Page 557 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-73
PERFORMANCE TEST M1552001400355
1. The vehicles to be tested should be in a place that
is not in direct sunlight.
2. Close the high and low-pressure valve of the
gauge manifold.
3. Connect the charging hose (blue) to the
low-pressure valve and connect the charging
hose (red) to the high-pressure valve of the gauge
manifold.
CAUTION
•To connect the quick joint, press section A
firmly against the service valve until a click is
heard.
•When connecting, run your hand along the
hose while pressing to ensure that there are
no bends in the hose.
4. Install the quick joint (for low-pressure) to the
charging hose (blue), and connect the quick joint
(for high-pressure) to the charging hose (red).NOTE: The high-pressure service valve is on the
A/C pipe and the low-pressure service valve is on
the suction hose.
5. Connect the quick joint (for low-pressure) to the
low-pressure service valve and connect the quick
joint (for high-pressure) to the high-pressure
service valve.
6. Start the engine.
7. Set the A/C controls as follows:
•A/C switch: A/C − ON position
•Mode selection: FACE position
•Temperature control: MAXIMUM COOLING
position
•Air selection: RECIRCULATION position
•Blower switch: "4" (Fast) position
8. Keep engine speed to idling speed with A/C clutch
engaged.
9. Engine should be warmed up with doors and all
windows opened.
10.Insert a thermometer in the centre air outlet and
operate the engine for 20 minutes.
NOTE: If the clutch cycles, take the reading before
the clutch disengages.
11.Note the discharge air temperature.
Performance Temperature Chart
AC001388
Low-pressure
valveHigh-pressure
valve
Gauge manifold
Charging
hose (red)
A
Sleeve Charging
hose (blue)
Adaptor valve
(for low-
pressure)
Low-
pressure
service
valveHigh-
pressure
service
valve
AB
Adaptor valve
(for high-
pressure)
AC304576
Thermometer
AB
Garage ambient temperature °C20 25 30 35
Discharge air temperature °C8.0 − 11.0 12.0 − 16.0 17.0 − 21.0 22.5 − 27.5
Compressor high pressure kPa 740 − 840 950 − 1,050 1,160 − 1,300 1,360 − 1,550
Compressor low pressure kPa 150 − 190 190 − 240 240 − 300 300 − 375
Page 558 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-74
REFRIGERANT LEAK REPAIR
PROCEDURE
M1552001500277
LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (Refer to P.55-72).
2. Charge the system with approximately 480 − 520
g of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
CAUTION
Replacement filter-drier units must be sealed
while in storage. The drier used in these units will
saturate water quickly upon exposure to the
atmosphere. When installing a drier, have all
tools and supplies ready for quick assembly to
avoid keeping the system open any longer than
necessary.
6. Replace receiver drier.
7. Evacuate and charge system.
LOW CHARGE
If the system has not lost all of its refrigerant charge;
locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak
(because of an especially low charge) add
refrigerant. If it is possible to repair the leak without
discharging the refrigerant system, use the
procedure for correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the
refrigerant hose lines will greatly reduce the capacity
of the entire system. High pressures are produced in
the system when it is operating. Extreme care must
be exercised to make sure that all connections are
pressure tight. Dirt and moisture can enter the
system when it is opened for repair or replacement of
lines or components. The following precautions must
be observed. The system must be completely
discharged before opening any fitting of connection
in the refrigeration system. Open fittings with caution
even after the system has been discharged. If any
pressure is noticed as a fitting is loosened, allow
trapped pressure to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the
correct line for the installation you are servicing. A
good rule for the flexible hose lines is keep the radius
of all bends at least 10 times the diameter of the
hose.Sharper bends will reduce the flow of refrigerant. The
flexible hose lines should be routed so that they are
at least 80 mm from the exhaust manifold. It is good
practice to inspect all flexible hose lines at least once
a year to make sure they are in good condition and
properly routed.
On standard plumbing fittings with O-rings, these
O-rings are not reusable.
COMPRESSOR NOISE CHECKM1552008700272
You must first know the conditions when the noise
occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any
other special conditions.
Noises that develop during A/C operation can often
be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be
caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory drive belt
tension (power steering or alternator).
Improper accessory drive belt tension can cause a
misleading noise when the compressor is engaged
and little or no noise when the compressor is
disengaged.
Drive belts are speed-sensitive. That is, at different
engine speeds, and depending upon belt tension,
belts can develop unusual noises that are often
mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate
conditions as much as possible. Switch the
compressor on and off several times to clearly
identify compressor noise. To duplicate high
ambient conditions (high head pressure), restrict
air flow through the condenser. Install a manifold
gauge set to make sure discharge pressure
doesn't exceed 2,070 kPa.
2. Tighten all compressor mounting bolts, clutch
mounting bolt, and compressor drive belt. Check
to assure clutch coil is tight (no rotation or
wobble).
3. Check refrigerant hoses for rubbing or
interference that can cause unusual noises.
4. Check refrigerant charge (Refer to P.55-69).
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting
bolts and retighten. Repeat Step 1.
7. If noise continues, replace compressor and repeat
Step 1.
Page 559 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-75
POWER RELAY CHECKM1552008800309
BLOWER RELAY CONTINUITY CHECKA/C COMPRESSOR RELAY CONTINUITY
CHECK
Battery voltage Tester
connectionSpecified
condition
Not applied 4 − 5 Open circuit
•Connect
terminal 3 to
the positive
battery
terminal
•Connect
terminal 1 to
the negative
battery
terminal4 − 5 Less than 2
ohms
AC305308
4
5 1
235
14
3
Blower relay
AB
Battery voltage Tester
connectionSpecified
condition
Not applied 1 − 4 Open circuit
•Connect
terminal 2 to
the positive
battery
terminal
•Connect
terminal 3 to
the negative
battery
terminal1 − 4 Less than 2
ohms
AC305307
A/C compressor relay
AB
21
34
1
24
3
Front of
vehicle
Page 560 of 788
ON-VEHICLE SERVICE
HEATER, AIR CONDITIONER AND VENTILATION55-76
FAN CONTROL RELAY CONTINUITY
CHECK
IDLE-UP OPERATION CHECK
M1552001600371
1. Before inspection and adjustment, set vehicle in
the following condition:
•Engine coolant temperature: 80 − 90 °C•Lamps, electric cooling fan and accessories: Set
to OFF
•Transmission: Neutral ("N" or "P" for vehicles with
A/T)
•Steering wheel: Straightforward
2. Check whether or not the idle speed is the
standard value. <1300, 1600> Refer to GROUP
13A, On-vehicle Service − Basic Idle Speed
Adjustment P.13A-387.
<2000> Refer to GROUP 13B, On-vehicle Service
− Basic Idle Speed Adjustment P.13B-324.
Standard value: 750 ± 50 r/min
3. When the A/C is running after turning the A/C
switch to ON, and the blower switch to the 3(MH)
or 4(HI) position, check to be sure that the idle
speed is at the standard value.
Standard value: 850 ± 50 r/min
NOTE: It is not necessary to make an adjustment,
because the idling speed is automatically
adjusted by the ISC system. If, however, a
deviation from the standard value occurs for some
reason, check the ISC system.
CLEAN AIR FILTER REPLACEMENT
PROCEDURE
M1552020100030
1. Remove the glove box (Refer to GROUP 52A,
Instrument Panel P.52A-2).
2. Remove the two screws as shown, and replace
the clean air filter.
3. Install the glove box. Battery voltage Tester
connectionSpecified
condition
Not applied 2 − 4 Open circuit
•Connect
terminal 1 to
the positive
battery
terminal
•Connect
terminal 3 to
the negative
battery
terminal2 − 4 Less than 2
ohms
AC305307
Fan control relay
13
4 2
3 4
1 2
AC
AC305114AB
Air filter
Instrument panel
Page 561 of 788
HEATER CONTROL ASSEMBLY AND A/C SWITCH
HEATER, AIR CONDITIONER AND VENTILATION55-77
HEATER CONTROL ASSEMBLY AND A/C SWITCH
REMOVAL AND INSTALLATIONM1552002400347
AC304650
1 2
3
4
5
AB
Removal steps
>>B<<1. Air mixing door control cable
connection
>>A<<2. Mode selection damper cable
connection
3. Knob4. Centre panel
5. Manual air conditioner control panel
assembly Removal steps (Continued)
Page 562 of 788
HEATER CONTROL ASSEMBLY AND A/C SWITCH
HEATER, AIR CONDITIONER AND VENTILATION55-78
INSTALLATION SERVICE POINT
>>A<< BLOWER VENT CHANGEOVER
DAMPER CABLE
1. Set the heater control assembly’s blower vent
changeover knob to the DEF position.
2. Set the heater unit’s blower vent changeover
damper relay to the DEF position (turn the
damper relay to the left until it stops) and install
the cable.
3. Set the mode locator to the heater unit case and
secure with a clip.
>>B<< AIR MIX DOOR CABLE
CONNECTION
1. Turn the heater control assembly’s temperature
adjustment knob all the way to the HOT side.
2. Set the heater unit’s air mix door lever to the MAX
HOT position (turn the damper lever as the left
illustration) and attach the cable.
3. Set the mode locator to the heater unit case and
secure with a clip.
AC304856DEF position
FACE
position
AB
Mode selection
damper link
Mode locator
AC304854DEF positionFACE position
AB
Mode
selection
damper link
Mode locator
AC304857
MAX HOT
position
MAX. COOL position
AB
Air mix damper leverMode locator
AC304855MAX HOT position
MAX. COOL
position
AB
Air mix damper leverMode locator
Page 563 of 788
Page 564 of 788
