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1. Suction hose
2. Discharge hose
3. Liquid pipe
4. Condenser outlet pipe
5. Expansion valve
6. Dual pressure switch
7. Suction pipe
: Apply compressor oil
(refrigerant oil) to O-ring.
1B-30 AIR CONDITIONING (OPTIONAL)
ON-VEHICLE SERVICE
WARNING:
Should refrigerant HFC-134a (R-134a) strike your eye(s), consult a doctor immediately.
DO NOT USE YOUR HAND TO RUB AFFECTED EYE(S).
Instead, use quantities of fresh cold water to splash it over affected area to thus gradually raise its
temperature above the freezing point.
Obtain proper treatment as soon as possible from a doctor or eye specialist.
Should liquid refrigerant HFC-134a (R-134a) get on your skin, such affected part should be treated
in the same manner as when skin is frostbitten or frozen.
CAUTION:
None of refrigerant, compressor oil and component parts is interchangeable between two types of A / C:
one using CFC-12 (R-12) and the other using HFC-134a (R-134a).
(For identification between these two types, refer to page 1B-2).
When replenishing or changing refrigerant and compressor oil and when replacing parts, make sure
that the material or the part to be used is appropriate to the A / C installed in the vehicle being serviced.
Use of incorrect one will result in leakage of refrigerant, damage in parts or other faulty condition.
PRECAUTION
When servicing air conditioning system, the following rules must be observed.
PIPING
When connecting hoses and pipes, apply a few drops of compressor oil (refrigerant oil) to seats of coupling nuts
and O-ring.
Never use heat for bending pipes. When bending a pipe, try to make its bending radius as slight as possible.
Keep internal parts of air conditioning free from moisture and dirt. When disconnecting any line from system,
install a blind plug or cap to the fitting immediately.
When tightening or loosening a fitting, use two wrenches, one for turning and the other for support.
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1. New compressor
2. Removed compressor
3. Excess oil (A ± B)
1B-32 AIR CONDITIONING (OPTIONAL)
REPLENISHING COMPRESSOR OIL
When replacing air conditioning parts with new ones, it is necessary
to replenish oil by the amount supposedly remaining in each part.
When changing gas only
When it is unavoidable to change gas without replacing any compo-
nent part for engine removal and installation or for some other rea-
son, replenish 20 cc oil. When replenishing gas only, oil replenish-
ment it not necessary.
When replacing compressor
Compressor oil is sealed in each new compressor by the amount
required for air conditioner cycle. Therefore, when using a new
compressor for replacement, drain oil from it by the amount calcu-
lated as follows.
ªCº = ªAº ± ªBº
ªCº: Amount of oil to be drained
ªAº: Amount of oil sealed in a new compressor
ªBº: Amount of oil remaining in removed compressor
When replacing other part
Replaced partAmount of compressor oil
to be replenished
Evaporator25 cc
Condenser15 cc
Receiver / dryer20 cc
Hoses10 cc each
Pipes10 cc each
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1B-34 AIR CONDITIONING (OPTIONAL)
5) Disconnect coupler from dual pressure switch (1).
6) Disconnect condenser outlet pipe (3).
7) Disconnect condenser cooling fan motor coupler (2).
8) Remove condenser with fan.
NOTE:
Be careful not to damage fins of condenser and radiator.
9) Remove A / C condenser cooling fan assembly from condenser.
INSTALLATION
Reverse removal sequence to install condenser, noting following
point.
1) When replacing condenser, add 20 to 30 cc of refrigerating oil
from compressor suction-side.
2) Evacuate and charge system according to previously-described
procedure.
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2. Condenser dryer section
1B-36 AIR CONDITIONING (OPTIONAL)
CONDENSER DRYER (RECEIVER / DRYER)
REMOVAL
1) Remove A / C condenser assembly (1) from vehicle (Refer to
ªA / C CONDENSER ASSEMBLY REMOVALº in this section.).
2) Remove the condenser dryer cap from condenser.
3) Remove the filter (1) from the condenser (2).
4) Remove the dryer (1) using a plier (2).
INSTALLATION
Reverse removal sequence to install condenser dryer, according to
instruction manual with supply parts.
NOTE:
When replacing condenser dryer, add 40 cc of refrigerating
oil the same as compressor oil.
Do not remove the dryer from the plastic bag until just before
inserting it into the receiver.
Install the condenser dryer (1) with its double-layer portion
facing the bottom of the receiver.
If condenser dryer cap installing is bolt type, tighten speci-
fied torque for its bolt.
Tightening Torque:
Cap: 12.5 N
.m (1.25 kg-m, 9 lb-ft)
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1. Ears1. Air flow
1B-38 AIR CONDITIONING (OPTIONAL)
CLEAN
Blow off dust by compressed air from air outlet side of the filter ele-
ment.
INSTALLATION
Reverse removal procedure for installation noting the followings:
Install filter into cooling unit directing arrow mark on its end face
to heater unit.
Enable air bag system after installation. Refer to ªENABLING AIR
BAG SYSTEMº in Section 10B.
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AIR CONDITIONING (OPTIONAL) 1B-41
INSPECTION
1) Check evaporator fins for blockage. If found clogged, use com-
pressed air to clean the fins.
CAUTION:
Do not use water for cleaning of evaporator.
Be careful not to damage evaporator fins. If evaporator
fin is bent, straighten it by using a screwdriver or pair of
pliers. If any leakage is found from fitting or tube, repair
or replace evaporator.
2) Check inlet and outlet fittings for crack or scratch. Repair them
as required.
REASSEMBLY and INSTALLATION
1) Reverse removal and disassembly sequence to install cooling
unit, noting the following points.
Install uniformly the evaporator packing to dash panel hole for
expansion valve.
Adjust fresh air control cable, refer to ªHEATER CONTROL
LEVER ASSEMBLYº in Section 1A.
2) Enable air bag system. Refer to ªEnabling Air Bag Systemº in
Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
NOTE:
When the thermistor removed, it should be reinstalled in
original position.
If cooling unit or evaporator is replaced, pour 25 cc of refrig-
erating oil to compressor suction-side.
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3. Pipe clamp
1B-42 AIR CONDITIONING (OPTIONAL)
EXPANSION VALVE
INSPECTION
Refer to ªTroubleshooting Procedure Using Manifold Gauge Setº in
this section.
REMOVAL
1) Recover refrigerant by using recovery and recycling equipment.
Be sure to follow the instruction manual for the equipment. The
amount of compressor oil removed must be measured and the
same amount added to the system.
2) Remove front grill.
3) Disconnect suction pipe (1), and liquid pipe (2) from evaporator
(Cooling unit).
CAUTION:
As soon as above hose and pipe are disconnected, cap
opened fittings so that moisture and dust may not enter
cooling unit.
4) Disconnect suction pipe, and liquid pipe from suction hose (1)
and condenser outlet pipe (2).
5) Remove pipe clamp then remove suction pipe and liquid pipe.
6) Remove expansion valve (1).
INSTALLATION
1) Reverse removal sequence to install expansion valve.
2) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
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1. Evaporator thermistorTemperature
Resistance ( )
AIR CONDITIONING (OPTIONAL) 1B-43
A / C EVAPORATOR THERMISTOR
(EVAPORATOR TEMPERATURE SENSOR)
A thermistor is a temperature sensor to sense the temperature of
air discharged from evaporator. The electrical characteristic is
shown in the figure.
When temperature is lower than preset temperature, amplifier
makes magnet clutch turn off to prevent evaporator from frosting.
INSPECTION
Check resistance between A / C evaporator thermistor (1) termi-
nals.
If check results are as not specified, replace thermistor.
Sensor Temperature
Resistance
0C, 32F7.0 ± 7.7 k
25C, 77F2.1 ± 2.4 k
REMOVAL
Refer to ªCOOLING UNIT (EVAPORATOR)º in this section.
INSTALLATION
1) Reverse removal sequence to install thermistor.
2) Enable air bag system. Refer to ªENABLING AIR BAG SYS-
TEMº in Section 10B.
3) Evacuate and charge system. Refer to ªEVACUATINGº and
ªCHARGINGº in this section.
