OIL
ATC-21
< SERVICE INFORMATION >
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1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.
No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Connect recovery/recycling equipment to vehicle. Confir m refrigerant purity in supply tank using recovery/
recycling equipment and refrigerant identifier. If NG, refer to AT C - 3 , "
Contaminated Refrigerant".
3. Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identi-
fier. If NG, refer to AT C - 3 , "
Contaminated Refrigerant".
4. Discharge refrigerant into the refrigerant recove ry/recycling equipment. Measure oil discharged into the
recovery/recycling equipment.
5. Drain the oil from the “old” (removed) compress or into a graduated container and recover the amount of
oil drained.
6. Drain the oil from the “new” compressor into a separate, clean container.
7. Measure an amount of new oil installed equal to am ount drained from “old” compressor. Add this oil to
“new” compressor through the suction port opening.
8. Measure an amount of new oil equal to the amount recovered during discharging. Add this oil to “new” compressor through the suction port opening.
9. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil at this
time.
CAUTION:
Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil if only replacing the compressor.
1. New compressor 2. Old compressor 3. Recovery/recycling equipment
4. Measuring cup X 5. Measuring cup Y 6. New oil
A. Drain oil from the new compressor
into clean container B. Record amount of oil recovered C.
Add an additional 5 m (0.2 US fl oz,
0.2 Imp fl oz) of new oil when replacing
liquid tank
D. Install new oil equal to recorded amounts in measuring cups X plus Y
WJIA1716E
ATC-106
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
High-pressure Side is Too High and Low-pressure Side is Too Low
High-pressure Side is Too Low and Low-pressure Side is Too High
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure sides
are too high. Pressure is reduced soon af-
ter water is splashed on con-
denser.
Excessive refrigerant charge in
refrigeration cycle
Reduce refrigerant until speci-
fied pressure is obtained.
Air suction by cooling fan is in-
sufficient. Insufficient condenser cooling
performance
↓
1. Condenser fins are
clogged.
2. Improper fan rotation of cooling fan • Clean condenser.
• Check and repair cooling fan
if necessary.
• Low-pressure pipe is not cold.
• When compressor is stopped high-pressure val-
ue quickly drops by approx-
imately 196 kPa (2 kg/cm
2 ,
28 psi). It then decreases
gradually thereafter. Poor heat exchange in con-
denser
(After compressor operation
stops, high-pressure decreas-
es too slowly.)
↓
Air in refrigeration cycle
Evacuate and recharge system.
Engine tends to overheat. Engine cooling systems mal-
function. Check and repair engine cool-
ing system.
• An area of the low-pressure pipe is colder than areas
near the evaporator outlet.
• Plates are sometimes cov- ered with frost. • Excessive liquid refrigerant
on low-pressure side
• Excessive refrigerant dis- charge flow
• Expansion valve is open a lit- tle compared with the speci-
fication.
↓
Improper expansion valve ad-
justment Replace expansion valve.
AC359A
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too high and
low-pressure side is too low.
Upper side of condenser and
high-pressure side are hot,
however, liquid tank is not so
hot.High-pressure tu
be or parts lo-
cated between compressor
and condenser are clogged or
crushed. • Check and repair or replace
malfunctioning parts.
• Check oil for contamination.
AC360A
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low and
low-pressure side is too high. High- and low-pressure sides
become equal soon after com-
pressor operation stops.Compressor pressure opera-
tion is improper.
↓
Damaged inside compressor
packings.
Replace compressor.
No temperature difference be-
tween high- and low-pressure
sides. Compressor pressure opera-
tion is improper.
↓
Damaged inside compressor
packings.
Replace compressor.
AC356A
TROUBLE DIAGNOSISATC-107
< SERVICE INFORMATION >
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Low-pressure Side Some
times Becomes Negative
Low-pressure Side Becomes Negative
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure sides
are too low. • There is a big temperature
difference between liquid
tank outlet and inlet. Outlet
temperature is extremely
low.
• Liquid tank inlet and expan-
sion valve are frosted. Liquid tank inside is slightly
clogged.
• Replace liquid tank.
• Check oil for contamination.
• Temperature of expansion valve inlet is extremely low
as compared with areas
near liquid tank.
• Expansion valve inlet may be frosted.
• Temperature difference oc- curs somewhere in high-
pressure side. High-pressure pipe located be-
tween liquit tank and expan-
sion valve is clogged.
• Check and repair malfunc-
tioning parts.
• Check oil for contamination.
Expansion valve and liquid
tank are warm or only cool
when touched. Low refrigerant charge.
↓
Leaking fittings or compo-
nents.Check refrigerant system for
leaks. Refer to
ATC-166,
"Checking of Refrigerant
Leaks" .
There is a big temperature dif-
ference between expansion
valve inlet and outlet while the
valve itself is frosted. Expansion valve closes a little
compared with the specifica-
tion.
↓
1. Improper expansion
valve adjustment.
2. Malfunctioning expansion
valve.
3. Outlet and inlet may be clogged. • Remove foreign particles by
using compressed air.
• Check oil for contamination.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet. Low-pressure pipe is clogged
or crushed.• Check and repair malfunc-
tioning parts.
• Check oil for contamination.
Air flow volume is too low. Evaporator is frozen. • Check intake sensor circuit.
Refer to ATC-120, "
Intake
Sensor Circuit" .
• Repair evaporator fins.
• Replace evaporator.
• Refer to AT C - 7 8 , "
Front
Blower Motor Circuit" .
AC353A
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes be-
comes negative. • Air conditioning system does
not function and does not cy-
clically cool the compart-
ment air.
• The system constantly func-
tions for a certain period of
time after compressor is
stopped and restarted. Refrigerant does not discharge
cyclically.
↓
Moisture is frozen at expan-
sion valve outlet and inlet.
↓
Water is mixed with refrigerant.
• Drain water from refrigerant
or replace refrigerant.
• Replace liquid tank.
AC354A
ATC-108
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
Insufficient Heating
INFOID:0000000003533261
SYMPTOM: Insufficient heating
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPER ATIONAL CHECK - TEMPERATURE INCREASE
1. Press the AUTO switch.
2. Turn the temperature control dial (driver) clockwise until 32 ° C (90 ° F) is displayed.
3. Check for hot air at discharge air outlets.
Can this symptom be duplicated?
YES >> GO TO 2.
NO >> Perform complete system operational check. Refer to ATC-50, "
Operational Check (Front)" .
2.CHECK FOR SERVICE BULLETINS
Check for any service bulletins.
>> GO TO 3.
3.PERFORM SELF-DIAGNOSIS
Perform self-diagnosis. Refer to ATC-48, "
A/C System Self-Diagnosis Function" .
OK or NG
OK >> GO TO 4.
NG >> Refer to ATC-48, "
A/C System Self-Diagnosis Function" .
4.CHECK ENGINE COOLING SYSTEM
1. Check for proper engine coolant level. Refer to CO-9, "
Inspection".
2. Check hoses for leaks or kinks.
3. Check radiator cap. Refer to CO-9, "
Inspection" .
4. Check for air in cooling system.
>> GO TO 5.
5.CHECK AIR MIX DOOR OPERATION
Check the operation of the air mix door.
OK or NG
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side becomes nega-
tive. Liquid tank or front/rear side of
expansion valve′s pipe is frost-
ed or dewed. High-pressure side is closed
and refrigerant does not flow.
↓
Expansion valve or liquid tank
is frosted. Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
• If water is the cause, initially
cooling is okay. Then the wa-
ter freezes causing a block-
age. Drain water from
refrigerant or replace refrig-
erant.
• If due to foreign particles, re-
move expansion valve and
remove the particles with dry
and compressed air (not
shop air).
• If either of the above meth- ods cannot correct the mal-
function, replace expansion
valve.
• Replace liquid tank.
• Check oil for contamination.
AC362A
ATC-134
< SERVICE INFORMATION >
HEATER & COOLING UNIT ASSEMBLY
5. Disconnect the front heater hoses from the front heater core.
6. Disconnect the high/low pressure pipes from the front expansion valve.
7. Remove the instrument panel and console panel. Refer to IP-10, "
Removal and Installation".
8. Remove the steering column. Refer to PS-10
.
9. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (J/B) electrical connectors. Refer to PG-3
.
10. Disconnect the steering member from each side of the vehicle body.
11. Remove the front heater and cooling unit assembly with it attached to the steering member, from the vehi-
cle.
CAUTION:
Use care not to damage the seats and interior tr im panels when removing the front heater and
cooling unit assembly with it at tached to the steering member.
12. Remove the front heater and cooling unit assembly from the steering member.
Installation
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply com-
pressor oil to it when installing it.
• After charging the refrigerant, check for leaks.
NOTE:
• Fill the engine cooling system with the s pecified coolant mixture. Refer to MA-12, "
Changing Engine Cool-
ant".
• Recharge the A/C system. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
REAR HEATER AND COOLING UNIT ASSEMBLY
Removal
1. Discharge the refrigerant from the A/C system. Refer to ATC-150, "HFC-134a (R-134a) Service Proce-
dure".
2. Drain the coolant from the engine cooling system. Refer to MA-12, "
Changing Engine Coolant".
3. Disconnect the rear heater core hoses from the rear heater core.
4. Disconnect the rear A/C pipes from the rear expansion valve.
5. Remove the luggage side finisher lower RH. Refer to EI-34
.
6. Disconnect the following electrical connectors: • Rear blower motor
• Rear blower motor resistor
• Rear air mix door motor
7. Disconnect the ducts from the rear heater and cooling unit assembly.
8. Remove the rear heater and cooling unit assembly.
Installation
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply com-
pressor oil to it when installing it.
• After charging the refrigerant, check for leaks.
NOTE:
• Fill the engine cooling system with the s pecified coolant mixture. Refer to MA-12, "
Changing Engine Cool-
ant".
• Recharge the A/C system. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
LJIA0021E
ATC-154
< SERVICE INFORMATION >
REFRIGERANT LINES
Removal and Installation for Compressor
INFOID:0000000003533293
A/C Compressor Mounting
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Remove the front right wheel and tire assembly. Refer to WT-7, "
Rotation".
3. Remove the engine under cover and the splash shield using power tool.
4. Remove the engine air cleaner and air ducts. Refer to EM-15
.
5. Remove the drive belt. Refer to EM-13
.
6. Disconnect the compressor electrical connector.
7. Disconnect the high-pressure flexible hose and low- pressure flexible hose from the compressor.
CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
8. Remove the compressor bolts and nut using power tools.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace the O-rings of the low-pressure flexibl e hose and high-pressure flexible hose with new
ones, apply compressor oil to the O-rings when installing them.
• After recharging the A/C system with refrigerant, check for leaks.
WJIA0958E
ATC-158
< SERVICE INFORMATION >
REFRIGERANT LINES
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-Pressure Flexible HoseINFOID:0000000003533295
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Remove the cowl top extension. Refer to EI-17
.
4. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
5. Remove the low-pressure flexible hose.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
CAUTION:
• Replace the O-ring of the low-pr essure flexible hose with a new one, then apply compressor oil to it
when installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseINFOID:0000000003533296
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer to EM-15
.
3. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
4. Remove the high-pressure flexible hose. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
CAUTION:
• Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to it
when installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeINFOID:0000000003533297
REMOVAL
1. Remove the cowl top extension. Refer to EI-17.
2. Disconnect the battery negative terminal and positive battery terminal.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer to WT-7, "
Rotation".
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer to ATC-150, "
HFC-134a (R-134a) Service Procedure".
7. Remove the low-pressure pipe. Refer to ATC-159, "
Removal and Installation for Low-Pressure Pipe".
8. Remove the high-pressure pipe. CAUTION:
Cap or wrap the joint of the pipe with suitable mate rial such as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
REFRIGERANT LINESATC-159
< SERVICE INFORMATION >
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Refer to ATC-152, "Component".
CAUTION:
• Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for Low-Pressure PipeINFOID:0000000003533298
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Remove the cowl top and the cowl top extension. Refer to EI-17
.
3. Remove the low-pressure pipe. CAUTION:
Cap or wrap the joint of the pipes with suitable material such as viny l tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-152, "
Component".
CAUTION:
• Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
• After charging refrigerant, check for leaks.
Removal and Installation for Rear High- and Low-Pressure A/C and Heater Core Pipes
INFOID:0000000003533299
REMOVAL
1. Discharge the refrigerant. Refer to ATC-150, "HFC-134a (R-134a) Service Procedure".
2. Drain the coolant from the engine cooling system. Refer to CO-9, "
Changing Engine Coolant".
3. Disconnect the underfloor rear heater hoses (1 and 2) from the rear heater pipes underneath the vehicle.
•⇐ : Front
4. Remove the rear high- and low-pressure pipes bolt (A) to dis- connect the rear high- and low-pressure pipes from the under-
floor rear high- and low-pressu re pipes underneath the vehicle.
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avo id the entry of air.
5. Remove the rear high- and low-pressure pipes nuts (B) under- neath the vehicle.
NOTE:
The remaining steps are performed inside the rear luggage area of the vehicle.
6. Remove the luggage side finisher lower RH. Refer to EI-39
.
7. Disconnect the rear heater core hoses (1 and 2) from the rear heater core (3).
•⇐ : Front
WJIA2310E
WJIA2311E