Page 1 of 4592
AC2810
AC0LG±02
AC2811
N11084
Wrong Okey
HI LO HILO
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±1
2483 Author: Date:
AIR CONDITIONING SYSTEM
PRECAUTION
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR WEAR EYE PROTECTION
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN
YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin.
(a) Wash the area with lots of cool water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
treatment.
4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED
FLAME
5. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
6. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERATION SYS-
TEM
If there is not enough refrigerant in the refrigerant system oil lu-
brication will be insufficient and compressor burnout may occur,
so that care to avoid this, necessary care should be taken.
7. DO NOT OPEN PRESSURE MANIFOLD VALVE WHILE
COMPRESSOR IS OPERATE
If the high pressure valve is opened, refrigerant flows in the re-
verse direction and could cause the charging cylinder to rup-
ture, so open and close the only low pressure valve.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as insuffi-
cient cooling, poor fuel economy, engine overheating etc.
Page 3 of 4592
AC0LI±02
N20242
Sight Glass
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±3
2485 Author: Date:
ON±VEHICLE INSPECTION
1. INSPECT REFRIGERANT VOLUME
Observe the sight glass on the liquid tube.
Test conditions:
Running engine at 1,500 rpm
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control dial at ºCOOLº position
Fully open the doors
ItemSymptomAmount of refrigerantRemedy
1Bubbles present in sight glassInsufficient*
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
2No bubbles present in sight glassNone, sufficient or too muchRefer item 3 and 4
3No temperature difference between com-
pressor inlet and outletEmpty or nearly empty
(1) Check for gas leakage with gas leak de-
tector and repair if necessary
(2) Add refrigerant until bubbles disappear
4Temperature between compressor inlet and
outlet is noticeably differentCorrect or too muchRefer to items 5 and 6
5Immediately after air conditioning is turned
off, refrigerant in sight glass stays clearToo much
(1) Discharge refrigerant
(2) Evacuate air and charge proper amount
or purified refrigerant
6When air conditioning is turned off, refriger-
ant foams and then stays clearCorrect±
*: Bubbles in the sight glass with ambient temperatures higher than usual can be considered normal if cooling
is sufficient.
Page 5 of 4592
I01387
Condition : Periodically cools and then fails to cool
I01388
Condition: Insufficient cooling
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±5
2487 Author: Date:
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
but normal state is restored after a
time when the ice melts Drier oversaturated state
Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace receiver
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant
(3) Insufficient cooling
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure low on both low and
high pressure sides
Bubbles seen in sight glass con-
tinuously
Insufficient cooling performance
Gas leakage at some place in re-
frigeration system Insufficient refrigerant in system
Refrigerant leaking
(1) Check for gas leakage with gas
leak detector and repair if neces-
sary
(2) Charge proper amount of re-
frigerant
(3) If indicated pressure value is
near 0 when connected to gauge,
create the vacuum after inspecting
and repairing the location of the
leak
Page 6 of 4592
I01389
Condition: Insufficient cooling
I01449
Condition: Does not cool (Cools from time to time in some cases) AC±6
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
2488 Author: Date:
(4) Poor circulation of refrigerant
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure low in both low and
high pressure sides
Frost on tube from receiver to
unit
Refrigerant flow obstructed by dirt
in receiverReceiver cloggedReplace receiver
(5) Refrigerant does not circulate
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Vacuum indicated on low pres-
sure side, very low pressure indi-
cated on high pressure side
Frost or dew seen on piping be-
fore and after receiver/ drier or ex-
pansion valve Refrigerant flow obstructed by
moisture or dirt in refrigeration sys-
tem
Refrigerant flow obstructed by
gas leakage from expansion valve
Refrigerant does not circulate
(1) Check expansion valve
(2) Clean out dirt in expansion
valve by blowing with air
(3) Replace receiver
(4) Evacuate air and charge new
refrigerant to proper amount
(5) For gas leakage from expan-
sion valve, replace expansion
valve
Page 7 of 4592
I01390
Condition: Insufficient cooling
I01392
Condition: Insufficient cooling
NOTE : These gauge indica-
tions are shown when the
refrigeration system has
been opened and the refrig-
erant charged without vacu-
um purging.
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±7
2489 Author: Date:
(6) Refrigerant overcharged or insufficient cooling of
condenser
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure too high on both low
and high pressure sides
No air bubbles seen through the
sight glass even when the engine
rpm is lowered Unable to develop sufficient per-
formance due to excessive refrig-
eration system
Insufficient cooling of condenser Excessive refrigerant in
cycle " refrigerant over charged
Condenser cooling " condenser
fins clogged of condenser fan
faulty
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check amount of refrigerant
Charge proper amount of refriger-
ant
(7) Air present in refrigeration system
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure too high on both low
and high pressure sides
The low pressure piping hot to
touch
Bubbles seen in sight glass
Air entered in refrigeration system
Air present in refrigeration sys-
tem
Insufficient vacuum purging
(1) Check compressor oil to see if
it is dirty or insufficient
(2) Evacuate air and charge new
refrigerant
Page 8 of 4592
I01450
Condition: Insufficient cooling
I01393
Condition : Does not cool AC±8
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
2490 Author: Date:
(8) Expansion valve improperly
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure too high on both low
and high pressure sides
Frost or large amount of dew on
piping on low pressure side
Trouble in expansion valve
Excessive refrigerant in low
pressure piping
Expansion valve opened too
wide
Check expansion valve
Replace if defective
(9) Defective compression compressor
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
Pressure too high on low and
high pressure sides
Pressure too low on high pres-
sure side
Internal leak in compressor
Compression defective
Valve leaking or broken sliding
parts
Repair or replace compressor
Page 9 of 4592
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±9
2491 Author: Date:
3. INSPECT IDLE±UP SPEED
(a) Warm up engine.
(b) Inspect idle±up speed when the these conditions are es-
tablished.
Warm up engine
Blower speed control switch at ºHIº position
A/C switch ON
Temperature control dial at ºCOOLº position
Magnetic clutch conditionIdle±up speed
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged700 ± 50 rpm
If idle speed is not as specified, check ISC valve and air intake
system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:
Stop engine.
Secure good ventilation (If not the gas leak detector
may react to volatile gases witch are not refrigerant,
such as evaporated gasoline and exhaust gas.)
Repeat the test 2 or 3 times.
Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approx. 392 ± 588 kPa
(4 ± 6 kgf/ cm
2, 57 ± 85 psi)
(b) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:
After the blower motor stopped, leave the cooling unit for
more than 15 minutes.
Expose the gas leak detector sensor the under the drain
hose.
When bring the gas leak detector close to the drain hose,
make sure that the gas leak detector does not react to the
volatile gases.
If such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected on the drain hose, remove the
blower resistor from the cooling unit. Then insert the gas
leak detector sensor into the unit and perform the test.
(d) Disconnect the connector and leave the pressure switch
for approx. 20 minutes. Then bring the gas leak detector
close to the pressure switch and perform the test.
(e) Bring the gas leak detector close to the refrigerant lines
and perform the test.
Page 13 of 4592
AC0LL±02
Z19146
1MZ±FE engine:
No. 1 Engine Coolant Temperature
(ECT) Switch
Compressor
Engine Room Junction Block No. 2
Engine Main Relay
(Marking: ENGINE MAIN)
No. 1 Cooling Fan Relay
(Marking: FAN NO.1)Engine Room Relay Block No. 1
Magnetic Clutch Relay
(Marking: MG CLT)
Heater Main Relay
(Marking: HTR)
No. 2 Cooling Fan Relay
(Marking: FAN NO.2)
No. 3 Cooling Fan Relay
(Marking: FAN NO.3)
5S±FE engine models:
Engine Coolant Temperature
(ECT) Switch Receiver Pressure SwitchCondenser Fan
Fan Motor1MZ±FE engine:
No. 2 Engine Coolant Temperature
(ECT) Switch
Condenser
Blower Unit A/C Unit
A/C Control Assembly
A/C Switch
Blower Speed Control Switch
Mode Switch
Air Outlet Servomotor
Heater Radiator
Thermistor
Blower ResistorBlower Motor 1MZ±FE:
A/C Amplifier Expansion Valve5S±FE engine:
ECM (Built in A/C Amplifier)
Evaporator
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±13
2495 Author: Date:
LOCATION
