IN-VEHICLE SENSOR
ATC-149
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: October 20052005 QX56
IN-VEHICLE SENSORPFP:27720
Removal and InstallationEJS003Y8
REMOVAL
1. Remove the cluster lid D. Refer to IP-12, "Cluster Lid D" .
2. Remove the two screws and remove the in-vehicle sensor.
INSTALLATION
Installation is in the reverse order of removal.
LJIA0132E
ATC-150
OPTICAL SENSOR
Revision: October 20052005 QX56
OPTICAL SENSORPFP:28576
Removal and InstallationEJS003Y9
The optical sensor is located in the top center of the instrument
panel. Refer to LT- 6 4 , "
Removal and Installation of Optical Sensor" .
WJIA0607E
INTAKE SENSOR
ATC-151
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: October 20052005 QX56
INTAKE SENSORPFP:27723
Removal and InstallationEJS003YA
REMOVAL
1. Remove the instrument panel. Refer to IP-10, "INSTRUMENT PANEL ASSEMBLY" .
2. Disconnect the intake sensor electrical connector.
NOTE:
The intake sensor is located on the top of the front heater and
cooling unit assembly next to the A/C evaporator cover.
3. Twist the intake sensor to remove the intake sensor from the
front heater and cooling unit assembly.
INSTALLATION
Installation is in the reverse order of removal.
LJIA0133E
ATC-178
REFRIGERANT LINES
Revision: October 20052005 QX56
Rear A/C
NOTE:
Refer to AT C - 7 , "
Precautions for Refrigerant Connection" .
1. High-pressure service valve 2. Grommet 3. High-pressure pipe
4. Refrigerant pressure sensor 5. Condenser 6. Compressor shaft seal
7. High-pressure flexible hose 8. Low-pressure flexible hose 9. Low-pressure service valve
10. Low-pressure pipe 11. Expansion valve (front) 12. Drain hose
WJIA2001E
1. Rear A/C pipes 2. Underfloor rear A/C pipes 3. Underfloor rear heater pipes
⇐Front
REFRIGERANT LINES
ATC-185
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: October 20052005 QX56
Removal and Installation for Refrigerant Pressure SensorEJS003YZ
REMOVAL
1. Discharge the refrigerant. Refer to ATC-175, "HFC-134a (R-134a) Service Procedure" .
2. Disconnect the refrigerant pressure sensor electrical connector
and remove the refrigerant pressure sensor from the condenser.
CAUTION:
Be careful not to damage the condenser fins.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-177, "
Components" .
CAUTION:
Be careful not to damage the condenser fins.
Apply compressor oil to the O-ring of the refrigerant pressure sensor when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for CondenserEJS003Z0
REMOVAL
1. Discharge the refrigerant. Refer to ATC-175, "HFC-134a (R-134a) Service Procedure" .
2. Remove the radiator. Refer to CO-12, "
RADIATOR" .
CAUTION:
Be careful not to damage the core surface of the condenser and the radiator.
3. Disconnect the high-pressure flexible hose and the high-pressure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
4. Disconnect the refrigerant pressure sensor connector.
Remove the refrigerant pressure sensor from the condenser
as necessary.
5. Lift the condenser out of the mounting grommets to remove the
condenser.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-177, "
Components" .
CAUTION:
Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
After charging refrigerant, check for leaks.
Replace the grommets as necessary.
LJIA0145E
LJIA0145E
REFRIGERANT LINES
ATC-189
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: October 20052005 QX56
CAUTION:
Cap or wrap the A/C refrigerant pipe ends with a suitable material such as vinyl tape to avoid the
entry of air and contaminants.
4. Remove the expansion valve.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace the O-rings on the A/C refrigerant pipes with new ones, then apply compressor oil to them
when installing them.
After charging refrigerant, check for leaks.
Checking for Refrigerant LeaksEJS003Z5
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage, and corrosion. Any A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector (J-41995) or fluo-
rescent dye leak detector (J-42220).
If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic
refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that was repaired and not
properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic refrigerant leak detector (J-41995), move the probe
along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the
component.
CAUTION:
Moving the electronic refrigerant leak detector probe slower and closer to the suspected leak area will
improve the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Dye Leak DetectorEJS003Z6
1. Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (J-42220) in a
low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye
will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evapo-
rator drain opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent
future misdiagnosis.
4. Perform a system performance check and then verify the leak repair using a electronic refrigerant leak
detector (J-41995).
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, wind-
shield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the sur-
faces to be checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the electronic refrigerant leak detector (J-41995) to contact with any sub-
stance. This can also cause false readings and may damage the detector.
Dye InjectionEJS003Z7
NOTE:
This procedure is only necessary when recharging the system or when the compressor has seized and must
be replaced.
1. Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm
2 , 50 psi). Expansion valve bolts : 4 N·m (0.41 kg-m, 35 in-lb)
A/C refrigerant pipe to expansion valve bolt : Refer to ATC-177, "
Components"
.
REFRIGERANT LINES
ATC-191
C
D
E
F
G
H
I
K
L
MA
B
AT C
Revision: October 20052005 QX56
2. When checking for leaks, circle each fitting completely with the
probe as shown.
3. Move the probe along each component at a speed of approxi-
mately 25 - 50 mm (1 - 2 in)/second as shown.
CHECKING PROCEDURE
NOTE:
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in a calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn the engine OFF.
2. Connect the manifold gauge set (J-39183-C) to the A/C service ports. Refer to ATC-175, "
SETTING OF
SERVICE TOOLS AND EQUIPMENT" .
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm
2 , 50 psi) above a temperature of
16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified
amount of refrigerant. Refer to ATC-175, "
HFC-134a (R-134a) Service Procedure" .
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa
(3.52 kg/cm
2 , 50 psi) pressure.
4. Perform the leak test from the high-pressure side (front A/C compressor discharge “a” to evaporator inlet
“f” or rear piping connection “l”) to the low-pressure side (front A/C evaporator drain hose “g” to shaft seal
“k” and rear A/C evaporator drain hose “o” to piping connection “r”). Refer to ATC-177, "
Components" .
Clean the component to be checked and carefully move the electronic refrigerant leak detector probe
completely around the following connections and components.
Check the compressor shaft seal
Check the high and low-pressure pipe and hose fittings, relief valve, and compressor shaft seal
Check the liquid tank
Check the refrigerant pressure sensor
Check all around the service valves. Check that the service valve caps are screwed tightly on the ser-
vice valves (to prevent leaks).
NOTE:
After removing manifold gauge set (J-39183-C) from the service valves, wipe any residue from the ser-
vice valves to prevent any false readings by the electronic refrigerant leak detector (J-41995).
Evaporator
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in
the heater and cooling unit assembly. Wait a minimum of 10 minutes accumulation time (refer to the
manufacturer's recommended procedure for actual wait time) before inserting the electronic refrigerant
leak detector probe into the heater and cooling unit assembly drain hose.
SHA7 06 E
SHA708EA
NAVIGATION SYSTEM
AV-61
C
D
E
F
G
H
I
J
L
MA
B
AV
Revision: October 20052005 QX56
NAVIGATION SYSTEMPFP:25915
System DescriptionEKS00BJD
The navigation system periodically calculates the vehicle's current
position according to the following three signals: Travel distance of
the vehicle as determined by the vehicle speed sensor, turning angle
of the vehicle as determined by the gyroscope (angular velocity sen-
sor), and the direction of vehicle travel as determined by the GPS
antenna (GPS information).
The current position of the vehicle is then identified by comparing the
calculated vehicle position with map data read from the map DVD-
ROM, which is stored in the DVD-ROM drive (map-matching), and
indicated on the screen with a current-location mark.
By comparing the vehicle position detection results found by the
GPS and by map-matching, more accurate vehicle position data can
be used.
The current vehicle position will be calculated by detecting the dis-
tance the vehicle moved from the previous calculation point and its
direction.
TRAVEL DISTANCE
Travel distance calculations are based on the vehicle speed sensor input signal. Therefore, the calculation
may become incorrect as the tires wear down. To prevent this, an automatic distance fine adjustment function
has been adopted. Adjustments can be made in extreme cases (such as driving with tire chain fitted on tires).
Refer to AV-107, "
Confirmation/Adjustment Mode" .
TRAVEL DIRECTION
Change in the travel direction of the vehicle is calculated by a gyroscope (angular velocity sensor) and a GPS
antenna (GPS information). As the gyroscope and GPS antenna have both merit and demerit, input signals
from them are prioritized in each situation. However, this order of priority may change in accordance with more
detailed travel conditions so that the travel direction is detected more accurately.
MAP-MATCHING
Map-matching is a function that repositions the vehicle on the road
map when a new location is judged to be the most accurate. This is
done by comparing the current vehicle position, calculated by the
method described in the position detection principle, with the road
map data around the vehicle, read from the map DVD-ROM stored in
the DVD-ROM drive.
Therefore, the vehicle position may not be corrected after the vehicle
is driven over a certain distance or time in which GPS information is
hard to receive. In this case, the current-location mark on the display
must be corrected manually.
CAUTION:
The road map data is based on data stored in the map DVD-
ROM.
WKIA1371E
SEL684V
Type Advantage Disadvantage
Gyroscope (angular velocity sensor)
Can detect the vehicle's turning angle
quite accurately.Direction errors may accumulate when the
vehicle is driven for long distances without
stopping.
GPS antenna (GPS information)
Can detect the vehicle's travel direction
(North/South/East/West).Correct direction cannot be detected when
the vehicle speed is low.
SEL685V