ATC-1
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
CONTENTS
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SECTION AT C
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AUTOMATIC AIR CONDITIONER
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 4
Precautions for Working with HFC-134a (R-134a) ..... 4
General Refrigerant Precautions .............................. 5
Lubricant Precautions .............................................. 5
Precautions for Refrigerant Connection ................... 5
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 6
O-RING AND REFRIGERANT CONNECTION ..... 7
Precautions for Servicing Compressor ................... 10
Precautions for Service Equipment ........................ 10
RECOVERY/RECYCLING EQUIPMENT ............ 10
ELECTRONIC LEAK DETECTOR ...................... 10
VACUUM PUMP ................................................. 10
MANIFOLD GAUGE SET .................................... 10
SERVICE HOSES ................................................ 11
SERVICE COUPLERS ......................................... 11
REFRIGERANT WEIGHT SCALE ....................... 11
CALIBRATING ACR4 WEIGHT SCALE ............... 11
CHARGING CYLINDER ...................................... 12
Precautions for Leak Detection Dye ....................... 12
IDENTIFICATION ................................................ 13
IDENTIFICATION LABEL FOR VEHICLE ........... 13
Wiring Diagrams and Trouble Diagnosis ................ 13
PREPARATION ......................................................... 14
Special Service Tools ............................................. 14
WITH GASOLINE ENGINE (CWV-615M COM-
PRESSOR) ......................................................... 14
WITH DIESEL ENGINE (DKV-11G COMPRES-
SOR) ................................................................... 14
HFC-134a (R-134a) Service Tools and Equipment ... 15
REFRIGERATION SYSTEM ..................................... 18
Refrigerant Cycle ................................................... 18
REFRIGERANT FLOW ....................................... 18
FREEZE PROTECTION (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 18
Refrigerant System Protection ............................... 18
REFRIGERANT PRESSURE SENSOR (WITH GASOLINE ENGINE: CWV-615M COMPRES-
SOR) ................................................................... 18
DUAL-PRESSURE SWITCH (WITH DIESEL
ENGINE: DKV-11G COMPRESSOR) .................. 18
PRESSURE RELIEF VALVE (WITH GASOLINE
ENGINE: CWV-615M COMPRESSOR) .............. 18
V-6 Variable Displacement Compressor (With Gas-
oline Engine: CWV-615M Compressor) .................. 19
GENERAL INFORMATION ................................. 19
DESCRIPTION .................................................... 20
Component Layout ................................................. 23
LUBRICANT .............................................................. 24
Maintenance of Lubricant Quantity in Compressor ... 24
LUBRICANT ........................................................ 24
LUBRICANT RETURN OPERATION .................. 24
LUBRICANT ADJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 25
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 25
AIR CONDITIONER CONTROL ............................... 27
Description of Air Conditioner LAN Control System ... 27
System Construction .............................................. 27
OPERATION ........................................................ 27
TRANSMISSION DATA AND TRANSMISSION
ORDER ............................................................... 28
AIR MIX DOOR CONTROL (AUTOMATIC TEM-
PERATURE CONTROL) ..................................... 29
FAN SPEED CONTROL ...................................... 29
INTAKE DOOR CONTROL ................................. 29
OUTLET DOOR CONTROL ................................ 29
MAGNET CLUTCH CONTROL ........................... 29
SELF-DIAGNOSTIC SYSTEM ............................ 29
Description of Control System ................................ 30
Control Operation ................................................... 31
MODE CONTROL DIAL ...................................... 31
TEMPERATURE CONTROL DIAL (POTENTIO
TEMPERATURE CONTROL) .............................. 31
FAN CONTROL DIAL .......................................... 31
REAR WINDOW DEFOGGER SWITCH ............. 31
ATC-2 INTAKE SWITCH ................................................. 31
A/C SWITCH ....................................................... 31
Discharge Air Flow ................................................. 32
System Description ................................................. 33
SWITCHES AND THEIR CONTROL FUNCTION ... 33
TROUBLE DIAGNOSIS ............................................ 34
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 34
WORK FLOW ...................................................... 34
SYMPTOM TABLE .............................................. 34
Component Parts and Harness Connector Location ... 35
ENGINE COMPARTMENT .................................. 35
PASSENGER COMPARTMENT .......................... 36
Schematic ............................................................... 37
WITH GASOLINE ENGINE ................................. 37
WITH DIESEL ENGINE ....................................... 38
Wiring Diagram —A/C— ......................................... 39
WITH GASOLINE ENGINE / LHD MODELS ....... 39
WITH GASOLINE ENGINE / RHD MODELS ...... 43
WITH DIESEL ENGINE / LHD MODELS ............ 47
WITH DIESEL ENGINE / RHD MODELS ............ 51
Auto Amp. Terminals and Reference Value ............ 55
PIN CONNECTOR TERMINAL LAYOUT ............ 55
TERMINALS AND REFERENCE VALUE FOR
AUTO AMP. ......................................................... 55
Self-diagnosis Function .......................................... 57
DESCRIPTION .................................................... 57
FUNCTION CONFIRMATION PROCEDURE ...... 59
AUXILIARY MECHANISM: TEMPERATURE
SETTING TRIMMER ........................................... 63
AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER ........................................... 63
AUXILIARY MECHANISM: INLET PORT MEM-
ORY FUNCTION ................................................. 64
Operational Check .................................................. 65
CHECKING BLOWER ......................................... 65
CHECKING DISCHARGE AIR ............................ 65
CHECKING INTAKE DOOR ................................ 65
CHECKING TEMPERATURE DECREASE ......... 66
CHECKING TEMPERATURE INCREASE .......... 66
CHECKING A/C SWITCH ................................... 66
Power Supply and Ground Circuit for Auto Amp. ... 67
INSPECTION FLOW ........................................... 67
COMPONENT DESCRIPTION ............................ 67
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM ... 68
LAN System Circuit ................................................ 69
DIAGNOSTIC PROCEDURE FOR LAN CIR-
CUIT .................................................................... 69
Mode Door Motor Circuit ........................................ 73
INSPECTION FLOW ........................................... 73
SYSTEM DESCRIPTION .................................... 74
COMPONENT DESCRIPTION ............................ 75
DIAGNOSTIC PROCEDURE FOR MODE
DOOR MOTOR ................................................... 75
Air Mix Door Motor Circuit ...................................... 76
INSPECTION FLOW ........................................... 76
SYSTEM DESCRIPTION .................................... 77
COMPONENT DESCRIPTION ............................ 78
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR .................................................... 78
Intake Door Motor Circuit ........................................ 79
INSPECTION FLOW ............................................ 79
SYSTEM DESCRIPTION ..................................... 80
COMPONENT DESCRIPTION ............................ 81
DIAGNOSTIC PROCEDURE FOR INTAKE
DOOR MOTOR .................................................... 81
Blower Motor Circuit ................................................ 82
INSPECTION FLOW ............................................ 82
SYSTEM DESCRIPTION ..................................... 83
COMPONENT DESCRIPTION ............................ 84
DIAGNOSTIC PROCEDURE FOR BLOWER
MOTOR ................................................................ 84
COMPONENT INSPECTION ............................... 87
Magnet Clutch Circuit .............................................. 88
INSPECTION FLOW ............................................ 88
SYSTEM DESCRIPTION ..................................... 89
DIAGNOSTIC PROCEDURE FOR MAGNET
CLUTCH .............................................................. 89
COMPONENT INSPECTION ............................... 94
Insufficient Cooling .................................................. 96
INSPECTION FLOW ............................................ 96
PERFORMANCE TEST DIAGNOSIS .................. 98
PERFORMANCE CHART ..................................100
TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SURE .................................................................102
Insufficient Heating ...............................................105
INSPECTION FLOW ..........................................105
Noise .....................................................................107
INSPECTION FLOW ..........................................107
Self-Diagnosis .......................................................108
INSPECTION FLOW ..........................................108
Ambient Sensor Circuit .........................................109
COMPONENT DESCRIPTION ..........................109
AMBIENT TEMPERATURE INPUT PROCESS .109
DIAGNOSTIC PROCEDURE FOR AMBIENT
SENSOR ............................................................109
COMPONENT INSPECTION ............................. 111
In-Vehicle Sensor Circuit ....................................... 111
COMPONENT DESCRIPTION .......................... 111
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
SENSOR ............................................................112
COMPONENT INSPECTION .............................113
Sunload Sensor Circuit .........................................114
COMPONENT DESCRIPTION ..........................114
SUNLOAD INPUT PROCESS ...........................114
DIAGNOSTIC PROCEDURE FOR SUNLOAD
SENSOR ............................................................114
COMPONENT INSPECTION .............................116
Intake Sensor Circuit .............................................117
COMPONENT DESCRIPTION ..........................117
DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SOR ...................................................................117
COMPONENT INSPECTION .............................119
CONTROLLER ........................................................120
Removal and Installation .......................................120
REMOVAL ..........................................................120
INSTALLATION ..................................................120
PRECAUTIONS
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IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
Wiring Diagrams and Trouble DiagnosisEJS000T9
When you read wiring diagrams, refer to the following:
GI-14, "How to Read Wiring Diagrams" in GI section.
PG-3, "Wiring Diagram — POWER —" in PG section.
When you perform trouble diagnosis, refer to the following:
GI-10, "How to Follow Trouble Diagnoses" in GI section.
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.
RJIA2721E
SHA867F
AIR CONDITIONER CONTROL
ATC-27
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AIR CONDITIONER CONTROLPFP:27500
Description of Air Conditioner LAN Control SystemEJS000TI
The LAN (Local Area Network) system consists of auto amp., mode door motor, air mix door motor and intake
door motor.
A configuration of these components is shown in the diagram below.
System ConstructionEJS000TJ
A small network is constructed between the auto amp., air mix door motor, mode door motor and intake door
motor. The auto amp. and motors are connected by data transmission lines and motor power supply lines. The
LAN network is built through the ground circuits of each door motor.
Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted
through the data transmission lines connecting the auto amp. and each door motor.
The following functions are contained in LCUs built into air mix door motor, mode door motor and intake door
motor.
Address
Motor opening angle signal
Data transmission
Motor stop and drive decision
Opening angle sensor (PBR function)
Comparison
Decision (Auto amp. indicated value and motor opening angle comparison)
OPERATION
The auto amp. receives data from each of the sensors. The auto amp. sends mode door, air mix door and
intake door opening angle data to the mode door motor LCU, air mix door motor LCU and intake door motor
LCU.
The mode door motor, air mix door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amp. and each of the motor position
sensors is compared by the LCUs in each motor with the existing decision and opening angles. Subsequently,
HOT/COLD, DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection data is
returned to the auto amp.
RJIA0480E
RHA350H
ATC-30
AIR CONDITIONER CONTROL
Description of Control SystemEJS000TK
The control system consists of input sensors, switches, the auto amp. (microcomputer) and outputs.
The relationship of these components is shown in the diagram below:
RJIA3093E
TROUBLE DIAGNOSIS
ATC-39
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Wiring Diagram —A/C—EJS004GR
WITH GASOLINE ENGINE / LHD MODELS
TJWA0078E
AV-1
AUDIO VISUAL, NAVIGATION & TELEPHONE SYS-
TEM
K ELECTRICAL
CONTENTS
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SECTION AV
A
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AV
AUDIO VISUAL, NAVIGATION & TELEPHONE SYSTEM
PRECAUTIONS .......................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
AUDIO ......................................................................... 4
System Description .................................................. 4
WITH CASSETTE DECK ...................................... 4
WITHOUT CASSETTE DECK .............................. 6
Component Parts Location ....................................... 8
Wiring Diagram —AUDIO— (With Cassette Deck) ..... 9
LHD MODELS ....................................................... 9
RHD MODELS ..................................................... 11
Schematic (Without Cassette Deck) ...................... 13
LHD MODELS ..................................................... 13
RHD MODELS .................................................... 14
Wiring Diagram —AUDIO— (Without Cassette
Deck) ...................................................................... 15
LHD MODELS WITH NAVIGATION .................... 15
LHD MODELS WITHOUT NAVIGATION ............ 18
RHD MODELS WITH NAVIGATION ................... 21
RHD MODELS WITHOUT NAVIGATION ............ 24
Terminals and Reference Value for Audio Unit With
Cassette Deck ........................................................ 27
Terminals and Reference Value for Audio Unit With-
out Cassette Deck .................................................. 28
Audio Steering Wheel Switch Resistance Check ... 29
Trouble Diagnoses ................................................. 30
AUDIO UNIT ....................................................... 30
Inspection ............................................................... 30
AUDIO UNIT ....................................................... 30
ANTENNA ........................................................... 30
Audio Steering Wheel Switch Does Not Operate
(With Cassette Deck) ............................................. 31
Audio Steering Wheel Switch Does Not Operate
(Without Cassette Deck) ........................................ 31
Speed Sensitive Volume System Does Not Work
(With Cassette Deck) ............................................. 33
Removal and Installation of Audio Unit (With Cas-
sette Deck) ............................................................. 34REMOVAL ........................................................... 34
INSTALLATION ................................................... 34
Removal and Installation of Audio Unit (Without
Cassette Deck) ....................................................... 35
REMOVAL ........................................................... 35
INSTALLATION ................................................... 35
Removal and Installation of Speakers .................... 35
REMOVAL ........................................................... 35
INSTALLATION ................................................... 35
Removal and Installation of Tweeters ..................... 35
REMOVAL ........................................................... 35
INSTALLATION ................................................... 36
AUDIO ANTENNA .................................................... 37
Antenna Route ........................................................ 37
Removal and Installation of Roof Antenna ............. 37
NAVIGATION SYSTEM ............................................. 38
System Description ................................................. 38
NAVIGATION SYSTEM ....................................... 38
Component Description .......................................... 41
NAVI CONTROL UNIT ........................................ 41
GPS ANTENNA ................................................... 41
DISPLAY .............................................................. 42
NAVI SWITCH ..................................................... 42
TRANSFER UNIT ................................................ 43
VOICE CHANGE RELAY .................................... 43
TMC TUNER ....................................................... 43
System Operation Description ................................ 44
NAVIGATION SYSTEM ....................................... 44
MAP VIEWING STYLE ........................................ 44
MAP DISPLAY ..................................................... 45
FUNCTION OF NAVI SWITCH ............................ 46
Precautions for NAVI Control Unit Replacement .... 49
Component Parts And Harness Connector Location
... 50
Schematic ............................................................... 51
Wiring Diagram — NAVI — .................................... 52
LHD MODELS ..................................................... 52
RHD MODELS .................................................... 57
Terminals and Reference Value for NAVI Control
Unit ......................................................................... 62
AV-2 Terminals and Reference Value for Display ............ 64
Terminals and Reference Value for NAVI Switch .... 65
Terminals and Reference Value for Transfer Unit ... 66
Terminals and Reference Value for TMC Tuner ...... 68
Terminals and Reference Value for Voice Change
Relay ...................................................................... 68
Self-Diagnosis Function .......................................... 70
DESCRIPTION .................................................... 70
DIAGNOSIS ITEM ............................................... 70
Self-Diagnosis Mode .............................................. 71
OPERATION PROCEDURE ................................ 71
SELF–DIAGNOSIS RESULT ............................... 72
CONFIRMATION/ADJUSTMENT Mode ................. 73
OPERATION PROCEDURE ................................ 73
DISPLAY .............................................................. 74
VEHICLE SIGNALS ............................................. 75
HISTORY OF ERRORS ...................................... 75
NAVIGATION ....................................................... 78
FEATURE RESTRICTION SETTING .................. 79
Power Supply and Ground Circuit Check for NAVI
Control Unit ............................................................. 80
Power Supply and Ground Circuit Check for Display ... 81
Power Supply and Ground Circuit Check for NAVI
Switch ..................................................................... 82
Power Supply and Ground Circuit Check for Trans-
fer Unit .................................................................... 83
Power Supply and Ground Circuit Check for TMC
Tuner ...................................................................... 84
Communication Line Check (Between NAVI Control
Unit and TMC Tuner) .............................................. 85
Communication Line Check (Between Display and
NAVI switch) ........................................................... 85
Communication Line Check (Between NAVI Switch
and Transfer Unit) ................................................... 86
Communication Line Check (Between NAVI Control
Unit and Transfer Unit) ........................................... 86
Communication Line Check (Between Transfer Unit
and Display) ............................................................ 88
Vehicle Speed Signal Check .................................. 89
Illumination Signal Check ....................................... 90
Ignition Signal Check .............................................. 90
Reverse Signal Check ............................................ 91
Color of RGB Image Is Not Proper ......................... 91
RGB Screen Is Not Shown ..................................... 93
RGB Screen Is Rolling ............................................ 94
Guide Sound Is Not Heard ..................................... 95
Display Quality Control Cannot Change Screen .... 97
Example of Symptoms Judged Not Malfunction ..... 98
BASIC OPERATIONS ......................................... 98
VEHICLE MARKS ............................................... 98
MAP DVD-ROM ................................................... 99DESTINATION, WAY POINTS OR MENU CON-
TENTS CANNOT BE CHOSEN OR SET ............ 99
VOICE GUIDANCE .............................................. 99
ROUTE CALCULATION ....................................100
EXAMPLES OF VEHICLE MARK DISPLACE-
MENT .................................................................101
VEHICLE MARK SHOWS A POSITION WHICH
IS COMPLETELY WRONG ...............................104
VEHICLE MARK JUMPS ...................................104
VEHICLE MARK IS IN A RIVER OR SEA .........105
VEHICLE MARK AUTOMATICALLY ROTATES .105
WHEN DRIVING ON SAME ROAD, SOME-
TIMES VEHICLE MARK IS IN RIGHT PLACE
AND SOMETIMES IT IS WRONG PLACE ........105
LOCATION CORRECTION BY MAP-MATCH-
ING IS SLOW .....................................................105
ALTHOUGH GPS RECEIVING DISPLAY IS
GREEN, VEHICLE MARK DOES NOT RETURN
TO CORRECT LOCATION ................................105
NAME OF CURRENT PLACE IS NOT DIS-
PLAYED .............................................................105
CONTENTS OF DISPLAY DIFFER FOR BIRD-
VIEW® AND THE (FLAT) MAP SCREEN ..........105
Program Loading ..................................................106
Removal and Installation of NAVI Control Unit ......107
REMOVAL ..........................................................107
INSTALLATION ..................................................107
Removal and Installation of GPS Antenna ............107
REMOVAL ..........................................................107
INSTALLATION ..................................................107
Removal and Installation of GPS Antenna Feeder .108
REMOVAL ..........................................................108
INSTALLATION ..................................................108
Removal and Installation of NAVI Switch ..............109
REMOVAL ..........................................................109
INSTALLATION ..................................................109
Removal and Installation of Display ......................109
REMOVAL ..........................................................109
INSTALLATION ..................................................109
Removal and Installation of Transfer Unit .............110
REMOVAL ..........................................................110
INSTALLATION ..................................................110
Removal and Installation of TMC Tuner ................110
REMOVAL ..........................................................110
INSTALLATION ..................................................110
Removal and Installation of Voice Change Relay . 110
REMOVAL ..........................................................110
INSTALLATION ..................................................110
TELEPHONE (PRE WIRE) ...................................... 111
Wiring Diagram — PHONE — .............................. 111