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TROUBLE DIAGNOSISMTC-53
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Insufficient HeatingINFOID:0000000005930855
SYMPTOM: Insufficient heating
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERAT IONAL CHECK - TEMPERATURE INCREASE
1. Turn temperature control dial clockwise to maximum heat position.
2. Check for hot air at discharge air outlets.
Can the symptom be duplicated?
YES >> GO TO 3.
NO >> GO TO 2.
2.CHECK FOR ANY SYMPTOMS
Perform a complete operational check for any symptoms. Refer to MTC-31, "
Operational Check" .
Does another symptom exist?
YES >> Refer to MTC-23, "How to Perform Trouble Diagnosis for Quick and Accurate Repair" .
NO >> System OK.
3.CHECK FOR SERVICE BULLETINS
Check for any service bulletins.
>> GO TO 4.
4.CHECK COOLANT SYSTEM
1. Check engine coolant level. Refer to CO-11, "
Inspection" (HR16DE) or CO-36, "Inspection" (MR18DE).
2. Check hoses for leaks or kinks.
3. Check Radiator cap. Refer to CO-14, "
Checking Radiator Cap" HR16DE or CO-39, "Checking Radiator
Cap" (MR18DE).
OK or NG
OK >> GO TO 5.
NG >> Repair/replace as necessary.
5.CHECK AIR MIX DOOR CABLE
Check air mix door cable operation. Refer to MTC-65, "
Air Mix Door Cable Adjustment" .
OK or NG
Gauge indication Refrigerant cycleProbable causeCorrective 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.
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TROUBLE DIAGNOSIS
YES >> GO TO 6.
NO >> Adjust or replace air mix door cable. Refer to MTC-65, "
Air Mix Door Cable Adjustment" .
6.CHECK AIR DUCTS
Check ducts for air leaks.
OK or NG
OK >> GO TO 7.
NG >> Repair air leaks.
7.CHECK HEATER HOSE TEMPERATURES
1. Start engine and warm it up to normal operating temperature.
2. Touch both the inlet and outlet heater hoses. The inlet hose should be hot and the outlet hose should be
warm.
Is the inlet hose hot and the outlet hose warm?
YES >> GO TO 8.
NO >> Both hoses warm: GO TO 9.
8.CHECK ENGINE COOLANT TEMPERATURE SENSOR
Check engine control temperature sensor. Refer to EC-172, "
Component Inspection" (MR18DE) or EC-690,
"Component Inspection" (HR16DE).
OK or NG
OK >> System OK.
NG >> Repair or replace as necessary. Retest.
9.CHECK HEATER HOSES
Check heater hoses for proper installation.
OK or NG
OK >> GO TO 10.
NG >> Repair /replace as necessary. Retest GO TO 7.
10.BACK FLUSH HEATER CORE
1. Back flush heater core.
2. Drain the water from the system.
3. Refill system with new engine coolant. Refer to CO-11, "
Changing Engine Coolant" (HR16DE) or CO-36,
"Changing Engine Coolant" (MR18DE) .
4. Start engine and warm it up to normal operating temperature.
5. Touch both the inlet and outlet heater hoses. The inlet hose should be hot and the outlet hose should be
warm.
Is the inlet hose hot and the outlet hose warm?
YES >> System OK.
NO >> Replace heater core and refill engine coolant. Refer to MTC-68, "
Removal and Installation" .
NoiseINFOID:0000000005930856
SYMPTOM: Noise
INSPECTION FLOW
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TROUBLE DIAGNOSISMTC-55
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*1. MTC-31, "Operational Check"*2.EM-13, "Checking" (HR16DE) or EM-
132, "Checking Drive Belts"
(MR18DE) *3.
MTC-46, "
Insufficient Cooling"
*4.MTC-92, "Removal and Installation of
Expansion Valve"
*5.MTC-78, "Removal and Installation of
Compressor - HR16DE" or MTC-80,
"Removal and Installation of Com-
pressor - MR18DE"
*6 MTC-78, "Removal and Installation of
Compressor - HR16DE" or MTC-80,
"Removal and Installation of Com-
pressor - MR18DE"
*7. MTC-78, "Removal and Installation of
Compressor - HR16DE" or MTC-80,
"Removal and Installation of Com-
pressor - MR18DE"
*8.MTC-17, "Maintenance of Oil Quanti-
ty in Compressor"
*9 MTC-90, "Removal and Installation of
Liquid Tank"
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CONTROLLER
CONTROLLER
Removal and InstallationINFOID:0000000005930857
REMOVAL
1. Remove instrument finisher E. Refer to IP-11, "Component Parts" .
2. Remove instrument finisher D. Refer to IP-11, "
Component Parts" .
3. Remove cluster lid C. Refer to IP-11, "
Component Parts" .
4. Remove intake door lever knob. Refer to MTC-57, "
Disassembly and Assembly" .
5. Remove controller finisher mounting screws and clips and the controller finisher.
6. Remove controller mounting screws and the controller.
7. Remove instrument panel lower cover. Refer to IP-11, "
Component Parts" .
8. Remove instrument panel side finisher. Refer to IP-11, "
Component Parts" .
9. Remove instrument panel lower finisher. Refer to IP-11, "
Component Parts" .
10. Remove glove box assembly. Refer to IP-11, "
Component Parts" .
11. Remove air mix door cable, mode door cable and intake door cable from A/C unit assembly.
12. Disconnect connector, and then remove controller.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Adjust the door cables duri ng installation. Refer to MTC-64, "
Intake Door Cable Adjustment" , MTC-66,
"Mode Door Cable Adjustment" and MTC-65, "Air Mix Door Cable Adjustment" .
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CONTROLLERMTC-57
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Disassembly and AssemblyINFOID:0000000005930858
CAUTION:
Install inner cable of each do or cable to the corresponding
lever, as shown in the figure. Pr ess outer cable until it hooks on
the tabs and becomes secure.
1. Air mix door cable 2. Intake door cable3. Mode door cable
4. A/C controller assembly 5. Mode control dial6. Rear DEF button
7. A/C button 8. Temperature control dial9. Illumination bulb
10. Intake door lever knob 11. Fan control dial
ZJIA0106J
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MTC-58
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THERMO CONTROL AMPLIFIER
THERMO CONTROL AMPLIFIER
Removal and InstallationINFOID:0000000005930859
NOTE:
Only MR18DE - TYPE 2 systems are equipped with a thermo control amplifier.
REMOVAL
1. Remove evaporator. Refer to MTC-91, "Removal and Installation of Evaporator" .
CAUTION:
Cap or wrap the joint of the pipe with suitable ma terial such as vinyl tape to avoid the entry of air.
2. Mark the mounting position of the thermo control amp. and then
remove thermo control amp. (1) from evaporator (2).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
• Install the thermo control amp. at the mark made during removal of the thermo control amp.
• When recharging refrigerant, check for leaks.
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A/C UNIT ASSEMBLYMTC-59
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A/C UNIT ASSEMBLY
Removal and InstallationINFOID:0000000005930860
REMOVAL
1. Use a recovery/recycling equipment (f or HFC-134a) to discharge refrigerant.
2. Drain coolant from cooling system. Refer to CO-36, "
Changing Engine Coolant".
3. Remove cowl top cover. Refer to EI-24, "
Removal and Installation".
4. Remove upper clip and position the lower dash insulator aside.
5. Remove bolt (A), and then disconnect low-pressure flexible hose (1) and high-pressure pipe (2) from evaporator.
CAUTION:
Cap or wrap the joint of the pi pe with suitable material such
as vinyl tape to avoid the entry of air.
6. Remove clamps (A), and then disconnect heater hoses (1) from heater core.
7. Remove console box assembly. Refer to IP-11, "
Component Parts".
A. A/C unit assembly boltsB. Steering member boltsC. Steering column nuts
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A/C UNIT ASSEMBLY
8. Remove instrument stay nuts (A) and harness clamps (B), andthen remove instrument stay (1).
9. Disconnect thermo control amp. connector (1) for MR18DE - TYPE 2 systems as shown. Di sconnect the thermo control amp.
short connector for MR18DE - TYPE 1 and HR16DE systems.
10. Remove instrument panel and pad. Refer to IP-11, "
Component Parts".
11. Remove side ventilator ducts. Refer to MTC-69, "
Removal and Installation".
12. Remove center ventilator ducts. Refer to MTC-69, "
Removal and Installation".
13. Remove side kicking plates. Refer to EI-41, "
Component".
14. Disconnect the fuel filler door cable and the rear hatch door cable.
15. Remove A/C unit assembly bolts, steering member bolts, steering column nuts and harness clips.
16. Remove steering member, and then remove A/C unit assembly.
INSTALLATION
Installation is in the reverse order of removal.
• When filling radiator with coolant, refer to CO-36, "
Changing Engine Coolant".
• Recharge the refrigerant.
CAUTION:
• Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
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A/C unit assembly bolt : 6.9 N·m (0.7 kg-m, 61 in-lb)
Steering member bolt : 12 N·m (1.25 kg-m, 9 ft-lb)
Steering column nut : Refer to PS-10, "
Removal and Installation".
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