Page 137 of 4087

No.Gauge reading kPa (kgf/cm2, psi)ConditionProbable cause Remedy
LO: 1.5 ± 2.0(21 ±28, 147 ±196)
HI: 14.5 ± 15.0(206 ±213, 1422 ±1471)
Normal coolingNormally functioning
system
During operation, pressure at low
pressure side sometimes becomes a
vacuum and sometimes normal.Periodically cools
and then fails to
cool.Moisture present in
refrigeration system.(1). Replace receiver
(2). Remove moisturein system through
repeatedly
evacuating air
Inspection of Refrigeration System with Manifold Gauge Set
This is a method in which the trouble is located by using a manifold gauge s\
et. (See ºInstallation of Manifold
Gauge Setº on page AC±15) Read the manifold gauge pressure when the following conditions are es\
tablished:
(a) Temperature at the air inlet with the switch set at RECIRC is 30±35 °C (86±95 °F).
(b) Engine running at 2,000 rpm.
(c) Blower fan speed control switch set at high speed.
(d) Temperature control switch set at max. cool side.
HINT: It should be noted that the gauge indications may vary slightly due to\
ambient temperature conditions.
NOTICE:
w Always recover refrigerant before removing the parts in the refrigerant \
line and evacuating air.
w Evacuate air and charge proper amount of purified refrigerant after installing th\
e parts in the
refrigerant line.
AC±100
±
AIR CONDITIONING SYSTEM Troubleshooting
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Page 138 of 4087

No.Gauge reading kPa (kgf/cm2, psi)ConditionProbable causeRemedy
Pressure low at both low and high
pressure sides
Pressure too high at both low and
high pressure sides
Insufficient cooling
Bubbles seen in
sight glass
Insufficient cooling
Frost on tubes from
receiver to
unit
Replace receiver
Insufficient refrigerant(1) Check for gas
leakage with gas
leak tester and
repair if
necessary
(2) Add refrigerant
until bubbles
disappear
Refrigerant flow
obstructed by dirt in
receiver
Insufficient coolingInsufficient cooling of
condenser(1). Clean condenser
(2). Check fan motoroperation
(1). Check amount ofrefrigerant
If refrigerant is
overcharged
(2). Recover refrigeran
t
(3). Evacuate air and charge proper
amount of purified
refrigerant
Refrigerant
overcharged
(1). Replace receiver
(2). Check compres- sor oil to see if
dirtyAir present in system
Insufficient cooling
Frost in Large
amount of dew on
piping at low
pressure side Expansion valve
improperly mounted,
heat sensing tube
defective
(Open too wide)(1) Check heat sensing
tube installation
condition
If (1) is normal
(2) Check expansion valve and replace
if defective
(3). Remove air insystem through
repeatedly
evacuating air
NOTICE:
wAlways recover refrigerant before removing the parts in the refrigerant line a\
nd evacuating air.
w Evacuate air and charge proper amount of purified refrigerant after installing th\
e parts in the
refrigerant line.
HINT at 6:
These gauge indication are for when the refrigeration system has been op\
ened and the refrigerant charged
without evacuating air.
±
AIR CONDITIONING SYSTEM TroubleshootingAC±101
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Page 139 of 4087
No.Gauge reading kPa (kgf/cm2, psi)ConditionProbable causeRemedy
Vacuum indicated at low pressure
side, very low pressure indicated at
high pressure.
Pressure too high at low pressure
sides, pressure too low at high
pressure side.
Refrigerant does not
circulate Does not cool(Cools from time
to time in some
cases)
Frost or dew seen
on piping before
and after receiver
or expansion
valve
(1) Check heat sensing
tube for gas
leakage and
replace expansion
If (1) is normal
(2) Clean out dirt in expansion valve by
blowing with air if
not able to remove
dirt replace
expansion valve
(3) Replace receiver
Does not coolInsufficient
compressionRepair or replace
compressor
NOTICE:
w Always recover refrigerant before removing the parts in the refrigerant line a\
nd evacuating air.
w Evacuate air and charge proper amount of purified refrigerant after installing th\
e parts in the
refrigerant line.
AC±102
±
AIR CONDITIONING SYSTEM Troubleshooting
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Page 140 of 4087

REFRIGERANT VOLUME
INSPECTION OF REFRIGERANT
VOLUME
1. RUN ENGINE AT IDLE SPEED
2. OPERATE A/C AT MAXIMUM COOLING FOR A FEWMINUTES
3. INSPECT AMOUNT OF REFRIGERANT Observe the sight glass on the liquid tube.
ItemSymptomAmount of refrigerantRemedy
1
Bubbles present in sight glassInsufficient*(1) Check for gas leakage with
gas leak tester and repair
if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight
glassNone, sufficient or too muchRefer to items 3 and 4
3
No temperature difference
between compressor inlet and
outletEmpty or nearly empty(1) Check for gas leakage withgas leak tester and repair
if necessary
(2) Add refrigerant until bubbles disappear
4
Temperature between
compressor inlet and outlet is
noticeably differentProper or too muchRefer to items 5 and 6
5
Immediately after air conditioner
is turned off, refrigerant in sight
glass stays clearToo much(1) Recover refrigerant
(2) Evacuate air and charge
proper amount of
purified refrigerant
6
When air conditioner is turned
off, refrigerant foams and then
stay clearProper
±
*: Bubbles in the sight glass with ambient temperatures higher can be cons\
idered normal if cooling is sufficient.
REFRIGERANT CHARGE VOLUME
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
±
AIR CONDITIONING SYSTEM Refrigerant VolumeAC±103
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Page 141 of 4087
DRIVE BELT TENSION
INSPECTION OF DRIVE BELT TENSION
1. INSPECT DRIVE BELT'S INSTALLATION CONDITIONCheck that the drive belt fits properly in the ribbed grooves.
2. INSPECT DRIVE BELT TENSION Check that the tension is within the A range on the auto ten-
sioner scale.
If the tension is not within the A range on the scale, replace
the belt with a new one.
HINT: When replacing the drive belt with a new one, the belt's
tension should be within the B range on the belt tensioner
scale.
IDLE±UP SPEED
INSPECTION OF IDLE SPEED
1. WARM UP ENGINE
2. INSPECT IDLE SPEED
Trans±
mission
Magnetic clutch
condition
Standard idle
speed (rpm)
A/T
(N range)
No engaged
650 rpm
Engaged
800 rpm
M/T No engaged 700 rpm
Engaged 900 rpm
AC±104±
AIR CONDITIONING SYSTEM Driver Belt Tension, Idle-Up Speed
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Page 142 of 4087
REFRIGERANT LINES
TIGHTENING TORQUE OF
REFRIGERANT LINES
ON±VEHICLE INSPECTION
1. INSPECT HOSES AND TUBES FOR LEAKAGEUse a gas leak tester. Replace if necessary.
2. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS
±
AIR CONDITIONING SYSTEM Refrigerant LinesAC±105
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Page 143 of 4087
REPLACEMENT OF REFRIGERANT
LINES
1. RECOVER REFRIGERANT IN REFRIGERATION SYSTEMSee page AC±16
2. REPLACE FAULTY TUBE OR HOSE NOTICE: To prevent the intrusion of moisture or dirt, caps
should be placed on hose or tube ends immediately.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE: Connections should not be torque tighter than the
specified torque.
4. EVACUATE REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
See page AC±17
Specified amount: 950 + 50 g (33.44 + 1.76 oz)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refrigerant.
6. INSPECT A/C OPERATION
AC±106
±
AIR CONDITIONING SYSTEM Refrigerant Lines
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Page 144 of 4087
A/C UNIT
REMOVAL OF A/C UNIT
1. RECOVER REFRIGERANT IN SYSTEMSee page AC±16
2. REMOVE ENGINE See page EM±118
3. REMOVE WATER VALVE
See page AC±127
4. REMOVE BRAKE TUBES BRACKET MOUNTING BOLTS FROM DUSH PANEL
5. REMOVE EVAPORATOR See page AC±122
6. REMOVE WATER HOSE FROM HEATER RADIATOR
7. REMOVE INSULATOR RETAINER Remove the two bolts and the retainer.
8. REMOVE INSTRUMENT PANEL REINFORCEMENT See page BO±109
9. REMOVE FLOOR CARPET See page BO±118
10. REMOVE REAR AIR DUCTS Remove the nut and the air duct.
11. REMOVE HEATER TO RESISTER NO. 3 DUCT Remove the screw and the duct.
±
AIR CONDITIONING SYSTEM A/C UnitAC±107
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