EC-942
[QR (WITHOUT EURO-OBD)]
ELECTRICAL LOAD SIGNAL
6. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
With CONSULT-II
Check “HEATER FAN SW” in “DATA MONITOR” mode with CON-
SULT-II under the following conditions.
OK or NG
OK >>INSPECTION END.
NG >> GO TO 16.
7. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION
Without CONSULT-II
Check voltage between ECM terminal 96 and ground under the fol-
lowing conditions.
OK or NG
OK >>INSPECTION END.
NG >> GO TO 16.
8. CHECK HEADLAMP FUNCTION
1. Start engine.
2. Turn the lighting switch ON at 2nd position (placed in LOW position for models with Xenon headlamp).
3. Check that headlamps are illuminated.
OK or NG
OK (Models without Xenon headlamp)>>GO TO 9.
OK (Models with Xenon headlamp)>>GO TO 11.
NG >> Refer to LT- 5 , "
HEADLAMP - XENON TYPE -" , LT- 2 5 , "HEADLAMP - CONVENTIONAL TYPE -"
, LT- 4 1 , "HEADLAMP (WITH DAYTIME) - XENON TYPE -" or LT- 5 1 , "HEADLAMP (WITH DAY-
TIME) - CONVENTIONAL TYPE -" .
Condition LOAD SIGNAL
Heater fan control switch: ON ON
Heater fan control switch: OFF OFF
PBIB1995E
Condition Voltage
Heater fan control switch: ON 0V
Heater fan control switch: OFF BATTERY VOLTAGE
PBIB1219E
EC-944
[QR (WITHOUT EURO-OBD)]
ELECTRICAL LOAD SIGNAL
12. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E105, M13
Harness for open and short between ECM and HID relay LH
>> Repair open circuit or short to ground or short to power in harness or connectors.
13. CHECK REAR WINDOW DEFOGGER FUNCTION
1. Start engine.
2. Turn ON the rear window defogger switch.
3. Check the rear windshield.
Is the rear windshield heated up?
Ye s o r N o
Yes >> GO TO 14.
No >> Refer to GW-17, "
REAR WINDOW DEFOGGER" .
14. CHECK REAR WINDOW DEFOGGER INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Stop engine.
2. Disconnect ECM harness connector.
3. Disconnect rear window defogger relay.
4. Check harness continuity between rear window defogger relay 3 (models without door mirror defogger), 5
(models with door mirror defogger) and ECM terminal 93.
Refer to Wiring Diagram.
5. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 18.
NG >> GO TO 15.
15. DETECT MALFUNCTIONING PART
Check the following.
Harness connectors B1, M17
Harness for open and short between rear window defogger relay and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors.
16. CHECK HEATER FAN CONTROL FUNCTION
1. Start engine.
2. Turn ON the fan control switch.
3. Check the blower fan motor.
Does the blower fan motor activate?
Ye s o r N o
Yes >> GO TO 17.
No >> Refer to AT C - 3 4 , "
TROUBLE DIAGNOSIS" or MTC-3, "TROUBLE DIAGNOSIS" . Continuity should exist.
ELECTRICAL LOAD SIGNAL
EC-945
[QR (WITHOUT EURO-OBD)]
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17. CHECK HEATER FAN SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Stop engine.
2. Disconnect ECM harness connector.
3. Disconnect A/C AUTO AMP. harness connector.
4. Check harness continuity between A/C AUTO AMP. terminal 19 and ECM terminal 96.
Refer to Wiring Diagram.
5. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 18.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.
18. CHECK INTERMITTENT INCIDENT
Perform EC-624, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>>INSPECTION END Continuity should exist.
SERVICE DATA AND SPECIFICATIONS (SDS)
EC-971
[QR (WITHOUT EURO-OBD)]
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SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Fuel PressureEBS01158
Idle Speed and Ignition TimingEBS01159
*: Under the following conditions:
Air conditioner switch: OFF
Electric load: OFF (Lights, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead position
Mass Air Flow SensorEBS0115B
*: Engine is warmed up to normal operating temperature and running under no-load.
Intake Air Temperature SensorEBS0115C
Engine Coolant Temperature SensorEBS0115D
Heated Oxygen Sensor 1 HeaterEBS0115E
Heated Oxygen sensor 2 HeaterEBS0115F
Crankshaft Position Sensor (POS)EBS0115G
Refer to EC-699, "Component Inspection" .
Fuel pressure at idle
Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi)
Target idle speedQR20DEM/T No load* (in Neutral position) 650±50 rpm
A/T No load* (in P or N position)
700±50 rpm
QR25DEM/T No load* (in Neutral position)
A/T No load* (in P or N position)
Air conditioner: ONQR20DEM/T In Neutral position
725 rpm or more
A/T In P or N position
QR25DEM/T In Neutral position 750 rpm or more
A/T In P or N position 700 rpm or more
Ignition timingQR20DEM/T In Neutral position
15°±5° BTDC A/T In P or N position
QR25DEM/T In Neutral position
A/T In P or N position
Supply voltageBattery voltage (11 - 14V)
Output voltage at idle0.7 - 1.1*V (QR20DE)
0.8 - 1.2*V (QR25DE)
Temperature °C (°F) Resistance kΩ
25 (77)1.800 - 2.200
80 (176)0.283 - 0.359
Temperature °C (°F) Resistance kΩ
20 (68)2.1 - 2.9
50 (122)0.68 - 1.00
90 (194)0.236 - 0.260
Resistance [at 25°C (77°F)] 3.3 - 4.0Ω
Resistance [at 25°C (77°F)] 5.0 - 7.0Ω
ATC-3
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AMBIENT SENSOR ................................................ 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 121
IN-VEHICLE SENSOR ............................................ 122
Removal and Installation ...................................... 122
REMOVAL ......................................................... 122
INSTALLATION ................................................. 122
SUNLOAD SENSOR .............................................. 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSTALLATION ................................................. 123
INTAKE SENSOR ................................................... 124
Removal and Installation ...................................... 124
REMOVAL ......................................................... 124
INSTALLATION ................................................. 124
BLOWER UNIT ....................................................... 125
Removal and Installation ...................................... 125
REMOVAL ......................................................... 125
INSTALLATION ................................................. 125
Disassembly and Assembly ................................. 126
BLOWER MOTOR .................................................. 127
Removal and Installation ...................................... 127
REMOVAL ......................................................... 127
INSTALLATION ................................................. 127
INTAKE DOOR MOTOR ......................................... 128
Removal and Installation ...................................... 128
REMOVAL ......................................................... 128
INSTALLATION ................................................. 128
FAN CONTROL AMPLIFIER .................................. 129
Removal and Installation ...................................... 129
REMOVAL ......................................................... 129
INSTALLATION ................................................. 129
AIR CONDITIONER FILTER ................................... 130
Removal and Installation ...................................... 130
FUNCTION ........................................................ 130
REPLACEMENT TIMING .................................. 130
REPLACEMENT PROCEDURES ..................... 130
HEATER & COOLING UNIT ASSEMBLY .............. 131
Removal and Installation ...................................... 131
REMOVAL ......................................................... 131
INSTALLATION ................................................. 132
Disassembly and Assembly ................................. 132
MODE DOOR MOTOR ........................................... 134
Removal and Installation ...................................... 134
REMOVAL ......................................................... 134
INSTALLATION ................................................. 134
AIR MIX DOOR MOTOR ......................................... 135
Removal and Installation ...................................... 135
REMOVAL ......................................................... 135
INSTALLATION ................................................. 135
HEATER CORE ...................................................... 136
Removal and Installation ...................................... 136
REMOVAL ......................................................... 136
INSTALLATION ................................................. 136
DUCTS AND GRILLES .......................................... 137
Removal and Installation ...................................... 137
REMOVAL ......................................................... 137
INSTALLATION ................................................. 140REFRIGERANT LINES ...........................................141
HFC-134a (R-134a) Service Procedure ...............141
SETTING OF SERVICE TOOLS AND EQUIP-
MENT ................................................................141
Components .........................................................143
WITH GASOLINE ENGINE ...............................143
WITH DIESEL ENGINE .....................................144
Removal and Installation of Compressor ..............144
REMOVAL .........................................................144
INSTALLATION .................................................146
Removal and Installation of Compressor Clutch ..146
REMOVAL .........................................................146
INSTALLATION .................................................150
Removal and Installation of Low-pressure Flexible
Hose .....................................................................153
REMOVAL .........................................................153
INSTALLATION .................................................154
Removal and Installation of High-pressure Flexible
Hose .....................................................................154
REMOVAL .........................................................154
INSTALLATION .................................................155
Removal and Installation of High-pressure Pipe ..155
REMOVAL .........................................................155
INSTALLATION .................................................155
Removal and Installation of Condenser ................155
REMOVAL .........................................................155
INSTALLATION .................................................156
Removal and Installation of Liquid Tank ...............156
REMOVAL .........................................................156
INSTALLATION .................................................157
Removal and Installation of Refrigerant Pressure
Sensor ..................................................................157
REMOVAL .........................................................157
INSTALLATION .................................................157
Removal and Installation of Dual-pressure Switch .158
REMOVAL .........................................................158
INSTALLATION .................................................158
Removal and Installation of Evaporator ................158
REMOVAL .........................................................158
INSTALLATION .................................................159
Removal and Installation of Expansion Valve .......159
REMOVAL .........................................................159
INSTALLATION .................................................159
Checking for Refrigerant Leaks ............................160
Checking System for Leaks Using the Fluorescent
Leak Detector .......................................................160
Dye Injection .........................................................160
Electronic Refrigerant Leak Detector ....................161
PRECAUTIONS FOR HANDLING LEAK
DETECTOR .......................................................161
CHECKING PROCEDURE ...............................161
SERVICE DATA AND SPECIFICATIONS (SDS) ....164
Compressor ..........................................................164
Lubricant ...............................................................164
Refrigerant ............................................................164
Engine Idling Speed .............................................164
Belt Tension ..........................................................164
PRECAUTIONS
ATC-7
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O-RING AND REFRIGERANT CONNECTION
With Gasoline Engine
NOTE:
This illustration is for RHD models. The blower and heater & cooling unit layouts for LHD models are symmet-
rically opposite.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
RJIA2817E
ATC-8
PRECAUTIONS
With Diesel Engine
NOTE:
This illustration is for RHD models. The blower and heater & cooling unit layouts for LHD models are symmet-
rically opposite.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-Ring Part Numbers and Specifications
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
RJIA2818E
Connec-
tion typeO-ring
sizePart number D mm (in) W mm (in)
New
892471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New
1292472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New
1692473 N8210 13.6 (0.535) 2.43 (0.0957)
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New
1992474 N8210 16.5 (0.650) 2.43 (0.0957)
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
SHA814E
TROUBLE DIAGNOSIS
ATC-75
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COMPONENT DESCRIPTION
Mode Door Motor
The mode door motor is attached to the heater & cooling unit. It
rotates so that air is discharged from the outlet set by the auto amp.
Motor rotation is conveyed to a link which activates the mode door.
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR
SYMPTOM: Mode door motor does not operate normally.
Perform diagnostic procedure. Refer to AT C - 6 9 , "
DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .
RJIA0513E
RJIA0514E