminary check 8.
Compressor component malfunction
-. Blower motor interference
Radiator cooling fan interference
Air conditioner control
Blown fuse
Proceed to Diagnostic procedure 20.
switch panel Htumina- Loose or open in harness
tion does not come on
Blown bulb
Insufficient heating Coolant temperature is low Proceed to Preliminary check 4. If air mix
Air mix doors not in correct position doors do not operate correctly. go to Diagnos-
Incorrect sensor input tic procedure 15.
Blower motor opera- Blower motor is not receiving power Proceed to Preliminary check 5. If blower rno-
tion is malfunctioning Vents may be obstructed tor is malfunctioning, go to Diagnostic proce-
Motor does not spin freely dura 25.
Air intake obstructed
Blown fuse
Malfunctioning blower relay
Magnet clutch does not
Blown fuse
Proceed to Preliminary check 6, then Diagnos-
engage AIC relay inoperative
tic procedure 19 if clutch is malfunctioning.
Open in wiring
Open ambient sensor circuit
Low freon level
Malfunctioning clutch assembly
HA-115
TROUBLE DIAGNOSES- Auto Air Conditioner
Symptom Chart (Cont'd)
Symptom Possible cause Diagnostic procedure
No display on Ale
Blown fuse
switch panel Malfunctioning bulb
Set temperature and Malfunctioning switch unit Proceed to Diagnostic procedure 21.
ambient temperature
Open in circuit
do not appear on dis- Malfunctioning auto amplifier
play window
When air conditioner Malfunctioning Ale switch Proceed to Diagnostic procedure 22.
switch is operated, if Open in harness or connector
does not beep Malfunctioning auto amplifier
Set and ambient tem-
Open in harness
perature do not appear Malfunctioning switch panel
in display and indicator Malfunctioning auto amplifier
lamp (L.E.D.) does not
come on
Switches do not work Malfunctioning switch panel Proceed to Diagnostic procedure 24.
Open in harness
Malfunctioning auto amplifier
HA-116
Self-diagnosis
CONSULT AND ONBOARD SELFDIAGNOSTIC SYSTEM
Function of CONSULT and ONBOARD SELF-DIAGNOSTIC SYSTEM are as follows:
: These can be set by self-dtaqnosia step II; their cornbinatlons are as follows:
MONITOR CHANGE PARAMETER
READOUT OF TROUBLE DATA
ITEM
STORED IN MEMORY
CONSULT ONBOARD CONSULT ONBOARD CONSULT ONBOARD
Ambient temp. 0 0 0 0
In-vehicle temp. (Upper) 0 0 0 0
In-vehicle temp. (Lower) 0 0 0 0
Duct temp. (Defroster) 0 0 0 0
Duct temp. (Ventilator) 0 0 0 0
Duct temp. (Floor) 0 0 0 0
Sunload .
0 0 0 0
Water temp. 0 0
Mode door P.B.R. 0 0
In-vehicle target temp. (Upper) 0
in-vehicle target temp. (Lower) 0
Outlet air target temp. (Upper) 0 0 '0
Outlet air target temp. (Lower) 0 0 '0
Mode door target position 0 0 '0
Intake door target position 0 0 '0
Blower motor target voltage 0 0 '0
Difference between upper and lower
0 0 '0
target temp.
Output signal to compressor 0 0 '0
Set temp. 0
Selected mode 0
Operated switches status 0
.
Actuator test
SET 30
AMB code
P'M' I
HI'SN.
Co," lnnlke Outlet A{Mdoo. Comp
3. Outside air Dri Flff Dff
Outside air Heet Flff Off

,.
Pertialoutside
'IC
30"C 186'F) 0.
air
6.
Recirculation
Vent FlC 0.
eir
[Blowe. volt;ogelfixedll
~ s w . !
ceee Voltage
.3 <V
6V
.,
'V
.. 12V
.: "x" refers to any VlIlue of 3, 4, 5
.ncf6.
HA-117
Self-diagnosis (Cont'd)
The self-diagnostic system diagnoses the sensors, door motors,
blower motor, etc. by system line. Refer to applicable sections
(items) for details. Shifting from normal control to the self-
diagnostic system is accomplished by starting the engine
(turning ignition switch from "OFF" to "ON"), and pressing both
the (AUTO) and (OFF) switch for at least 5 seconds.
This system will be cancelled by either pressing the (OFF)
switch or turning the ignition switch "OFF". Shifting from one
step to another is accomplished by means of pushing the
(AUTO) switch, as required.
Start engine.
(Ignition switch OFF -+ ON)
Press !AUTOI switch, while continu-
ingto press it press JOFFl switch.
Hold these two switches for at least 5
seconds.
~
STEP 1
iJIJiJIJ
Ignition switch: OFF
Monitor diagnosis
IbIlIbil
IOFFI switch: PRESS
Press /AUTOI switch.
STEP 2
30
Self-diagnostic function is
Actuator test
IOFFI switch: PRESS
cancelled.
Press IAUTOI switch.
1
STEP3
40
Change of difference between upper
IOFFI switch: PRESS and lower target temperatures
Press IAUTOIswitch.
STEP 4
SO
Readout of. trouble data memory
IOFFI switch: PRESS
1
Press IAUTol switch.
I
HA-118
CHECKING PROCEDURE Note
Start engine.
Check if
SET and AMBdata No
I
Faulty wiring or VFD
I
(VFD display)
illuminate.
"TVes
Set in self-diagnostic mode.
(Press AUTO switch, while continuing to press it
press OFF switch. Hold these two switches for
at least 5 seconds.)
Check if
air conditioner operates No
I
Faulty"AUTO" or "OFF" switch
and SET "00" appears.
I
Yes
Sensor monitor
STEP 1
SETOO
Temperature variation n1nge
SENSOR MONITOR
Cod. Item IWhen comPartment
temperature is stabilized!
l I SET I Code I 00 Ambient temperature 30 to 4S"C I 22 to 113"FI
Identification data of each sensor is
I AMB I data I
ot
Upper companment
18 - 30C 164 _86F)
,. temperature
shown.
Lower compartment
02 20- 3SoC168-95"F)
temperature
1
DEf outlet air
+
Press
00
temperature
5 70"C (41 -lSS0F)
HISW.
Y
.. VENT air temperature 5 40C (41 . 104F)
Press HI switch or LO switch.
05
FLOOR outlet air
20 70
0
e (68 _158F)
temperature
., 0 -1.047 kW (0900 kcal/h,
+
Press
O 3,571 BTU/h)fm'
LOWS'N.
00 SunlOad [0 -11.26 kW (09,684
kcalfh, 0 - 38,430
Press AUTO switch.
BTU/hlfsq ft]
or Water temperature
'2 20
0
e (68FI Or 80C
IH6"F)
08 MODE door voltage 0-5V
09
,
Internal data -
'0
'1: Indication figure is one tenth of the value in kcal/h unit.
SET30
~ 2 : When coolant temperature is below 40"C (l04"F) indicates 2o"C (68"FI.
STEP2
ACTUATOR TEST
When coolant temperature is above 40
0
e (104' FI indicates eo-c (176 Fl.
+
Code No. of actuators test pattern is
Aetuetor test
indicated on display.
"".
Intake Outlet AJMdoor Com,
I I SET 301
"
Out.idea!r Od
'IH on
+
IAMB
00'"
.,
Outside air Heat
'IH on
I
50<
Partialout.ide
'IL
3O"C (B6F) 00
Press HI switch or LOswitch.
Press
."
HISW.
0,
Recirculation
Vent nc 00
air
[Blower voltage Wxed)]
"".
Voltage
"
.v
@ Press
J
,.
ov x" refers to any value of 3. 4, 5
LOSW.
x 9V
and 6.
Note:
><6
"V
,. Without engine running, STEP 1 and 2 are not useful
for some case because compressor not operate.
2. While in the self-diagnosis mode, set temperature
switch functions remain as usual.
HA-119
1
Press AUTO switch.
!
EP3
I
SET40 ..... STEP 3 should notbe used for diagnostic purposes.
~
Press AUTO switch.
I
~
SET 50
EP4
READOUT OF TROUBLE
DATA STORED IN MEMORY
!
[No. of engine starts/stops occurring
since last problem was detected for
each sensor1
Press HI switch or LOswitch.
~
Press 0 FF switch.
J.
END
Readout of trouble data stored In memory
Cod. Data contents
Trouble diagnosis
Remarks
criteria
SET cod'
SO
Ambient sensor trouble less than _70
o
e (_94FI.
det. greater than 141C (286FI
AMB data
S
a
a
trouble data
S2
Lower in-vehiclesensor
P- f
trouble date
LOSW.
S3
Defroster (duet) sensor Less than _38
D
e (_36F)
trouble deta greater than 141C 1286FI
S ~
Vent (duct) sensor
trouble data
55
Floor (duct) sensor
trouble data
Press Greater than 1.784 kW
HISW.
56
Sunloacl sensor trouble
(1,534 keel/h, 6.087
Detects shorted
data
BTU/h)/m
2
slde"onlv
119.19 kW 116,506 kcal/h,
65.502 BTU/h)/sq ttl
Identification of trouble data
\Shortad ..esor trouble
Jo:;c;;mo'
0:.0 0:.0 No. of engine lItarts/stopS occurring since last problem was detected
V T,oubl. det. 50 , No probl.m.
49 - 01 : Problem existed .
o: Problem exim
ST
ST
HA-120
AMB
Code
<.
Changes from Changes from
"0" to "1" "0" to "9"
\ ,
uO uO
SET

1------o--a--'-1
I = IAMB
0
Data L , j
Changes from "-62" to "199"
SHA248C
Aluminate.
c::70 uO
dJ SET
=0 =0
dJdJ
I code No.
First code No. (Blower voltage)
(Actuator positions) Changes from "3" to "6"
Changes from "3" to "6"
SHA249C
STEP 1: MONITOR DIAGNOSIS
In STEP 1 mode, "00" and "data", respectively appear in SET
and AMB section of display.
Each time the "HI" switch is pressed, the code number in the
SET section advances one number, and data corresponding
with the code number appears in the AMB section. Each time
the "LO" switch is pressed, the code number reduces by one
number, and data corresponding with the code number appears
in the AMB section.
If the temperature shown on the display greatly differs from the
actual temperature, check the sensor circuit first, then inspect
the sensor itself according to the procedures described in
Electrical Components Inspection.
For cross-reference of code number and corresponding
data, refer to "Monitor Diagnosis" in STEP 1.
STEP 2: ACTUATOR TEST
In STEP 2 mode, "30" and "33" respectively appear in the SET
and AMB sections of the display.
When the "HI" switch is pressed one time, the first code
advances. This code returns to "3" after it reaches "6".
Similarly, when the "LO" switch is pressed one time, the
second code advances one number. After the code number "6"
appears, it returns to "3".
HA-121
During inspection in STEP 2 mode, the auto amplifier will forcefully transmit an output to the affected
actuators in response to the code No. shown on the display, as indicated in the table below.
Checks must be made for improper operation visually, by listening to any noise, or by touching air outlets
with your hand, etc.
~ o .
3 4 5 6
Actuator
Mode door DEF HEAT BtL VENT
Intake door FRE FRE
50%
REC
FRE
Air mix door
Full Full 30C Full
Hot Hot (86F) Cold
Compressor OFF OFF ON ON
~ o
3 4 5 6
Blower motor
Voltage 4V 6V 9V j2V
Operating condition of each actuator cannot be checked by
indicators.
1) First and second codes can be set independently.
2) When first code "5" appears, air mix door activates.
A stabilized outlet temperature 30C (86F) is reached after air mix door has been operating for
approximately one minute.
STEP 3:AUXILIARY MECHANISM
Changes of difference between upper and lower target temper-
atures.
* Figures in parentheses "( )" refer to values for '<OF"
specifications.
In STEP 3 mode, "40" and "0" (if this number is changed, the
corresponding number appears) respectively appear in the SET
and AMB sections of the display.
Each time the "HI" switch is pressed, the number in the AMB
section advances. This number will increase up to 20 for C
specifications and 36 for OF specifications. Each time the "LO"
switch is pressed, the number decreases. This number de-
creases to -20 for Cspecifications and -36 for OF specifications.
For C specifications, pressing the "HI" or "LO" switch each
time increases or decreases the data number by "1" degree
(and by "1" through "3" degrees for OF specifications).
SET
AMB
Illuminates
r.
D
C20
uO
UfbO
uO
/ ~ O
Data
Changes of upper and lower target
compartment temperatu res
"oe" specifications: "-20" to "20"
,,0F" specifications: "-36" to "36"
SHA250C
Data -20 --- -1 0 1 --- 20
~ C specifications
Difference between
upper and lower tar- -2.0C ---
_jOC
OC 0.1C --- 2.0C
get temperatures
Data -36 --- -2 0 2C --- 36
OF specifications
Difference between
upper and lower tar- -3.6F --- --o.2F OF 0.2F --- 3.6F
get temperatures
Difference between upper and lower target temperatures changed In the preceding procedure IS kept until the next change
is done or the battery cable is removed.
HA-122
STEP 4: READOUT OF TROUBLE DATA STORED IN
MEMORY
In STEP4 mode, "50" and "trouble data" respectively appear in
the SET and AMB sections.
Each time the "HI" switch is pressed, the code number ad-
vances by one number. After it reaches "6", it will return to "0".
Each time the "LO" switch is pressed, the code number reduces
by one number. After it reaches "0", it will return to "6",
AMB
Code No.
changes from "0" to "6"
I
uO
SET
[bO
U 0=0

Illuminates
\
U
dJ
Trouble dete e 50 (no problems)
49 ...., 01 (Problem existed)
o(Problem exists) SHA251C
Illuminates
\
Dc::J
dJ
Code No.
changes from "0" to "6"
I
uO
SET
[bO
When the sensor becomes inoperative, number of engine
starts/stops occurring since last problem was detected, ap-
pears in the AMB section of the display.
Open circuit or short circuit is indicated by " 0" or "=".
SHA252C
Indicating a open circuit
=0
D AMB
\
No. of :S/stoPS occurnnq
SIncelast problem was detected
Indicating a short circuit
Code No. Sensor Open circuit Short circuit
SO
Ambient sensor Less than -70C (-94F) Greater than 141C(286F)
5
0
Room upper sensor Less than -38C (-36F) Greater than 141C (286F)
a
52
Room lower sensor Less than -38C (-36F) Greater than 141C (286F)
53
DEF duct sensor Less than -38C (-36F) Greater than 141C (286F)
VENT duct sensor Less than -38C (-36F) Greater than 141C(286F)
55
Floor duct sensor Less than -38C (-36F) Greater than 141C (286F)
56
Open circuit can not be
Greater than 1.784 kW (1,534 kcal/h, 6,087
Sunload sensor BTU/h)/m' [19.19 kW (16,506 kcal/h, 65,502
detected by self-diagnosis.
BTU/h)/sq It]
HA-123
CONSULT
SMA185C
F = = = ~ = = = = = i
, ....,. , ,
.::> i ,;";",)"::, i
SEF3921
A/T
, "
SHA535C
-_.
_._--"-""-"...,,._---,,._---_._----"
~ - - - - - _ . _ - _ .. -_.,.._-_.._---_._-------,
SEF3941
Consult
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect "CONSULT" to diagnostic connector.
(Diagnostic connector is located in left dash side panel.)
3. Turn on ignition switch.
4. Touch " START" .
5. Touch "AUTO A/C".
6. Perform each diagnostic mode according to the inspection
sheet as follows:
For further information, read the CONSULT Operation Manual.
HA-124
Preliminary Check
PRELIMINARY CHECK 1
Air outret does not change.
CHECK SENSOR CIRCUIT.
N.G.
CHECK SENSOR CIRCUIT IN DETAil ACCORDING TO
00Read out trouble data
THE DIAGNOSTIC PROCEDURE BELOW CORRE-
! with CONSULT. SPONDING TO EACH CODE NO.
or
00
@
@ Set up selt-diagnosis
How to repair
Reference
= STEP 4. Is each sen- $elf-diegnosis
....
CONSULT indication
COde No. ...
sor circuit normal?
Ambient sensor circuit is
SO
Go to DIagnostic
HA-l38 0
O.K.
ccen procedure 2.
SO
Go to Diagnostic
HA-l39
shorted. - procedure 3.
5
0
0
Go to Diagnostic
HA-140
circuit is open. 0 procedure 4.
5
0
-
Go 10 Diagnostic
HA-141
circuit is shorted.
0
procedure 5.
CHECK MODE DOOR OPERATION.
Go to Diagnostic
00~ ~ t Up "ACTIVE TEST" mode with CONSULT.
52
0 HA-142
circuit is open. procedure 6.
52
-
Go to Diagnostic
HA-143
@Set up self-diagnosis STEP 2.
circuit is shorted. procedure 7.
Defroster (duet) sensor
S3
0
Go to Diagnostic
HA-l44
Does air outlet change according to each mode?
S3
-
Go to Diagnostic
HA-l45
ooSetmOde
Vent (duct) sensor circuit
S ~
0
Go to Diagnostic
HA-146
DEF HEAT B/l VENT is open. procedure 10.
Vent (duet) sensor circuit
S ~
Go to Diagnostic
HA-147
is shorted.
~
procedure 11.
@CodeNO.
3X 4X 5X 6X
Floor (duet) sensor circuit
55
0
Go to Diagnostic
IHA-148
is open. procedure 12.
Floor (duct) sensor circuit
55 -
Go to Diagnostic
iHA-149
FDOTI FOOTI
is shorted. procedure 13.
Air outlet DEF
DEF VENT
VENT
Sunload sensor circuit
56
~
Go to Diagnostic
IHA-150
Reter to AIR DISTRIBUTION. When malfunctioning sensor circuit, ambient sensor, in-
vehicle sensor, and duct sensors are suspected, it is
O.K. N.G.
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the temperature
is within normal range before performing Diagnostic
Procedures.
CHECK SiDE LINK N.G. I Repair or adjust.
MECHANISM.
Refer to DOOR CON-
TROL - Aulo Air
Conditioner.
O.K.
Air outlet control system is normal. Go to Diagnostic Pro-
Refer to Outlet door control specification. cedure 17 or 18.
HA125
PRELIMINARY CHECK 2
Intake door does not change.
N.G.
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO
00Read out trouble data THE DIAGNOSTIC PROCEDURE BELOW CORRE-
! with CONSULT. SPONDING TO EACH CODE NO.
or
(j)
@
@ Set up selt-diagnosis
How to repair
Reference
~ STEP 4. Is each sen- Self-diagoosis
....
CONSU LT indication
code No. ...
sor circuit normal?
Ambient sensor cireuit is
SO
0
Go to Diagnostic
O.K. "".n
procedure 2.
HA-l38
50 -
Go to Diagnostic
HA-139
shorted. procedure 3.
5
0
0
Go to Diagnostic
HA-140
circuit is open. G procedure 4.
Upper invehicle sensor
5
0
-
Go to Diagnostic
HA-141
circuit is shorted.
0
procedure 5.
CHECK INTAKE DOOR MOTOR.
Go to Diagnostic
00
S2
0 HA-142
Set up "ACTIVE TEST" mode with CONSULT. circuit is open. procedure 6.
or Lower in-vehicle sensor
52
~
Go to Diagnostic
HA-143
Set up self-diagnosis STEP 2.

Defroster (duct) sensor
53
0
Go to Diagnostic
HA-l44
Does intake air change according to each ordered po-
53
~
Go to DiagnOstic
HA-l45
altlcn?
S'i
0
Go to Diagnostic
HA-146
0050, posltlon
FREt
5"-
~
Go to Diagnostic
HA-147
FRE
REC
REC
5S
,
Go to Diagnostic
I HA-148
@CodONO. 3X 4X 5X 6X
5S
~
Go to Diagnostic
HA-149
56
~
Go to Diagnostic
i HA-150
FREt
Air intake FRE
REC
REC
When malfunctioning sensor circuit, ambient sensor, in-
vehicle sensor, and duct sensors are suspected, it is
O.K. N.G.
useful to check temperature detected by each sensor
with self-diagnosis STEP 1 to confirm the temperature
is within normal range before performing Diagnostic
Procedures.
CHECK INTAKE
N.G.
1 Repair or adjust.
I
DOOR ROD or LEVER
MECHANISM.
Refer to DOOR CON
TROL - AUlD Air
Conditioner.
O.K.
Intake door control system is normal. Go to Diagnostic Pro-
Refer to Intake door control specification. cedure 16.
HA-126
PRELIMINARY CHECK 3
Insufficient cooling
Read out self-diagnosis result with CONSULT or perform self-diagnosis STEP4 before referring to the
CHECK MODE DOOR OPERA- 1N.G.. 1Go to Preliminary Check 1.
TION.
~ O K
CHECK INTAKE DOOR OPERA- 1N.G.. 1Go to Preliminary Check 2.
TION.
~ O K
CHECK BLOWER MOTOR OPER- N.G.1Go to Preliminary Check 5.
ATION.
~ O K
CHECK MAGNET CLUTCH OPER- 1N.G. 1Go to Preliminary Check 6.
ATION.
~ O K
CHECK COMPRESSOR BELT N.G. "I Adjust or replace compressor
TENSION. belt.
Refer to MA section
~ O . K .
CHECK AIR MIX DOOR OPERA- 1N.G.. 1Go to Preliminary Check 7.
TION.
J,0.K.
CHECK RADIATOR FAN MOTOR 1N.G..1Refer to EF & EC section.
OPERATION.
J,0.K.
CHECK REFRIGERATION CYCLE N.G. Go to Performance Test 018g-
PRESSURE WITH MANIFOLD noses.
GAUGE CONNECTED.
Refer to Performance Chart.
J,0.K.
CHECK FOR EVAPORATOR COIL N.G. Replace suction throttle valve.
FREEZE UP.
1. Set up "DATA
(Freeze up)
00
MONITOR" mode with
CONSULT.
or
@
Set up self-diagnosis
STEP 1.
2. Measure evaporator outlet air
temperature detected by vent
duct sensor.
O.K. (Does not freeze up)
A
HA-127
r
CHECK DUCTS FOR AIR LEAKS. I N.G.1Repair air leaks.
I
or
STEP 3.
2. Adjust difference between
upper and lower target tem-
peratures.
PERFORMTEMPERATURE SET-
TING (Upper and lower).
1. Set up "WORK
(ij\ SUPPORT" mode with
~ CONSULT.
HA128
Preliminary Check (Conl'd)
PRELIMINARY CHECK 4
Insufficient heating
Check coolant level, engine temperature and heater hoses and read out self-diagnosis result with
CONSULT or perform self-diagnosis STEP 4 before referring to the following flow chart.
CHECK MODE DOOR N.G.. 1Go to Preliminary Check 1.
I
OPERATION.
~ O . K
CHECK INTAKE DOOR N.G.1Go to Preliminary Check 2.
I
OPERATION.
~ O . K
CHECK BLOWER MOTOR N.G.1Go to Preliminary Check 5.
I
OPERATION.
~ O . K
CHECK AIR MIX DOOR N.G.. I Go to Preliminary Check 7.
I
OPERATION.
~ O . K
CHECK AIR DUCTS FOR AIR N.G.. 1Repair air leaks.
I
LEAKS.
~ O . K .
PERFORMTEMPERATURE
SETIING (Upper and lower).
1. Set up "WORK
00 SUPPORT" mode with
CONSULT.
or
@
STEP 3.
2. Adjust difference between
upper and lower target tem-
peratures.
HA-129
PRELIMINARY CHECK 5
Blower motor operation is malfunctioning.
N.G.
00Read out trouble data
with CONSULT.
SPONDING TO EACH CODE NO.
or
00
@
@Set up self-diagnosis
How to repair
Reference
STEP 4. Is each sen- Self-diagnosis
....
CONSULT indication
code No.
".
sor circuit normal?
SO
0
Go to Diagnostic
HAl38
O.K.
open procedure 2.
SO
~
Go to Diagnostic
HAl39
p
"
Go to Diagnostic
HAl40
circuit is open. ~
a
0
procedure 4.
05
0
~
Go to Diagnostic
HA141
circuit is shorted.
a
procedure S.
CHECK BLOWER MOTOR OPERATION.
Go to Diagnostic Lower in-vehicle sensor
052
0 HA142
00Set up "ACTIVE TEST" mode with CONSULT. circuit is open. procedure 6.
- or Lower in-vehicle sensor
S2
~
Go to Diagnostic
HA143
circuit is shoned. procedure 7.
Defroster lduct) sensor
S3
0
Go to Diagnostic
HAl44
Does blower motor speed change according to each
S3
~
Go to Diagnostic
HA145
ordered fan speed?
S'4i
0
Go to Diagnostic
HA146
(i)Set fan speed
4V 6V 9V 12V
SO",!
~
Go to Diagnostic
HA147
S5
0
Go to Diagnostic
HA148
@COdeNO.
X3 X4 X5 X6
SS
~
Go to Diagnostic
HA149
Sunloacl sensor circuit
S6
-
Go to Diagnostic
HA150
Middle Middle
is shorted.
procedure 14.
Fan speed Lo HI
Lo HI
When malfunctioning sensor circuit, ambient sensor,
in-vehicle sensor, and duct sensors are suspected, it
O.K. N.G.
is useful to check temperature detected by each sen-
sor with self-diagnosis STEP 1 to confirm the tempera-
ture is within normal range before performing Diag-
nestle Procedures.
I
Is engine coolant temperature below 40"C (104"F) and
N.G.
Blower motor operation is normal.
foot duct temperature below 30"C (86"F)? Refer to Fan speed control specification.
O.K.
IS BLOWER MOTOR CONTROLLED UNDER FAN
No
Check engine temperature sensor control circuit.
STARTING SPEED CONTROL? Refer to EF & EC section.
Refer to Starting fan speed control specification.
Yes
I Blower motor operation IS normal.
HA-130
CHECK MAGNET CLUTCH OPERATION.
~ ~ t up "ACTIVE TEST"' mode with CONSULT.
Check if magnet clutch engages according to order
from CONSULT or each code No.
O.K.
or
STEP 4. Is each sen-
sor circuit normal?
nostic Procedures.
(j)
@
How10 replIir
Reference
Self-diagnosis
....
CONSULT indication
code No. ...
SO
0
Go to Diagnostic
HAl36
ceen
procedure 2.
Amtent sensor cin::uit is
SO
~
Go to Diagnostic
HAl39
S
0
0
Go to Diegnostic
HA-l40
circuit is open. a procedure 4.
Upper in-vehiele sensor
S
0
~
Go to DiagnOstic
HA141
circuit is shorted.
a
procedure 5.
S2
0
Go to Diagnostic
HA142
lower in-vehicle sensor
S2
~
Go to Diagnostic
HA143
53
0
Go to Diagnostic
HAl44
S3
~
Go to Diagnostic
HAl45
eireuit is shorted. procedure 9.
Vent (duet) sensor eireuit
5 ~
0
Go to Diagnostie
HA146
is open. proc:edure 10.
5Y
~
Go to Diagnostie
HA147
is shorted. proc:edure 11.
Floor (duet) sensor eircuit
SS
0
Go to Diagnostic:
HA-l48
is open, procedure 12.
Floor (duet) sensor eircuit
55
~
Go to Diagnostic:
HA149
56
~
Go to Diagnostie
HA150
6X
OFF
OFF
5X
N.G.
4X
ON
ON
3X
O.K.
Magnet clutch
operation
@CodeNO.
oo
set magnet
clutch
iJ operation
fi;\ Read out trouble data
\..!!) with CONSULT.
'-----------+1 CHECK REFRIGER-

ANT.
Connect manifold
gauge then check
system pressure.
N.G.
Check for refrigerant
leaks.
O.K.
Magnet clutch control system is normal.
Refer to MAGNET CLUTCH CONTROL.
Go to Diagnostic Pro-
cedure 19.
HA-131
PRELIMINARY CHECK 7
Discharged air temperature does not change.
N.G.
00 Read out trouble data THE DIAGNOSTIC PROCEDURE BELOW CORRE-
, with CONSULT.
or
(j) @
How to repair
Reference
STEP 4. Is each sen-
Self-dill9nosis
....
sor circuit normal?
CONSULT indication
code No.
".
SO
Go to Diagnostic
1
0 K
a
HAl38
"".n
procedure 2.
SO
Go to Diagnostic
HA139
shorted.
~
procedure 3.
CHECK AIR MIX DOOR OPERATION.
00 ~ ~ t up "ACTIVE TEST" mode with CONSULT.
Upper in.vehicle sensor
5
0
0
Go to Diagnostic
HAl40
circuit is open. a procedure 4.
5
0
-
Go to Diagnostic
HA141
Set up self-diagnosis STEP 2.
circuit is shorted.
a
procedure 5.
Lower in-vehiele sensor
52
a
Go to Diagnostic
HA142
Check if discharge air temperature changes as in fol-
Lower in-vehiele sensor
52
Go to Diagnostic
-
HA143
lowing chart. circuit is shorted. procedure 7.
Defroster lduet) sensor
S3
Go to Diagnostic
a
H A - l ~
00Set discharge
Full Hot
30C Full
53
Go to Diailnostic
air
(86
0
F)
~
HA145
Cool
temperature
Vent {ducd sensor circuit
54
a
Go to Diagnostic
HA146
@COdeNO.
3X 4X 5X 6X
54
~
Go to Diagnostic
HA147
55
a
Go to Diagnostic
HA-l48
Discharge air 30C Full
Full Hot
temperature (86FI Cool
FlOOr(duetJ sensor circuit
55
~
Go to Diagnostic
HA-149
56
~
Go to Diagnostic
HA150
1O.K.
N.G.
Air mix door control system
is normal.
Refer to Specification of air
mixdoor control.
nostic Procedures.
CHECK AIR MIX DOOR MECHANISM.
N.G.
- I Repair or adjust,
I
Refer to DOOR CONTROL.
O.K.
PRELIMINARY CHECK 8
Noise
Refer to page HA-71.
HA-132
Main Power Supply and Ground Circuit Check
POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" in section EL and AIC
ELECTRICAL CIRCUIT - Auto Air Conditioner.
AUTO AMP. REMOVAL
1. Remove driver side instrument lower lid.
2. Remove vent duct.
3. Remove auto amp. with harness connected.
Auto amp. harness connector
WIG IEffim
-..m
1Yi IV
SHA369C

IV 1J1j
00
SHA370C
AUTO AMP. CHECK
1. Disconnect auto amp. harness connectors.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. @ or No. @ and
body ground.
Voltmeter terrnlnal
Voltage
$ e
.
(Approx.)
@
Body ground 12V
@
Check body ground circuit for control unit with ignition
switch OFF
1. Disconnect auto amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check continuity between terminal No. @ or and body
ground.
HA-133
TROUBLE DIAGNOSES Auto Air Conditioner
Harness Layout for AIC System
Engine compartment
- - ~ = : : : : = - - ~ =
,-,
" ,
/ t '
, ,
nector
Ambient sensor con
(ill)
Receiver drier
------;!i(
Ambient sensfYJ:J-
~ 5 f
HA-134
)
Radiator fan sub-relay
Air conditioner
connector
' - , ~ ~
SHA726C
Harness Layout for AIC System (Cont'd)
Passenger compartment
_/
Oef duct sensor and
"=-'sunload sensor
-=ir.c-,V [connector
: Defroster duct
i Sunload sensor connector
~ ~ ~ ~
Blower motor
relay connector
~
Intermediate _
connector@)
~ ~ -
l Auto air conditioner
control amp.
Foot duct L.H.
o
~ , - - - - , _ Auto amp. harness
conl"lectors,
<,
SHA543C
HA-135
-
4
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l
SYMPTOM: Self-diagnosis detects Intermittent short or open
circuit in each sensor circuil.
Check each connector connection as shown in the following
table, and check the condition of each wire.
Connector No. to be checked
Malfunctioning circuit
Engine room Body
Main harness
harness harness
Ale sub-harness
Ambient sensor
(L.H.D. model) @ @ @) @
(R.H.D. model) @ @ (47.xE10:j)
-
(L.H.D. model)
~
@
~
@
(R.H.D. model) @ @ @
Lower in-vehicle sensor @@
@
@
DEF duct sensor @@
VENT duct sensor @@
@@
Floor duct sensor @@ @ @
Sunload sensor @@ @)@)
HA-137
ole
connector.
m
Ambient sensor harness
i connector @
SYMPTOM: Ambient sensor circuit is open. (CONSULT or self-
~ ~ i 5 ~
diagnosis STEP 4 indicates this.)
m
RIL w
00
CHECK AMBIENT SENSOR
N.G.
Disconnect auto amp. harness
CIRCUIT BETWEEN AMBIENT connector.
+
SENSOR AND AUTO AMP.
1 Disconnect ambient sensor har-
(i
Note
ness connector.
SHA373C
ambient sensor harness connec-
between ambient sensor har-
tor terminal No. @ and auto
I!J
Ambient sensor harness ness connector terminal No.@
amp. harness connector term i-
connector
and @?
nal No. @.
~ i 5 =
f
1
0 K
1
0 K
[ill
Disconnect auto amp. harness Replace auto amp.
=( ~
connector.
~
00
I!J 1 Note
m=tm=mJ1
Auto amp. harness ambient sensor harness connec-
connector @
SHA374C
tor terminal No. and auto
amp. harness connector termi-
(i
Auto amp, harness
nal No. @.
connector
connector
&
~
IDl 1
0 K
.
I ~ I
N.G. ~ I Replace ambient sensor.
..-"
CHECK AMBIENT SENSOR.
w
IV
w
Inspection.)
~
1
0 K
[ill
00 ~
II Replace auto amp.
SHA375C
N :
HA-138
m
connector (ill)
SYMPTOM: Ambient sensor circuit is shorted. (CONSULT or
~
~ i 5 ~
self-diagnosis STEP 4 indicates this.)
m
RIL w
[Y]
CHECK AMBIENT SENSOR
N.G.
+
CIRCUIT BETWEEN AMBIENT connector.
l
Disconnect ambient sensor
I;)
Note
harness connector.
Check the circuit between auto
SHA376C
between ambient sensor har-
nal No. @ and is not
I!I Auto amp. harness
ness connector terminal No. @
shorted.
connecter
and @?
lOX
~ 1 ~ i 5
O.K.
Replace auto amp.
RIL tW [ill ~
1
CHECK AMBIENT SENSOR. N.G.. 1Replace ambient sensor.
Inspection.)
Continuity should
not exist
SHA377C !OK.
Replace auto amp.
HA-139
m
In-vehicle upper sensor
harness connector @
SYMPTOM: Upper in-vehicle sensor circuit is open. (CONSULT
;E[itijOO
or self-diagnosis STEP 4 indicates this.)
m
OR
Ril
IYJ
CHECK IN-VEHICLE UPPER
N.G.
-

SENSOR CIRCUIT BETWEEN connector.
J
IN-VEHICLE UPPER SENSOR
1
AND AUTO AMP.
[iJ
Note
Disconnect in-vehicle upper sen-
sor harness connector.
SHA378C
in-vehicle upper sensor harness
m
between in-vehicle upper sensor
harness connector @
harness connector terminal No.
auto amp. harness connector
00
[itij
sa
@ and @?
terminal No. @.
1
0 K
[ill
TR/L
m
LOK
Note
+
Disconnect auto amp. harness IReplace auto amp.
I
rl
RIL connector.
mIhl
in-vehicle upper sensor harness
SHA379C auto amp. harness connector
terminal No. .
[iJ

harness connector @

N.G.
Replace in-vehicle upper sen-
SENSOR. sor.
[ill
Inspection.)
+
JR

---lEil

I Replace auto amp.
SHA380C
Note:
connector.
HA-140
m
harness connector
SYMPTOM: Upper in-vehicle sensor circuit Is shorted. (CON-
m 3 J ~ i 5 ~
SULT or self-diagnosis STEP 4 Indicates this.)
m
BR
RIL
N.G.
[Y]
CHECK IN-VEHICLE UPPER Disconnect auto amp. harness
+
1
IN-VEHICLE UPPER SENSOR
1
AND AUTO AMP. m Note
Disconnect in-vehicle upper
SHA381C
sensor harness connector.
I!J
j
between in-vehicle upper sensor
shorted.
'D
~ i 5
lO.K
If2,W32 l\i I9N II @ and @?
rr l';7I';{ ,I
I
-
~
O.K.
Replace auto amp.
R/L BR
[ill
~ CHECK IN-VEHICLE UPPER
N.G.
Replace in-vehicle upper sen-
SENSOR. sor.
Continuity should not exist.
Inspection.)
SHA382C
lO.K.
IReplace auto amp.
Nole:
If the result Is H.G. after checking circuit continuity, repair hamess or
connector.
HA-141
m
ln-vehlcle lower sensor
harness connector @)
SYMPTOM: Lower in-vehicle sensor circuit is open. (CONSULT
~ ~ i 5 0 0
or self-diagnosis STEP4 indicates this.)
m
RIL
p
[Y]
CHECK IN-VEHICLE LOWER
N.G.
+
IN-VEHICLE LOWER SENSOR
1
AND AUTO AMP.
[!J
Note
Disconnect in-vehicle lower sen-
sor harness connector.
SHA383C
in-vehicle lower sensor harness
1iJ Auto amp. harness
ln-vehlcle lower sensor between in-vehicle lower sensor
connector @) harness connector
~ I ~
~
@ and @?
terminal No. @.
TOK
1
0 K
RIL
eo
RIL
1 Replace a u t ~ amp.
I
~
~
connector.
[ill
~
iii Note
SHA3B4C Check circuit continuity between
in-vehicle lower sensor harness
[!) Auto amp. harness ln-vehlcle lower sensor
connector @
harness connector
fD1
~ ocfh
~ I
terminal No. @.
-.
lK.
ED
p
p
CHECK IN-VEHICLE LOWER N.G. I Replace in-vehicle lower sensor.
~
00
SENSOR.
[ill (Refer to Electrical Components
~
Inspection.)
SHA385C
1
0K.
Replace auto amp.
Note:
connector.
HA-142
m
In-vehicle lower sensor
harnessconnector
SYMPTOM: Lower in-vehicle sensor circuit is shorted. (CON-
d ~ ~ i 5
00
SULT or self-diagnosis STEP 4 indicates fhis.)
m
RIL p
[YJ
N.G.
CHECK IN-VEHICLE LOWER Disconnect auto amp. harness
+
1
IN-VEHICLE LOWER SENSOR
1 AND AUTO AMP. Iil Note
Disconnect in-vehicle lower
SHA386C
sensor harness connector.
Iil
Auto amp. harness
between in-vehicle lower sensor
shorted.
connector
lO.K. 01 ~ ......r
@ and @?
"f;> -,;t1 1Y1'Vf
~ ~ 2 9 KTTRRril eJ
O.K.
I Replace auto amp.
I
RIL p TQl ~
N.G. I Replace in-vehicle lower sensor. 1
~
1
SENSOR.
Inspection.)
SHA387C
lOK.
Replace auto amp.
Nole:
connector.
HA-143
m
Oef. duct sensor harness
connector @
SYMPTOM: Del. duct sensor circuit is open. (CONSULT or

m
WIL RIL
CHECK DEF. DUCT SENSOR
N.G.
[Y]
CIRCUIT BETWEEN DEF. DUCT connector.
-

1
Disconnect def. duct sensor
[;]
1 Note
harness connector.
SHA388C
def. duct sensor harness con-
between def. duct sensor har-
nector terminal No. @ and auto
m
Auto amp. harness Def. duet sensor
and @?
amp. harness terminal No. @.
connector harnessconnector@
lO.K..
ICJI
dtJJ
1
0 K
.

-
RIL
IV
RiL connector.
00

[ill
m
1- _
Nole
""'-'"
$HA389C def. duct sensor harness con-
II Auto amp. harness De1. duct sensor
connector @ harness connector @
nal No. @.
1=1

TO.K

-
CHECK DEF. DUCT SENSOR. N.G. 1Replace del. ducl sensor.

IV
WIL
(Reier 10 Electrical Components
00
Inspeclion.)
[ill
1
0 K
Replace aula amp.

SHA390C
Note:
II the result Is N.G. after checking circuit continuity, repair harness or
connector.
HA144
m Oef. duct sensor harness
connector @
SYMPTOM: Del. duct sensor circuit is shorted. (CONSULT or

sell-diagnosis STEP 4 Indicates this.)
m
w/L RIL
N.G.
[Y]
CHECK DEF. DUCT SENSOR
- +
CIRCUIT BETWEEN DEF. DUCT connector.
1 Disconnect def. duct sensor
Ii)
Note
harness connector.
SHA391C
between def. duct sensor har-
nal No. @ and @ is not
Ii) Auto amp. harness ness connector terminal No. @
shorted.
connector
and @?
1
0 K
101
liti]
O.K.
,M 2.r>? = 'I
Replace auto amp.
I

W/L
[ill

CHECK DEF. DUCT SENSOR.
N.G.. I Replace del. duct sensor.
Inspection.)
SHA392C
1
0 K
rReplace auto amp.
Note:
II the result is N.G. after checking circuit continuity, repair harness or
connector.
HA-145
m
Vent duct sensor harness
connector @
SYMPTOM: Vent duct sensor circuit is open. (CONSULT or
[am [lI ij 00
m
AIL W!A
W
CHECK VENT DUCT SENSOR
N.G.
CIRCUIT BETWEEN VENT DUCT connector.
!
Disconnect vent duct sensor
[iJ
Note
harness connector.
SHA393C
vent duct sensor harness con-
between vent duct sensor har-
nector terminal No. and auto
I!J Auto amp. harness
Vent duct sensor harness
connector @
connector
and @?
nal No. @.
~ I
~
00
!OK LOK
-.
AIL
AIL
eo
connector.
TIll
00 IiI Note
~
SHA394C
vent duct sensor harness con-
Auto amp. harness
Vent duct sensor harness amp. harness connector termi-
connector @) connector
nal No. @.
fD\
~
[[]8
~ I
~ O K
_T
CHECK VENT DUCT SENSOR.
N.G.
Replace def. duct sensor.
eJ
till
Inspection.)
00
lO.K.
IA +
=--=
SHA395C
IReplace auto amp.
Note:
connector.
HA-146
m
Vent duet sensor harness
connector
SYMPTOM: Vent duct sensor circuit is shorted. (CONSULTor
~ ~ i j @ 9
selfdiagnosis STEP 4 indicates this.)
m
RIL
W/R
[JZJ
CHECK VENT DUCT SENSOR
N.G.
CIRCUIT BETWEEN VENT DUCT connector.
+
1
1
Disconnect vent duct sensor
Ii) Note
harness connector.
SHA396C
between vent duct sensor har-
nal No. and is not
Ii)
Auto amp. harness
shorted.
connector
and @?
~ 1 ~ i 5
lO.K.
O.K.
Replace auto amp.
I
RIL WIR [ID 00
~
+
CHECK VENT DUCT SENSOR. N.G. 1Replace vent duct sensor.
J
Inspection.)
lO.K.
SHA397C
IReplace auto amp.
I
Note:
connector.
HA-147
Fa
foot duct sensor harness Diagnostic Procedure 12
connector
SYMPTOM: Floor duct sensor circuit is open. (CONSULT or
~ l i t i 5 ~
self-diagnosis STEP 4 indicates this.) ,
Fa
W/B' RIL
N.G.
[J[]
CHECK FOOT DUCT SENSOR Disconnect auto amp. harness
CIRCUIT BETWEEN FOOT DUCT connector.
+
T
Disconnect foot duct sensor
[!]
Note
harness connector.
SHA398C
foot duct sensor harness con-
between foot duct sensor har-
mAuto amp. harness
Foot duct sensor harness
and @?
nal No. @.
connector connector
E5l
~ d!JJ
1
0 K
lO.K.
~ I
- RIL
ED
RIL
connector.
~
00
[ill
Ii)
Note
~ Check circuit continuity between
SHA399C
foot duct sensor harness con-
I) Auto amp. harness
connector @ connector@
nal No. @.
E5l
~ ~
lOK
I ~ I
......er
CHECK FOOT DUCT SENSOR. N.G. _I Replace foot duct sensor.
ED
WI.
WI.
ill]
00
Inspection.)
lO.K.
~
Replace auto amp.
SHA400C
Note:
connector.
HA-148
m
connector
flIi3
SYMPTOM: Floor duct sensor circuit is shorted. (CONSULTor
~
00
m
WIB
Rll
IYl
CHECK FOOT DUCT SENSOR
N.G.
-
't-
CIRCUIT BETWEEN FOOT DUCT
connector.
)
1 Disconnect foot duct sensor har- m Note
ness connector.
SHA4Q1C
between foot duct sensor har-
nal No. @ and @ is not
m Auto amp. harness
[iti3
shorted.
connector
and @?
1
0 K
lDl
~
O.K.
~ I
I Replace auto amp.
I
RIL
rn
WIB
CHECK FOOT DUCT SENSOR. N.G. J Replace vent duct sensor.
I +
~
J
Inspection.)
SHA402C
1
0 K
I Replace auto amp.
Note:
connector.
HA149
mSunload sensor harness
connector
~ i 5
SYMPTOM: Sunload sensor circuit is shorted. (CONSULT or
~ ~
00
m
!Vi
CHECK SUNLOAD SENSOR CIR-
N.G.
CUlT BETWEEN SUNLOAD SEN- connector.
~ SOR AND AUTO AMP.
1
Disconnect sunload sensor nar- m Note
ness connector.
SHA403C
between sunload sensor har-
nat No. @ and @ is not
m
Auto amp. harness
~ i 5
shorted.
connector
IE5l
and @?
1
0 K
~
00
O.K.
Replace auto amp.
RIl
ffiJ
WIG
~
CHECK SUNLOAD SENSOR. ~ I Replace sunload sensor.
I
J
Inspection.)
SHA404C
1
0 K
IReplace auto amp.
Nole:
connector.
HA-150
SHA698C
SHA699C
N.G.
Yes
Yes
Yes
Yes
Inter- Auto
mediate amp. Continuity
connector connector
Replace auto
amp.
terminals and intermediate con-
nector terminals.
Continuity
Air mix
door II
motor
connector
Inter-
mediate
connector
Inter-
Air mix
mediate
door I
Continuity
motor
connector
connector
@ @
Yes
@ @
Yes
00
@
Terminal No.
Air mix Air mix
Airmix door I door II
door Code No.
E> E>
position e e
FUll-Hot 3X @ @ @ @
Full-Cool 6X @ @ @ @
Check continuity between inter- O.K. \ Repair harness or connector.
mediate connector terminal and
each air mix door motor har-
ness connector terminal.
Remove heater unit assembly.
@ @ Yes
O.K.
*. After two minutes power
supply is automatically cut off.

1
@ @ Yes
CHECK FOR SIGNALS TO AIR N.G.
MIX DOOR MOTOR.
fij\ Set up ':ACTIVE TEST"
mode with CONSULT.
M Set up self-diagnosis

Set air mix door position as
shown in the following chart.
Check if approximately 10V ex-
ists for 3 seconds every 10 sec-
onds between each terminal. *
SYMPTOM: Air mix door does not operate normally.
Read out self-diagnosis result with CONSULT or perform
self-diagnosis STEP 4 before referring to the following flow
chart.
Remove combination meter assembly to make working
space and reconnect air conditioner switch connector.
B ;=r!J'---- -,
IReplace air mix door motor.
Auto amp.

\ connector

fIBHB
IJJ
(R.H.D)
[ill
Air mix door II
motor connector @)

'---!:!.-!l---"----:L-l
(L.H.D.) Air mix door II
em motor connector
..
'-------J GY
Intermediate connector

BR/Y Air mix door I
G/V J motor connector
GY L BRtY
; 0
I-.... 43
Intermediate connector between auto amp.
harness and air mix door motor harness.
@D
(L.HD.) L.dI SCJ
Intermediate
connector @)
43 0 I II
444542 I II
1
(R.H.D)
Intermediate connector
II .311 1lIi500
1
2 5 Air mix door I
BRty r I, , motor connector
JLJGY GIY_
BR/V
TQ1
SHA700C
HA-151
(j)
@
Terminal
SHA701C
No.
Intake door
Code No.
m
Intake door motor
position
Ef>
19

conneetor@
FREIREC-
@ (@ -. 5X -6X
REC
Auto amp. harness
I?J
connector @
6X-3X REC- FRE
(@ @
SYMPTOM: Intake door does not operate normally.
self-diagnosis STEP4 before referring to the following flow
chart.
Intake door motor
harness connector

(L.H.O.)
SR I
(RHO.)

'J!u G/V
G/Y SR

SHA409C
Intake door motor
connector @
GIY
00 Z (L.H.O)
[ill ;a
46
i Ell
[rill" (RHO.)

..J=ll
$HA702C
CHECK FOR SIGNALS TO IN-
TAKE DOOR f\i10TOR.
Disconnect intake door motor
harness connector.
rF.i\ Set up "ACTIVE TEST"
\J!i) mode with CONSULT.
ta\ Set up self-diagnosis
STEP 2.
Set intake door position as
Check if approximately 10V
exists for 2.5 seconds between
each terminal.
lOK
I Replace intake door motor.
HA-152
N.G. CHECK OUTPUT OF AUTO AMP.
rF.i\ Set up "ACTIVE TEST"
W mode with CONSULT.
ta\ Set up self-diagnosis

Set intake door position as
exists for 2.5 seconds between
each terminal.
(j) @
Terminal
No.
Intake door
Code No.
position
Ef> 9
5X-6X
FRE/REC-
@ @
REC
6X-3X REC- FRE
@ @
O.K. N.G.
Replace auto
amp.
Check continuity between auto
nal No. @ and intake door mo-
tor harness connector terminal
No. @.
Check auto amp. harness con-
nector terminal No. @ and in-
take door motor harness con-
nector terminal No. @.
m

SYMPTOM: Mode door does not operate normally.
Read out self-diagnosis result with CONSULTor perform

Auto amp, harness connectors @
JEil ...JC5L
chart.
IXl IXlx3 II IXIXI I II
m
IX IX I IXIX IIXIX 48
RIL
CHECK P.B.R. CIRCUIT N.G.
CHECK MODE DOOR MOTOR.
58
Set up "ACTIVE TEST" Refer to Electrical Components
mode with CONSULT.

Inspection.
O.K.
!
N.G.
SHA411C
STEP 2.
m
Set mode door motor as shown
Replace mode
in the following chart.
door motor.
Check P.B.R. voltage with
Auto amp. harness is
! data monitor function in
m
"ACTIVE TEST" mode.
CHECK HARNESS BETWEEN
connectors
Mode door P.B.R. voltage
AUTO AMP. AND MODE DOOR
iEjl
A \
position Iepprox.I
MOTOR.
DEF 4.SV
Mode
Mode door motor
FOOT/DEF 2.5V
Auto
door
k 1&1harness connector
i.rv
amp.
motor
B/l
harness Continuity
II 0!48 S8
harness
48 II
7372
1 Ii ...
VENT OV
connector
/, '
terminal
connector
IL.H.D.}'" , I
terminal
58
RIG .,
@Check if voltage between
= auto amp. harness con- @ No

nector terminals @ and
@ @ Yes
72 731 "
@ varies from approxi-
@
No
/0
TQlIR.H.D.I
mately 5V to approxi-
@ Yes
mately OV according to
@ @ No
mode door position var-
tes.
@ No
... _---

@ No
@
Voltage
@
No
SHA703C
@ @
@
Yes
Code No.
e
(J
3X 4.8V
I O.K.
1
N.G.
4X 2.5V
5X 1.1V
ax OV
lO.K.
[ Go to diagnostic procedure 18.
I
i
HA-153
SYMPTOM: Mode door does not move at all.
chart.
Mode door motor
harness connector
L
(L.H.O.)
OR
(RHO.)

L
CHECK FOR SIGNALS TO MODE N.G.
DOOR MOTOR.
(ij\ Set up "ACTIVE TEST"
mode with CONSULT.

Set mode door position as
exists between mode door mo-
tor harness connector terminals
and @ for approximately 1.3
seconds every 10 seconds.
CHECK OUTPUT OF AUTO AMP.
(ij\ Set up "ACTIVE TEST"
mode with CONSULT.

Set mode door position as
exists between mode door mo-
tor harness connector terminals
@ and @ for approximately 1.3
seconds every 10 seconds.
SHA704C
00
Terminal
No.
Mode door
Code No. G)
8
position
DEF 3X @ @
VENT ax @ @
O.K. N.G.
Replace auto
amp.
Terminal
No.
3X @
ax @
Code No. i) 8
1
0 K
y
Modedoor
position
DEF
VENT
'---- 1
IReplace mode door motor.
Mode door
motor connector
[Y]
If-.
litiS@]
Auto amp. harness
connector @
IEHiJimI
L ifOR
SHA414C
nal No. @, @ and mode door
motor harness connector termi-
nal No. @, @ respectively.
O.K. LNG.
Repair har-
ness or con-
nector.
"
_____1
1 INSPECTION END

L (RHO.)
Mode door motor
harness connector

01' (L.H.O.)
L OR
Auto amp. harness
connector

SHA705C
HA-154
m

SYMPTOM: Magnet clutch does not engage.
Perform Preliminary check 6 before referring to the follow-

ing flow chart.
m 151
Compressorharness
-
CHECK POWER SUPPLY FOR N.G. CHECK AIC RELAY OPERATION.
connector @
[Y]
COMPRESSOR.


Disconnect compressor harness between Ale relay harness eon-
G
connector. nector terminal No. @ and body
=
SHA416C
00Set up "ACTIVE TEST" ground?
! mode with CONSULT.
I N.G. O.K.
151

STEP 2.
Set compressor as shown in the
Disconnect Ale relay harness
-
following chart.
connector.
Ale relay harness
[Y]
connector
Check jf approximately 12V ex-
a. - ists between compressor har-

G

ness connector terminal and
[!]
'"
Note
body ground.
= AIC relay harness connector ter-
00
@
minal No. @ and compressor
SHA417C Terminal No.
Compressor Code No.
@
[!]
ON 6X @ l:odY
ground
00
-r
0 K
Compressor
Check magnet clutch.
harness

Ale relay harness connector
connector [ill @)
Replace magnet clutch.

rr%
G G
e.-.::
Refer to COMPRESSOR - Model
MJS170 (HITACHI make).
SHA418C
I!l
..
I!l
rIIiSOO
CHECK POWER SUPPLY FOR N.G. CHECK POWER SUPPLY CIR-
AIC RELAY. CUlT.
Ale relay harness
Disconnect Ale relay. (Refer to "POWER SUPPLY
connector@)
GAY
Do approximately 12 volts exist ROUTING" in EL section and AIC
e---fo3
between Ale relay harness con- ELECTRICAL CiRCUiT.)
nector terminal No. , @ and

GIW'
-
body ground respectively?
[SZ]
-r
0
.
K
-
CHECK AIC RELAY AFTER DiS- N.G. IReplace AIC relay.

I =
CONNECTING IT.
SHA419C
II
Low-pressure
[lti) 001
Inspection.)
Note:
switch harness
lO.K
II the result is N.G. aller checking
CO"i; circuit continuity, repair harness
Reconnect AIC relay.
I or connector.
lG/B
[Y]
&
(Go to next page.)
SHA420C
HA-155
Low-pressure
switch harness
connector @)
o
LG/B
Ale relay
harness
connector
IID
LG/B
SHA421C
Cf
Turn ignition switch ON and
press @ switch.
Note
CHECK COIL SIDE CIRCUIT OF
AIC RELAY.
between low-pressure switch
harness connector terminal' No.
@ and body ground?
o
For terminal
arrangement
refer to Circuit '------
Diagram for Quick Pinpoint Check.
Note

!O.K.
CHECK LOW-PRESSURE
SWITCH.
Inspection.)
CHECK E.C.C.S. CONTROL
UNIT.
(Refer to EF & EC section.)
IReplace low-pressure switch. I
N.G.
O.K.
Do approximately 8 to 9 volts
exist between E.C.C.S. control
unit harness connector terminal
No. @ and body ground?
connector.
terminal No. @ and E.C.C.S.
control unit harness connector
terminal No. @.
O.K.

between E.C.C.S. control unit
and body ground?
o
OR
OR
OR
E.C.C.S. control unit
connector
i'===:==",
II [It i)
Ale switch 00
OFF
lVT
'---+i"!!.-(t)+..."::'AI--.......

Circuit Diagram for QUick Pinpoint Check.
SHA341C
II EJ CONNECTOR II [It i)
E.C.C.S. control 46 Ale switch
Unit connector OFF f!F:t1
SB TVi

Circuit Diagram for Quick Pinpoint Check.
SHA343C =
t1F,l) Low-pressure
SClJ switch connector
1;=1 CONNECTOR II@)
E.C.C.S. control 9
unit connector
III
Nole:
connector.
'----- 1
I Replace auto amp.
For terminal arrange-

ment, refer to Circuit
Diagram for Quick
Pinpoint Check.
SHA425C
E.C.C.S. control unit connector
[11 IV II """"IT]Of ClNIECTOR II
(00 LID L
Auto amp.
harness
connector
HA156
m
~ i )
00
SYMPTOM: Air conditioner control switch panel illumination
does not come on.
m
Switch unlt hamess ~
Turn on light switch.
N.G.
Check illumination control sys-
connector @
Set illumination control switch at tern. Refer to section EL.
- +
the brightest position.
l ~ i R / V
exists between switch panel har-
G/V
SHA426C
and @.
Lo.K.
IRepiace bulb.
HA-157
m
Switch unit harness
litiS
connector SYMPTOM: Set temperature and ambient temperature do not
1c:::::J1
~
appear on display window.
[IXI
I
14 :113]
m m
I
Check if approximately 0.5 to 2V
N.G.
Check if approximately 0.5 to 2V
OR BRIW
[YJ
exist between switch unit har- exist between auto amp. har-
I", +
ness connector terminals No. ness connector terminals @
=-.:
@ and @. and @ .
~ O . K .
O.K.
L
N.G.
SHA427C
I Replace switch unit.
I
Replace auto
m
litl)
amp.
Auto amp. harness
connector
wffim\
~
Repair harness or connector
(terminal No. @, @).
-fl-
~
SHA428C
HA-158
m
[iii)
Switch unit harness
SYMPTOM: When air conditioner switch is operated it does not
connector @)
beep.
I ~ m
00
m
Do approximately 12 volts exist ~ ...I Replace air conditioner switch
I
NJ
between air conditioner switch
G'B BRIW
unit harness connector terminal
~
No. 0 and @?
m
~ O K
SHA429C
N.G.
m
~ i )
between auto amp. harness con- (terminal No. @).
Auto amp. harness
nector terminal No. 0 and @?
connector @
@8
1
0 K
[,,\ I [flfil
..
Check switch panel. ~ I Replace auto amp.
I
I'-l'
Refer to Electrical Components
Inspection.
~ O K
( Replace switch panel.
I
SHA430C
HA-159
N.G.
between auto amp. harness con-
nector terminal No. @, @ and
@?

Repair har- Replace auto
ness or con- amp.
nector
(Terminal No.
@. @ and
@)
Ii]
N.G.
Measure voltage between auto
nal No. 0. 0. @. @ and @.
Terminal No.
Voltage
EEl e
(epprox.I
1.0V
I

O.65V
@
O.8V
@
OV (Light OFF)
12V (Ligh' ON)

!N.G.
Repair har- Replace auto
ness or con- amp.
nector
(Terminal No.
0.0.@.
@ and @).
O.K.
O.K.
Check switch unit.
Inspection.
connector terminal No. @, @
and @?
SYMPTOM: Figures of set temperature and ambient tempera-
ture do not appear on the display window and
Indicator lamp (L.E.D.) does not come on.
m lEI
r-.-----------,
IReplace switch panel.
Switch unit harness
connector'@
fEjl
LYJ

'-- >--.J
1,6 I
IIXI I I
R

8 fm
SHA432C
.R/W
$HA433C
SHA431C
BR/Y R/W
\ Auto amp. harness
BR/W \ connector
Auto amp. harness
connector @
,.f----......
171sj BR
1:.

SHA434C
HA-160
SYMPTOM: Switches do not work.
Check switch panel. N.G. I Replace switch panel.
Inspection.
Switch unit harness
connector @
Auto amp. harness
connector @
SHA435C
O.K.
nal No. CD '" and switch
panel harness terminal No. CD
""" respectively.
O.K.
IReplace auto amp.
HA-161
N.G. ~ Repair harness or connector.
SYMPTOM: Blower motor operation is malfunctioning.
Perform Preliminary check 5 before referring to the of
flowing flow chart.
N.G.
O.K.
B
(Go to page after next.)
Note
CHECK BLOWER MOTOR.
inspection.)
GiI=--.!'--- --'-'=;
I;]
'------------,
CHECK POWERSUPPLY FOR
BLOWER MOTOR.
between blower motor harness
body ground?
L
O.K. N.G.
blower motor harness connector
terminal No. and fan control
amp. harnessconnector termi-
nal No. @.
L
N.G.
f - - ~
Note
FAN CONTROL AMP.
between fan control amp. har-
ness connector terminal No. ,@
and body ground?
CUIT FOR FAN CONTROL AMP.
fan control amp. harness con-
nector terminal No. @ and body
ground?
1
0 K
...
CHECK OUTPUT OF AUTO AMP.
M Set up "ACTIVE TEST"
\!!J mode with CONSULT.
~ Set up self-diagnosis
~ STEP 2.
Measure voltage across fan con-
trol amp. harness connector ter-
minals No. @ and @.
SHA449C
= SHA450C ;:[i=-- -L ~
6 L
L
Blower control
amp. harness
connector
_-1!13616s!!-i!---.....
mBlower control
amp. harness ~ COIIBT ~
connector IAdII II) ~
lEE
NJ
m
Blower control
amp. harness fii,;jjJ COllET ~
connector ~ II) ~
E ; ~
I Replace blower motor.
1.2
1.3
1.4
1.6
I
Terminal
No.
x3
x4
x5
x6
Code
No.
4
6
9
12
motor
voltage
(V)
00 ~ Voltage
B';we, ~ I - ~ ~ (App'Ox.)
(vi
SHA451C
L/R
Ii] Blower motor
harness connector
~ ! - - - - - .
SHA452C
o
(Go to next page.)
L
Blower motor
harness connector
;
SHA453C
HA-162
fa
fa
~
[!I
Blower control
~ ~
..
amp. harness
00
Set up "ACTIVE TEST"
N.G.
CHECK FOR OUTPUT OF AUTO
connector@
mode with CONSULT. AMP.
!I'61..!! ((tB
Set blower motor voltage
00
Set up "ACTIVE TEST"
L
L
at 9 volts mode with CONSULT.
(i) Set up self-diagnosis Set blower motor voltage
lli
- STEP 2. Set code No. in at 9 volts
X5. (j) Set up self-diagnosis
Do approximately 12 volts exist - STEP 2. Set code No. in
SHA454C
between fan control amp. har- X5.
ness connector terminal No. @ Do approximately 12 volts exist
[!I
and @? between auto amp. harness con-
~ i )
Auto amp. harness
t
o
.
K
.
nector terminal No. @ and body
connector@
ground?
Imm,
I Replace fan control amp.
I
IN.G.
O.K.
L
NJ
~ ..
-
00
I:J
CHECK FOR FEEDBACK SIGNAL ~
TO AUTO AMP.
" SHA455C
~ ..\ Repair harness or connector
I
Disconnect fan control amp. con-
nector only.
I:J
Auto amp. harness
connector @) between auto amp. harness con-
~ I Replace auto amp.
I
~ i ) O O l d m
nector terminal No. ' @ and
body ground?
fl19 ]}
SHA456C
HA-163
0
0

..
Blower relay

N.G.
harness
CHECK POWERSUPPLY FOR Check power supply circuit.
connector
BLOWER RELAY. (Refer to "POWER SUPPLY
Do approximately 12 volts exist ROUTING" in EL section.)

between blower relay harness
1
NJ
connector terminal No. @, @
and body ground?
--
IJ
!OK
13
N.G.
Check voltage between blower
';" SHA536C
between blower relay harness relay harness connector termi-
IJ
connector terminal No. @ and nal No. @ and body ground is
Blower relay
body ground? less than 1.5 volt.
harness

1
0 K
!
O.K. N.G.
connector

Check 12A fuse at fuse block. Replace
Refer to "POWER SUPPLY blower relay.
[ill
ROUTING" in EL section and
AIC ELECTRICAL CIRCUIT.) II Note
blower relay harness connector
SHA458C terminal No. @ and auto amp.

13
@
Blower relay
!
harness
I Replace auto amp.
I
connector
00
[YJ
Note:
connector.
SHA537C
II

Auto amp. harness Blower relav
connector @) connector
m:fim

SHA460C
HA-164
SHA437C
Temperature 'C CF) Resistance kQ
-40 (-40) 210.55
-35 (-31) 146.86
-30 (-22) 103.97
-25 (-13) 74.63
-20 (-4) 54.28
-15 (5) 39.97
-10 (14) 29.77
-5 (23) 22.43
0(32) 17.07
5 (41) 13.11
10 (50) 10.18
15 (59) 7.96
20 (68) 6.29
25 (77) 5.00
30 (86) 4.01
35 (95) 3.24
40 (104) 2.63
45 (113) 2.15
50 (122) 1.77
55 (131) 1.47
60 (140) 1.22
65 (149) 1.02
70 (158) 0.86
75 (167) 0.73
80 (176) 0.62
Electrical Components Inspection
TEMPERATURE SENSORS
After disconnecting temperature sensors harness connector
measure resistance between terminals of each sensor, using
the table below.
@)Ambient
sensor
connector
SHA436C
Aspirator and
in-vehicle sensor (LWR)
INVEHICLE SENSOR LOWER
ANO FLOOR OUCT SENSOR
.i->
ij ="J.ZJ-----..
00
rr

(fF In-vehicle r-:-;
sensor upper connector

OEFROSTER Def duct
sensor
......,
E{)
SHA439C
HA-165
VENT DUCT SENSOR
~
~ / ( }
Vent duct L.H.
Vent duct /'
sensor ---
o
o
->:
Auto amp. harness
connector
~ i 5
SHA440C
SHA441C
SUNLOAD SENSOR
Measure voltage between terminals @ and ~ at vehicle
harness side using the table below.
Input current rnA Output voltage (V)
0 5
0.1 4
0.2 3
0.3 2
0.4 1
0.5 0
When checking sunload sensor, select a place where sun
shines on it directly.
MODE DOOR MOTOR
Check to see if motor rotates when 12V is applied across mode
door motor connector terminals No. and No. @.
Terminal No.
@ @
Mode door operation
8
(B VENT ~ DEF
e e
STOP
(B
e
DEF ~ VENT
Check to see if mode door P.B.R. resistance is varied according
to mode door position, as shown in the following table.
Mode door position
DEF
FOOT/DEF
B/L
VENT
HA166
Resistance between terminal
No. @ and @
3 kn
on
AIR CONDITIONER SWITCH UNIT
Check the resistance between switch unit connector terminals
as follows:
Example:
When Auto switch is pressed. the resistance between terminal
No. CD and @ is less than soon.
AUTO ECON OEF
OFF HI UP
2
REC LO OOWN
3
4
5
6
Switch condition
Press
Free
Resistance
Less than 500Q
00
SHA442C
BLOWER MOTOR
RELAY
LOWPRESSURE SWITCH
HA-167
COMPRESSOR
SERVICE DATA AND SPECIFICATIONS (S.O.S.)
General Specifications
LUBRICATION OIL
Model
Type
Displacement ern" (cu in)/Rev.
Cylinder bore x stroke
mm (in)
Oirection of rotation
Drive belt
HITACHI make
MJS170
Swash plate
170 (10.37)
40.0 x 22.6 (1.575 x 0.890)
Clockwise
(Viewed from drive end)
Poly V
Model
Type
Capacity
me (Imp 11 oz)
Total in system
Amount of oi I which can be
drained
Compressor (Service parts)
charging amount
REFRIGERANT
Type
HITACHI make
MJS170
SUNISO 5GS
150 (5.3)
Approx. 120 (4.2)
150 (5.3)
R-12
Capacity
VG30DE engine model
k9 (Ib)
0.85 - 0.95 (1.87 - 2.09)
VG30DETI engine model
Inspection and Adjustment
ENGINE IDLING SPEED (When AIC is ON.) COMPRESSOR
Refer to EF & EC section.
Model
0.75 - 0.85 (1.65 - 1.87)
MJS170
BELT TENSION
Refer to Checking Drive Belts (MA section).
Clutch disc-pulley clearance
mm (in)
0.5 - 0.8
(0.020 - 0.031)
HA-168

16 - Section HA - Heater & Air Conditioner Net

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16 - Section HA - Heater & Air Conditioner Net

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HEATER &

, sl 54 (4A. 5,5, 32 - 40)

Check if blower motor rotates

Conduct checks as per flow

Disconnect blower motor har-

Replace blower motor.

Oonnnuitv should exist.

NESS TERMINAL VOLTAGE.

Perform PRELIMINARY CHECK 4 and Main Power Supply

(Go to next page.)

Perform PRELIMINARY CHECK 2 before referring to the

Disconnect compressor harness

Do approximately 12 volts exist AIC RELAY.

00 approximately 12 volts exist

control amp. harness connector

CHECK AIC SWITCH OF SWITCH

Ohmmeter should show some resistance when

CHECK POWER SUPPLY FOR

@ Air mix door I Direction of

Outside air Heet Flff Off

Set up self-diagnosis STEP 2.

'-----------+1 CHECK REFRIGER-

Replace aula amp.

Read out self-diagnosis result with CONSULTor perform

mode with CONSULT.

Perform Preliminary check 6 before referring to the follow-

a. - ists between compressor har-

Replace magnet clutch.

nector terminal No. , @ and

CHECK AIC RELAY AFTER DiS- N.G. IReplace AIC relay.

Do approximately 12 volts exist

For terminal arrangement, refer to

For terminal arrangement, refer to

For terminal arrange-

Do approximately 12 volts exist ROUTING" in EL section.)

SHA458C terminal No. @ and auto amp.

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