Page 245 of 2389
Evaporator
INSPECTION OF EVAPORATOR
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
ASSEMBLY OF COOLING UNIT
INSTALL COMPONENTS ON EVAPORATOR
(a) Connect the expansion valve to the inlet fitting of the
evaporator. Torque the nut.
Torque: 230 kg±cm (16 ft±Ib, 22 N±m)
HINT: Be sure that the 0±ring are positioned on the tube
fitting.
(b) Install the holder to the suction tube with heat sensi-
tizing tube.
(c) Connect the liquid tube to the inlet fitting of the expan-
sion valve. Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
(d) Install lower unit case to the evaporator.
(e) Install thermistor to the evaporator.
(f) Install upper unit case.
(g) Install four screws.
(h) Install four clips.
(i) Install wire harness.
(j) Install condenser fan control amplifier.
(k) Install compressor control amplifier.
(I) Connect connectors.
INSTALLATION OF COOLING UNIT
1. INSTALL COOLING UNIT
Install the cooling unit with three nuts and four bolts.
2. CONNECT CONNECTORS
3. INSTALL GLOVE BOX REINFORCEMENT(c) Remove the expansion valve.
± AIR CONDITIONING SYSTEMCooling UnitAC±41
Page 246 of 2389
Evaporator
INSPECTION OF EVAPORATOR
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
ASSEMBLY OF COOLING UNIT
INSTALL COMPONENTS ON EVAPORATOR
(a) Connect the expansion valve to the inlet fitting of the
evaporator. Torque the nut.
Torque: 230 kg±cm (16 ft±Ib, 22 N±m)
HINT: Be sure that the 0±ring are positioned on the tube
fitting.
(b) Install the holder to the suction tube with heat sensi-
tizing tube.
(c) Connect the liquid tube to the inlet fitting of the expan-
sion valve. Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
(d) Install lower unit case to the evaporator.
(e) Install thermistor to the evaporator.
(f) Install upper unit case.
(g) Install four screws.
(h) Install four clips.
(i) Install wire harness.
(j) Install condenser fan control amplifier.
(k) Install compressor control amplifier.
(I) Connect connectors.
INSTALLATION OF COOLING UNIT
1. INSTALL COOLING UNIT
Install the cooling unit with three nuts and four bolts.
2. CONNECT CONNECTORS
3. INSTALL GLOVE BOX REINFORCEMENT(c) Remove the expansion valve.
± AIR CONDITIONING SYSTEMCooling UnitAC±41
Page 247 of 2389
4. INSTALL GROMMETS ON INLET AND OUTLET
FITTINGS
5. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
6. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 330 kg±cm (24 ft±ib, 32 N±m)
7. IF EVAPORATOR WAS REPLACED, ADD
COMPRESSOR OIL TO COMPRESSOR
Add 40 ± 50 cc (1.4 ± 1.7 fl.oz.)
Compressor oil: DENSOOIL 6,
SUNISO NO. 5GS or equivalent
8. CONNECT NEGATIVE CABLE TO BATTERY
9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
10. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 700 g (1.3 ± 1.7 Ib)
REFRIGERANT LINES
(See page AC±12)
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT
LOOSE
Tighten or replace as necessary.
REPLACEMENT OF REFRIGERANT
LINES
1. DISCHARGE REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fitting immediately to keep moisture
out of the system.
3. TIGHTENING TORQUE FOR O±RING AND BOLTED
TYPE FITTINGS
(See page AC±12)
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 750 g (1.3 ± 1.7 Ib)
± AIR CONDITIONING SYSTEMCooling UnitAC±42
Page 248 of 2389
4. INSTALL GROMMETS ON INLET AND OUTLET
FITTINGS
5. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 140 kg±cm (10 ft±Ib, 14 N±m)
6. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 330 kg±cm (24 ft±lb, 32 N±m)
7. IF EVAPORATOR WAS REPLACED, ADD
COMPRESSOR OIL TO COMPRESSOR
Add 40 ± 50 cc (1.4 ± 1.7 fl.oz.)
Compressor oil: DENSOOIL 6,
SUNISO NO. 5GS or equivalent
8. CONNECT NEGATIVE CABLE TO BATTERY
9. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
10. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 700 g (1.3 ± 1.7 Ib)
REFRIGERANT LINES
(See page AC±12)
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak detector. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NOT
LOOSE
Tighten or replace as necessary.
REPLACEMENT OF REFRIGERANT
LINES
1. DISCHARGE REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fitting immediately to keep moisture
out of the system.
3. TIGHTENING TORQUE FOR O±RING AND BOLTED
TYPE FITTINGS
(See page AC±12)
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 ± 750 g (1.3 ± 1.7 Ib)
± AIR CONDITIONING SYSTEMRefrigerant LinesAC±42
Page 249 of 2389
THERMISTOR
(See page AC±40)
REMOVAL AND INSPECTION OF
THERMISTOR
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE GLOVE BOX AND UNDER COVER
3. CHECK THERMISTOR INSTALLED OPERATION
Using an ohmmeter, measure the resistance at the con-
nector.
Resistance: 1,500
at 25°C (77°F)
If resistance value is not as speci¿¿ed, replace the
thermistor.
4. REMOVE THERMISTOR
(a) Disconnect the connector.
(b) Remove the screw and thermistor from the cooling
unit.
5. CHECK THERMISTOR OPERATION
(a) Place the thermistor in cold water. While varying the
temperature of the water, measure the resistance at
the connector and at the same time, measure the tem-
perature of the water with a thermometer.
(b) Compare the two readings on the chart.
If the intersection is not between the two lines, replace the
thermistor.
INSTALLATION OF THERMISTOR
1. INSTALL THERMISTOR
(a) Install the thermistor with the screw.
(b) Connect the connector.
2. INSTALL GLOVE BOX AND UNDER COVER
3. CONNECT NEGATIVE CABLE TO BATTERY
± AIR CONDITIONING SYSTEMThermistorAC±43
Page 250 of 2389
HINT: When checking for continuity in circuits which
contain an LED, please observe the following in-
structions.
(a) Use a tester with a power source of 3V or greater to
overcome the circuit resistance.
(b) If a suitable tester is not available, apply battery volt-
age and check that the LED lights up.
If there is no continuity as specified, replace the A/C
switch.
4. INSTALL A/C SWITCH
5. CONNECT NEGATIVE CABLE TO BATTERY
A/C SWITCH (Push Type)
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE HEATER CONTROL ASSEMBLY
3. DISCONNECT HEATER CONTROL CONNECTOR
4. CHECK A/C SWITCH CONTINUITY
Using an ohmmeter, check continuity between the termi-
nals for each switch position as shown in the table.
AC SWITCH (Lever Type)
(See page AC±12)
ON±VEHICLE INSPECTION
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE A/C SWITCH
3. CHECK A/C SWITCH FOR CONTINUITY
Using an ohmmeter, check continuity between the termi-
nals for each switch position as shown in the table.
If there in no continuity as specified, replace the A/C
switch.
5. CONNECT HEATER CONTROL CONNECTOR
6. INSTALL HEATER CONTROL ASSEMBLY
7. CONNECT NEGATIVE CABLE TO BATTERYSwitch position
Switch positionIllumination
Terminal
Terminal
A/C
A/C
OFFOFF
± AIR CONDITIONING SYSTEMA C SwitchAC±44
Page 251 of 2389
AMPLIFIERS
Inspection of Amplifier
(See page AC±12)
Air Conditioner Amplifier
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect the connector on the
wire harness side as shown in the chart below.
Test conditions:
(1) Ignition: ON
(2) Temperature control lever: MAX. COOL
(3) Blower switch: Hl
If circuit is as specified, replace the amplifier.
ApProx. 1.7 k at 25°C (77°F)
3S±FE Engine Model
Turn ignition switch off.Turn ignition switch on.
Turn ignition switch off.Turn ignition switch on.
Turn ignition switch off.
Turn ignition switch on.Turn A/C switch off.
Turn A/C switch on.
Turn A/C switch off.Turn A/C switch on.
4pprox. 10 to 14 V
Tester
connectionSpecified value
Battery voltage
Battery voltageBattery voltageBattery voltage
Battery voltage
ApproX. 250 W Start engine.
Stop engine.No voltageNo voltage
No voltage
No voitage
No voltageNo voltage ContinuityContinuity
Resistance
Condition
Check for
Constant
ConstantConstant
Voltage
Voltage
± AIR CONDITIONING SYSTEMAmplifiersAC±45
Page 252 of 2389
Condenser Fan Control Amplifier
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect the connector on the
wire harness side as shown in the chart below. If the circuit is as specified, replace the amplifier.
If circuit is as specified, replace the amplifier. 2VZ±FE Engine Model
Approx. 1.5 k at 27°C (77°F)
Turn ignition switch off.
Turn ignition switch off. Turn ignition switch on±. Turn ignition switch on. Turn ignition switch off.Turn ignition switch on. Turn ignition switch off. Turn ignition switch on.
Turn A/C switch on.
Turn A/C switch on.
Turn A/C switch off. Turn A/C switch off.
Tester
connection
Approx. 10 to 14 V Tester
connection
Specified valueSpecified value
Battery voltageBattery voltageBattery voltage Battery voltage
Battery voltage
Approx. 250 Battery voltage
Start engine.
Stop engine.
No voltageNo voltage
No voltage
No voltage
No voltage ContinuityNo voltageNo voltage
ContinuityContinuity
Continuity Continuity
Continuity
Condition
Continuity ResistanceCondition
Check forCheck for
Constant Constant Constant
Constant Constant
Constant Constant
VoltageVoltage
± AIR CONDITIONING SYSTEMAmplifiersAC±46