1986 TOYOTA CAMRY V20 cooling

(e) Tighten the O±ring fittings or the bolted type fittings to
the specified torque.
4. WHEN CONNECTING MANIFOLD GAUGE;
(a) Be sure to connect the charging hose end with a pin
to the compressor charging valve.
(b) The letter ºDº engraved near the compressor service
valve indicates the high pressure side, and ºSº indi-
cates the low pressure side. Pay careful attention
when connecting the hose.
(c) Tighten hose by hand.
(d) To prevent loosening of connected hose, do not apply
drops of compressor oil to the seat of connection.
HINT: After connecting the manifold gauge and the refrig±
erant container (service can), discharge any air in the
hoses.
5. WHEN EVACUATING;
Approx. 15 minutes after removal, check the system for
leaks, then take at least another 15 minutes to make sure
the air is fully removed.
6. WHEN HANDLING REFRIGERANT CONTAINER
(SERVICE CAN);
(a) Must never be heated.
(b) Must be kept below 4

°C (1 04°F).
(c) If warming service can with hot water, be careful that
the valve on top of the service can is never immersed
in the water, as the water may permeate into the refrig-
erant cycle.
(d) Empty service cans must never be re±used.
7. WHEN A/C IS ON AND REFRIGERANT GAS IS
BEING REPLENISHED;
(a) If there is not enough refrigerant gas in the refrigerant
cycle, oil lubrication becomes insufficient and com-
pressor burnout may occur, so take care to avoid this.
(b) If the valve on the high pressure side is opened, refrig-
erant flows in reverse and causes the service can to
rupture, so only open and close the vlave on the low
pressure side.
(c) If the service can is inverted and refrigerant is inserted
in a liquid state, the liquid is compressed and the com-
pressor brakes down, so the refrigerant must be in-
serted in a g¿¿seous state.
(d) Be careful not to insert too much refrigerant gas, as
this causes trouble such as inadequate cooling, poor
fuel economy, engine overheat, etc.
8. WHEN USING GAS±CYLINDER TYPE LEAK
DETECTION INSTRUMENT;
(a) As a naked flame is used, first make sure that there are
no flammable substances nearby before using it.
(b) Be careful, as poisonous gas is produced when
refrigerant gas comes in contact with heat parts.
± AIR CONDITIONING SYSTEMGenera! InformationAC±3

Blower does not, operate
(a) GAUGE fuse blown
(b) FL blown
(c) Circuit breaker faulty
(d) HEATER relay faulty
(e) HEATER fuse blown
(f) Blower motor faulty
(g) Blower resistor faulty
(h) Blower switch faulty
(i) Wiring or ground faulty
Magnetic clutch does not engage
(a) FL (30A CDS) blown
(b) Magnetic clutch relay faulty
(c) Magnetic clutch faulty
(d) A/C fuse faulty
(e) A/C switch faulty
(f) Thermistor faulty
(g) A/C amplifier faulty
(h) Revolution detecting sensor faulty
(i) Pressure switch faulty
(j) Wiring or ground faulty
(k) Refrigerant empty
Compressor does not rotate properly
(a) Drive belt loose or broken
(b) Compressor faulty
Expansion valve faulty
Leak i n systemReplace FL and check for short
Check relay
Check magnetic clutch
Replace fuse and check for short
Check switch
Check thermistor
Check amplifier
Check sensor
Check switch
Repair as necessary
Check refrigerant pressure Replace fuse and check for short
Replace FL and check for short
Check circuit breaker
Check relay .
Replace fuse and check for short
Check blower motor
Check blower resistor
Check blower switch
Repair as necessary
Magnetic clutch slipping
Expansion valve faulty
Excessive moisture in the system
Revolution detecting sensor faulty
A/C amplifier faulty
Wiring connection faulty
Condenser clogged
Drive belt slipping
Compressor faulty
Insufficient or too much refrigerant
Air i n systemCheck magnetic clutch
Check expansion valve
Evacuate and charge system
Check sensor
Check amplifier
Repair as necessary
Check condenser
Check or replace drive belt
Check compressor
Check refrigerant volume
Evacuate and charge systemAC±4 to 11
AC±37
AC±23
AC±4 to 11
AC±44
AC±43
AC±45 to 47
AC±24
AC±36
AC±4 to 11
AC±18, 22
Ajust or replace drive belt
Check compressor
Check expansion valve
Test system for leaks
TROUBLESHOOTING
AC±4 to 11
AC±4 to 11
AC±4 to 11
BE±73
AC±4 to 11
Cool air comes out
only at high speedAC±24
AC±45 to 47
AC±4 to 11 Coo! air comes
out intermittently
BE±73
BE±72, 74
AC±4 to 11
AC±33
AC±21
AC±23
AC±22 AC±21
AC±23
AC±39
AC±42
* FL: Fusible LinkPossible cause
AC±23
AC±39 No coolingRemedy Problem
Page
± AIR CONDITIONING SYSTEMTroubleshootingAC±16

Discharging of Refrigeration System
Evacuating and Charging of
Refrigeration System
(See Air Conditioning Fundamentals and Repairs Pub. No.
36950E)
Condenser clogged
Drive belt slipping
Magnetic clutch faulty
Compressor faulty
Expansion valve faulty
Thermistor faulty
A/C amplifier faulty
Insufficient or too much refrigerant
Air or excessive compressor oil in
system
Receiver clogged
Water valve cable set faultyCheck condenser .
Check or replace drive belt
Check magnetic clutch
Check compressor
Check expansion valve
Check thermistor
Check amplifier
Check refrigerant volume
Evacuate and charge system
Evaporator clogged or frosted
Air leakage from cooling unit or air duct
Air inlet blocked
Blower motor faulty
A/C amplifier faulty
Drive belt slipping
Revolution detecting sensor faulty
(w/Power steering)
A/C amplifier faultyAC±33
AC±21
AC±23
AC±23
AC±39
AC±43
AC±45 to 47
AC±22
Repair as necessary
Replace blower motor
Check amplifierClean evaporator fins or filters
Repair as necessary
Check or replace drive belt
Check sensor
Check receiver
Reset water valve cable
A/C switch
indicator
flashingInsufficient
velocity of cool
airAC±41
AC±39 to 42 Insufficient
cooling
Check amplifier Possible cause
AC±21
AC±24AC±32
BE±79
AC±39 to 42
AC±45 to 47
AC±45 to 47 Remedy ProblemPage
± AIR CONDITIONING SYSTEMTroubleshooting Refrigeration SystemAC±17

Checking of Refrigeration System with Manifold Gauge
This is a method in which the trouble is located by using a manifold gauge. Read the manifold gauge
pressure when the following conditions are established:
(a) Temperature at the air inlet is 30 ± 35
°C (86 ± 95°F)
(b) Engine running at 1,500 rpm
(e) Blower fan speed switch set at high speed
(d) Temperature control lever set at cool side
HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature condi±
tions.
NORMALLY FUNCTIONING
REFRIGERATION SYSTEM
Gauge reading:
Low pressure side
1.5 ± 2.0 kg/cm
2
(21 ± 28 psi, 147 ± 196 kPa)
High pressure side
14.5 ± 15.0 kg /cm
2
(206 ± 213 psi, 1,422±1,471 kPa
Each pointer of manifold gauge
point to position A
Expansion valve improperly mounted, heat
sensing tube defective (opens too wide)
Does not coo! (cools from time to time in
some cases) Refrigerant overcharge or insufficient
cooling of condenserMoisture present in refrigeration system
Periodically cools and then fails to cool
Air present in refrigeration systemPoor circulation of refrigerant
Refrigerant does not circulateDoes not cool sufficiently
Does not cool sufficiently
Insufficient compressionInsufficient refrigerantPosition of Pointers
Insufficient cooling Insufficient cooling
Insufficient cooling
Low is D
High is OBetween A and B
Does not coolCondition Trouble
± AIR CONDITIONING SYSTEMTroubleshootingAC±18

*NOTE at No.6
These gauge indications are shown when the refrigeration system has been opened and the re-
frigerant charged without vacuum purging.
(1)Clean condenser
(2)Check fan motor operation
(3)If (1) and (2) are normal,
check refrigerant amount
HINT: Vent out refrigerant
through gauge manifold low
pressure side by gradually
opening valve.
(1)Replace receiver and drier
(2)Check compressor oil to
see if dirty or insufficient
(3)Vacuum purge and charge
new refrigerant Drier in oversaturated state
Moisture in refrigeration
system freezes at expansion
valve orifice and blocks
circulation of refrigerant(1)Replace receiver and
drier
(2)Remove moisture in cycle
through repeated vacuum
purging
(3)Charge refrigerant to proper
amount
Excess refrigerant in cycle ±
refrigerant overcharged
Condenser cooling
insufficient ± condenser fins
clogged or fan motor faulty Unable to develop
±sufficient performance due to
excessive refrigerant in system
Condenser cooling insufficientMoisture entered in
refrigeration system freeze
at expansion valve orifice
and temporarily stops
cycle, but normal state is
restored after a time when the
ice melts
Pressure too high at both low
and high pressure sides
Frost or large amount of dew
on piping at low pressure side(1)Check heat sensing
tube installed condition
(2)If (1) is normal, test
expansion valve in unit
(3) Replace if defective Pressure low at both low and
high pressure sides
Bubbles seen in sight glass
Insufficient cooling
performance
Air present in refrigeration
system
Insufficient vacuum
purging During operation, pressure at
low pressure side sometimes
becomes a vacuum and
sometimes normal
Trouble in expansion valve
or heat sensing tube not
installed correctly
Refrigerant flow out Pressure low at both low and
high pressure sides
Frost on tubes from
receiver to unit(1)Check with leak tester
and repair
(2)Charge refrigerant to
proper amount
Excess refrigerant in low
pressure piping
Expansion valve opened too
wideInsufficient refrigerant in
system
Refrigerant leaking
Pressure too high at both low
and high pressure sidesPressure too high at both
tow and high pressure sidesGas leakage at some place i n
refrigeration system
Refrigerant flow
obstructed by dirt in
receiver
Air entered refrigeration
system Symptom seen in
refrigeration system
Receiver clogged Replace receiver Probable causeDiagnosis
Remedy
No.
± AIR CONDITIONING SYSTEMTroubleshootingAC±19

8. CHECK CONDENSER FAN MOTOR ROTATES
9. CHECK AMOUNT OF REFRIGERANT
If you can see bubbles in the sight glass, additional refrig-
erant is needed.
(See page AC±22)
10. IF NO COOLING OR IT IS INSUFFICIENT, INSPECT
FOR LEAKAGE
Using a gas leak tester, inspect each component of the re-
frigeration system.
REFRIGERATION SYSTEM
Checking of Refrigerant Volume
1. RUN ENGINE AT APPROX. 1,500 RPM
2. OPERATE AIR CONDITIONER AT MAXIMUM
COOLING FOR A FEW MINUTES
3. CHECK AMOUNT OF REFRIGERANT
Observe the sight glass on the receiver.
Immediately after the air conditioner is
turned off, refrigerant in sight glass stays
clear
When the air conditioner is turned off,
refrigerant foams and then stays clearEvacuate and charge system.
Then check for leak with gas leak
detector
Temperature between compressor inlet
and outlet is noticeably different
Discharge the excess refrigerant to
specified amount No temperature difference between
compressor inlet and outletCheck for leak with gas leak
tester
No bubbles present in sight glassBubbles present in sight glass
Empty, proper or too much Empty, proper or too muchAmount of refrigerant
Empty or nearly empty
Refer to items 5 and 6
Refer to items 3 and 4Refer to items 3 and 4
Proper or too muchInsufficient Symptom
Too muchRemedy. Item
± AIR CONDITIONING SYSTEMOn±Vehicle InspectionAC±22

8. CHECK CONDENSER FAN MOTOR ROTATES
9. CHECK AMOUNT OF REFRIGERANT
If you can see bubbles in the sight glass, additional refrig-
erant is needed.
(See page AC±22)
10. IF NO COOLING OR IT IS INSUFFICIENT, INSPECT
FOR LEAKAGE
Using a gas leak tester, inspect each component of the re-
frigeration system.
REFRIGERATION SYSTEM
Checking of Refrigerant Volume
1. RUN ENGINE AT APPROX. 1,500 RPM
2. OPERATE AIR CONDITIONER AT MAXIMUM
COOLING FOR A FEW MINUTES
3. CHECK AMOUNT OF REFRIGERANT
Observe the sight glass on the receiver.
Immediately after the air conditioner is
turned off, refrigerant in sight glass stays
clear
When the air conditioner is turned off,
refrigerant foams and then stays clearEvacuate and charge system.
Then check for leak with gas leak
detector
Temperature between compressor inlet
and outlet is noticeably different
Discharge the excess refrigerant to
specified amount No temperature difference between
compressor inlet and outletCheck for leak with gas leak
tester
No bubbles present in sight glassBubbles present in sight glass
Empty, proper or too much Empty, proper or too muchAmount of refrigerant
Empty or nearly empty
Refer to items 5 and 6
Refer to items 3 and 4Refer to items 3 and 4
Proper or too muchInsufficient Symptom
Too muchRemedy. Item
± AIR CONDITIONING SYSTEMRefrigeration SystemAC±22

REMOVAL OF COOLING UNIT
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. DISCHARGE REFRIGERATION SYSTEM
3. DISCONNECT SUCTION TUBE FROM COOLING UNIT
OUTLET FITTING
4. DISCONNECT LIQUID TUBE FROM COOLING UNIT
INLET FITTING
HINT: Cap the open fittings immediately to keep moisture
out of the system.
5. REMOVE GROMMETS FROM INLET AND OUTLET
FITTINGS
6. REMOVE GLOVE BOX
7. DISCONNECT CONNECTORS
8. REMOVE COOLING UNIT
Remove three nuts and four bolts.
COOLING UNIT
(See page AC±12)
ON±VEHICLE INSPECTION OF
EXPANSION VALVE
1. CHECK QUANTITY OF REFRIGERANT GAS DURING
REFRIGERATION CYCLE
2. INSTALL MANIFOLD GAUGE SET
(See page AC±23)
3. RUN ENGINE
Run the engine at 2.000 rpm at least 5 minutes.
4. CHECK EXPANSION VALVE
If the expansion valve is clogged,the low pressure reading
will drop to 0 kg/cm2 (0 psi, 0 kPa), otherwise it is OK.
± AIR CONDITIONING SYSTEMCooling UnitAC±39