Installation
Install free-running hub in the reverse order of removal.
Apply multi-purpose grease to bushing and drive clutch
before installing on wheel hub and axle shaft, respectively.
+Install drive clutch.
+Place snap ring in drive shaft groove.
Axial end play:
0.4 mm (0.016 in) or less
Snap ring size:
Refer to SDS.
+When installing manual-lock free-running hub, make sure the
position ``FREE''.
Apply multi-purpose grease to drive shaft end.
+Check operation of manual-lock free-running hub after install-
ing it.
Inspection
+Check that hub moves smoothly and freely.
+Check that clutch moves smoothly in the body.
SFA860B
SFA200
SFA428A
FRONT AXLE Ð Manual-lock Free-running Hub
FA-12
SAE J1930 Terminology List
All emission related terms used in this publication in accordance with SAE J1930 are listed. Accordingly, new
terms, new acronyms/abbreviations and old terms are listed in the following chart.
***: Not applicable
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Air cleaner ACL Air cleaner
Barometric pressure BARO ***
Barometric pressure sensor-BCDD BAROS-BCDD BCDD
Camshaft position CMP ***
Camshaft position sensor CMPS Crank angle sensor
Canister *** Canister
Carburetor CARB Carburetor
Charge air cooler CAC Intercooler
Closed loop CL Closed loop
Closed throttle position switch CTP switch Idle switch
Clutch pedal position switch CPP switch Clutch switch
Continuous fuel injection system CFI system ***
Continuous trap oxidizer system CTOX system ***
Crankshaft position CKP ***
Crankshaft position sensor CKPS ***
Data link connector DLC ***
Data link connector for CONSULT DLC for CONSULT Diagnostic connector for CONSULT
Diagnostic test mode DTM Diagnostic mode
Diagnostic test mode selector DTM selector Diagnostic mode selector
Diagnostic test mode I DTM I Mode I
Diagnostic test mode II DTM II Mode II
Diagnostic trouble code DTC Malfunction code
Direct fuel injection system DFI system ***
Distributor ignition system DI system Ignition timing control
Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater
Early fuel evaporation system EFE system Mixture heater control
Electrically erasable programmable read only
memoryEEPROM ***
Electronic ignition system EI system Ignition timing control
Engine control EC ***
Engine control module ECM ECCS control unit
Engine coolant temperature ECT Engine temperature
Engine coolant temperature sensor ECTS Engine temperature sensor
Engine modi®cation EM ***
Engine speed RPM Engine speed
Erasable programmable read only memory EPROM ***
Evaporative emission canister EVAP canister Canister
SAE J1930 TERMINOLOGY LIST
GI-43
***: Not applicable
NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
Three way + oxidation catalytic converter system TWC + OC system ***
Throttle body TB Throttle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid
Lock-up solenoid
Transmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air ¯ow sensor VAFS Air ¯ow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter system WU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter system WU-TWC system ***
Wide open throttle position switch WOTP switch Full switch
SAE J1930 TERMINOLOGY LIST
SAE J1930 Terminology List (Cont'd)
GI-46
HEATER &
AIR CONDITIONER
SECTION
HA
CONTENTS
MANUAL AND AUTO
PRECAUTIONS AND PREPARATION............................1
Supplemental Restraint System (SRS) ``AIR
BAG'' and ``SEAT BELT PRE-TENSIONER'' ...............1
Precautions for Working with HFC-134a (R-134a) .....1
General Refrigerant Precautions .................................2
Precautions for Refrigerant Connection ......................2
Precautions for Servicing Compressor ........................6
Special Service Tools ..................................................6
HFC-134a (R-134a) Service Tools and
Equipment ....................................................................7
Precautions for Service Equipment .............................9
DESCRIPTION............................................................... 11
Refrigeration Cycle .................................................... 11
Component Layout ....................................................12
Discharge Air Flow.....................................................13
REAR HEATER
TROUBLE DIAGNOSES...............................................14
Wiring Diagram Ð R/HEAT Ð/LHD Models .............14
Wiring Diagram Ð R/HEAT Ð/RHD Models .............15
MANUAL
DESCRIPTION...............................................................16
System Description ....................................................16
Control Operation ......................................................16
TROUBLE DIAGNOSES...............................................17
Component Location..................................................17
Wiring Diagram Ð A/C, M Ð ....................................19
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................21
Operational Check .....................................................22
Intake Door Motor ......................................................24
Blower Motor..............................................................28
Insufficient Cooling ....................................................32
Trouble Diagnoses for Abnormal Pressure ...............36
Insufficient Heating ....................................................39Air Outlet ....................................................................41
Magnet Clutch............................................................43
Noise ..........................................................................48
AUTO
DESCRIPTION...............................................................49
Introduction ................................................................49
Features .....................................................................49
Overview of Control System ......................................52
Control Operation ......................................................53
TROUBLE DIAGNOSES...............................................55
Component Location..................................................55
Circuit Diagram ..........................................................57
Wiring Diagram Ð A/C, A Ð .....................................58
Auto Amp. Terminals and Reference Value...............61
Self-diagnosis ............................................................63
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................69
Operational Check .....................................................70
A/C System ................................................................73
Mode Door Motor.......................................................75
Air Mix Door Motor ....................................................79
Intake Door Motor ......................................................82
Blower Motor..............................................................86
Magnet Clutch............................................................92
Insufficient Cooling ....................................................98
Insufficient Heating ....................................................99
Noise ........................................................................100
Self-diagnosis ..........................................................101
Memory Function .....................................................102
Ambient Sensor .......................................................103
In-vehicle Sensor .....................................................105
Sunload Sensor .......................................................107
Intake Sensor........................................................... 110
HA
MANUAL AND AUTO
SERVICE PROCEDURES........................................... 112
HFC-134a (R-134a) Service Procedure .................. 112
Maintenance of Lubricant Quantity in
Compressor ............................................................. 114
Ventilation Air Filter .................................................. 116
Refrigerant Lines ..................................................... 117Checking Refrigerant Leaks .................................... 119
Compressor Mounting .............................................122
Compressor Ð DKS-17CH......................................123
Compressor Clutch ..................................................123
SERVICE DATA AND SPECIFICATIONS...................126
General Speci®cations .............................................126
Inspection and Adjustment ......................................126
When you read wiring diagrams:
+Read GI section, ``HOW TO READ WIRING DIAGRAMS''.
+See EL section, ``POWER SUPPLY ROUTING'' for power distribution circuit.
When you perform trouble diagnoses, read GI section, ``HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES'' and ``HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT''.
Precautions for Servicing Compressor
+Plug all openings to prevent moisture and foreign matter from entering.
+When the compressor is removed, store it in the same position as it is when mounted on the car.
+When replacing or repairing compressor, follow ``Maintenance of Lubricant Quantity in Compres-
sor'' exactly. Refer to HA-114.
+Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with
lubricant, wipe it off by using a clean waste cloth moistened with thinner.
+After compressor service operation, turn the compressor shaft by hand more than ®ve turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
+After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
Special Service Tools
Tool number
Tool nameDescription
KV99231260
Clutch disc wrench
NT204
Removing shaft nut and clutch disc
KV992T0001
Clutch disc puller
NT206
Removing clutch disc
KV992T0002
Pulley installer
NT207
Installing pulley
PRECAUTIONS AND PREPARATIONMANUAL AND AUTO
HA-6
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant ¯ow is in the standard pattern. Refrigerant ¯ows through the compressor, condenser, liquid
tank, evaporator and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a speci®ed range. When the
evaporator coil temperature falls below a speci®ed point, the thermo control ampli®er interrupts the compres-
sor operation. When the evaporator coil temperature rises above the speci®cation, the thermo control ampli-
®er allows compressor operation.
REFRIGERANT SYSTEM PROTECTION
Dual-pressure switch
The dual-pressure switch is located on the liquid tank. If the system pressure rises or falls out of specifications,
the switch opens to interrupt compressor clutch operation.
RHA735G
DESCRIPTIONMANUAL AND AUTO
HA-11
How to Perform Trouble Diagnoses for Quick
and Accurate Repair
WORK FLOW
*1: HA-22
SYMPTOM TABLE
Symptom Reference page
+Intake door does not change.+Go to Trouble Diagnosis Procedure for Intake Door
Motor Circuit.HA-24
+Blower motor does not rotate at all.+Go to Trouble Diagnosis Procedure for Blower Motor
Circuit.HA-28
+Insufficient cooling.+Go to Trouble Diagnosis Procedure for Insufficient
Cooling.HA-32
+Insufficient heating.+Go to Trouble Diagnosis Procedure for Insufficient
Heating.HA-32
+Air outlet does not change.+Go to Trouble Diagnosis Procedure for Air Outlet. HA-41
+Magnet clutch does not engage when A/C switch and
fan switch are ON.+Go to Trouble Diagnosis Procedure for Magnet Clutch
Circuit.HA-43
+Noise+Go to Trouble Diagnosis Procedure for Noise. HA-48
SHA900E
TROUBLE DIAGNOSESMANUAL
HA-21