TROUBLE DIAGNOSIS
ATC-63
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MA
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AT C
AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER
The trimmer compensates for differences in range of ±3°C between temperature setting (Temperature control
dial position) and temperature felt by driver.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C.
2. Set fan control dial to OFF.
3. Turn ignition switch ON.
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired. Temperature will change at a rate of 1°C each time a dial is
turned.
When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial
condition, i.e. 0°C.
AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER
Wind distribution ratio in FOOT mode can be set.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C.
2. Set fan control dial to AUTO.
3. Turn ignition switch ON.
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired.
Setting temperatureLED status of each switch
FRE REC A/C
−3°CON ON ON
−2°CON ON OFF
−1°CON OFF ON
0°C (Initial setting) OFF OFF OFF
1°COFFOFF ON
2°COFF ON OFF
3°C OFF ON ON
RJIA2825E
ATC-64
TROUBLE DIAGNOSIS
AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION
When ignition switch is turned from OFF to ON, inlet port can be set to AUTO or manual.
Operating procedures for this trimmer are as follows:
1. Set fan control dial to 1st-25th speed.
2. Turn ignition switch ON.
3. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
4. Press intake switch as desired.
Ty p eLED status of each switch
FRE REC A/C
Type-A (initial setting) OFF OFF ON
Ty p e - B O F F O N OF F
Ty p e - C O F F O N O N
Ty p e - D ON O F F OF F
LED status
of FRE
positionLED status
of REC posi-
tionSetting status
Setting changeover method
FRE REC
OFF OFF AUTO control AUTO control
Intake SW: ON OFF ON AUTO control (Initial setting)Manual REC status is memorized.
(Initial setting)
ON OFF Manual FRE status is memorized. AUTO control
ON ON Manual FRE status is memorized. Manual REC status is memorized.
TROUBLE DIAGNOSIS
ATC-71
C
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AT C
5. CHECK MOTOR GROUND CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect each door motor connector.
3. Check continuity between mode door motor harness connector
M37 terminal 2 (B), air mix door motor harness connector M38
terminal 2 (B) or intake door motor harness connector M47 ter-
minal 2 (B) and ground.
OK or NG
OK >> GO TO 6.
NG >> Replace harness or connector.
6. CHECK MOTOR OPERATION
1. Turn ignition switch OFF.
2. Disconnect each door motor connector.
3. Reconnect each door motor connector.
4. Turn ignition switch ON.
5. Confirm each door motor operation.
OK or NG
OK >> (Return to operate normally.)
Poor contact in motor connector.
NG >> (Does not operate normally.)
GO TO 7.
7. CHECK AIR MIX DOOR MOTOR AND INTAKE DOOR MOTOR OPERATION
1. Turn ignition switch OFF.
2. Disconnect mode, air mix, and intake door motor connectors.
3. Reconnect air mix and intake door motor connectors.
4. Turn ignition switch ON.
5. Confirm air mix door motor and intake door motor operation.
OK or NG
OK >> (Air mix and intake door motors operate normally.)
Replace mode door motor.
NG >> (Air mix and intake door motors does not operate normally.)
GO TO 8.
8. CHECK MODE DOOR MOTOR AND INTAKE DOOR MOTOR OPERATION
1. Turn ignition switch OFF.
2. Disconnect air mix door motor connector.
3. Reconnect mode door motor connector.
4. Turn ignition switch ON.
5. Confirm mode door motor and intake door motor operation.
OK or NG
OK >> (Mode and intake door motors operate normally.)
Replace air mix door motor.
NG >> (Mode and intake door motors does not operate normally.)
GO TO 9. 2 – Ground : Continuity should exist.
RJIA1990E
ATC-72
TROUBLE DIAGNOSIS
9. CHECK MODE DOOR MOTOR AND AIR MIX DOOR MOTOR OPERATION
1. Turn ignition switch OFF.
2. Disconnect intake door motor connector.
3. Reconnect air mix door motor connector.
4. Turn ignition switch ON.
5. Confirm mode door motor and air mix door motor operation.
OK or NG
OK >> (Mode and air mix door motors operate normally.)
Replace intake door motor.
NG >> (Mode and air mix door motors does not operate normally.)
Replace auto amp.
ATC-84
TROUBLE DIAGNOSIS
Starting Fan Speed Control
Start Up from COLD SOAK Condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 56°C (133°F), the blower will not
operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the
ambient and engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described
above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above
56°C (133°F), and then the blower speed will increase to the objective speed.
Start Up from Usual or HOT SOAK Condition (Automatic mode)
The blower will begin operation momentarily after the A/C switch is pushed. The blower speed will gradually
rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).
Blower Speed Compensation
Sunload
When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low
speed. The low speed will vary depending on the sunload. During conditions of low or no sunload, the blower
low speed is usual low speed (approx. 4V). During high sunload conditions, the auto amp. causes the blower
fan speed to increase.(Approx. 7V)
Fan Speed Control Specification
COMPONENT DESCRIPTION
Fan Control Amp.
The fan control amp. is located on the intake unit. The fan control
amp. receives a gate voltage from the auto amp. to steplessly main-
tain the blower fan motor voltage in the 4 to 12 volt range.
DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR
SYMPTOM: Blower motor operation is malfunctioning.
RJIA0522E
RJIA0523E
RHA467GA
ATC-134
MODE DOOR MOTOR
MODE DOOR MOTORPFP:27731
Removal and InstallationEJS004GN
REMOVAL
1. Remove rod from rod holder.
2. Remove mounting screws, and then remove mode door motor.
3. Disconnect mode door motor connector.
INSTALLATION
1. Install rod to mode door.
2. Reconnect mode door motor connector.
3. Install mode door motor.
4. Turn ignition switch ON.
5. Turn mode control dial to VENT position.
6. Turn side link clockwise, and then install rod to rod holder.
RJIA0065E
RJIA0574E
ATC-162
REFRIGERANT LINES
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2 , 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet g) to the
low-pressure side (evaporator drain hose h to shaft seal k). Refer to ATC-143, "
Components" . Perform a
leak check for the following areas carefully. Clean the component to be checked and move the leak
detected probe completely around the connection/component.
Compressor
Check the fitting of high- and low- pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor or dual pressure switch.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7-10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Mode control dial: VENT (Ventilation)
c. Intake position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure on the high-pressure side will gradually drop after refrigerant
circulation stops and pressure on the low-pressure side will gradually
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high.
11. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent if necessary.
12. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
SHA839E
MA-4
DESCRIPTION
DESCRIPTIONPFP:00000
Pre-delivery Inspection ItemsELS000Y5
Shown below are Pre-delivery Inspection Items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
Install vehicle protection kit
Fit all accessories ordered (if applicable) (e.g. towbar, audio, navigation, air conditioner, styling kit)
UNDER HOOD — engine off
Check coolant level and cooling system for leaks
Charge battery and check terminals for condition
Check drive belts tension (diesel only)
Check fuel filter for water or dust (diesel only) and fuel system for leaks
Check engine oil level and for oil leaks
Check brake and clutch fluid levels and fluid lines for leaks
Check and top up washer reservoirs
Check power steering fluid level and fluid lines for leaks (if applicable)
Check air conditioning system for gas leaks (if applicable)
ON INSIDE AND OUTSIDE
Install transit fuse if removed for vehicle storage
Check instruments, gauges, lamps, horn and accessories for operation
Check wipers and washers for operation and adjustment
Check interior and door mirrors and sun visors for operation
Set radio code and set clock
Check parking brake adjustment
Check clutch pedal adjustment
Check steering lock operation
Check seat adjusters and seat belts for operation
Check all windows for operation and alignment
Check mouldings, trim and fittings for fit and alignment
Check weatherstrips for fit and adhesion
Check hood, trunk lid, door panels and fuel lid for fit and alignment
Check latches, keys, remote key, door locks and remote trunk lid and fuel lid release for operation
Check wheel nut torques
Check tyre pressure (incl. spare tyre)
Check tool kit and jack for operation
Check automatic transmission/transaxle starter inhibitor (if applicable)
Check sunroof for operation and alignment (if applicable)
UNDER BODY
Check manual transmission/transaxle, differential and transfer box for oil level and oil leaks
Tighten bolts and nuts steering linkage and gear box, axle/suspension parts, propeller and exhaust system
Check brake and clutch lines, and oil/fluid reservoirs for leaks
Remove front suspension spacer blocks (if applicable)
Check body mounting torque (if applicable)