AIR CONDITIONING AIR CONDITIONING SYSTEM

AC1
AC
AIR CONDITIONING SYSTEM
PRECAUTION
NOTICE:
When the cable is disconnected from the negative (-)
battery terminal, initialize the following system(s) after
the cable is reconnected.
1. Before performing electronic work, disconnect the cable
from the negative (-) battery terminal in order to prevent it
from shorting and burning out.
2. Before disconnecting and reconnecting the battery cable,
turn the ignition switch OFF and the headlight dimmer
switch OFF. Then loosen the terminal nut completely. Do
not damage the cable or terminal.
3. When the battery cable is disconnected, the clock and
radio settings and stored DTCs are erased. Therefore,
before disconnecting the battery cable, make a notes of
them.
1. CONNECT THE BATTERY NEGATIVE TERMINAL TO
THE CABLE AND RUN THE ENGINE AT NO LESS
THAN 2,000 RPM FOR 2MINUTE
NOTICE:
If the engine exceeds 2,000 rpm, the clutch is
automatically disengaged by the compressor
protection control system.
2. DO NOT HANDLE REFRIGERANT IN ENCLOSED
AREAS OR NEAR OPEN FLAMES
3. ALWAYS WEAR EYE PROTECTION
4. BE CAREFUL NOT TO GET LIQUID REFRIGERANT
IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin:
(a) Wash the area with lots of cold water.
CAUTION:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a hospital or a physician for
professional treatment.
5. NEVER HEAT CONTAINER OR EXPOSE THE
CONTAINER TO OPEN FLAME
6. BE CAREFUL NOT TO DROP CONTAINER OR APPLY
ANY PHYSICAL SHOCKS TO IT
System name See procedure
METER / GAUGE SYSTEM See page ME-10
Negative (-)
Battery Terminal
Cable
D033496E01
Charging
Cylinder
AC02810E02
AC02811E01
AC2
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC
7. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM
If there is not enough refrigerant in the refrigerant
system, oil lubrication will be insufficient and compressor
burnout may occur. Necessary care should be taken to
avoid this.
8. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILE COMPRESSOR IS OPERATING
Open and close only the low pressure valve. If the high
pressure valve is open, refrigerant flows in the reverse
direction. This could cause the charging cylinder to
rupture.
9. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH
REFRIGERANT
If refrigerant is overcharged, it causes problems such as
insufficient cooling, poor fuel economy, engine
overheating, etc.
10. DO NOT OPERATE ENGINE AND COMPRESSOR
WITH NO REFRIGERANT
CAUTION:
Doing so may damage the inside of the compressor
because the compressor parts always move
regardless of whether the A/C system is turned on or
off.
11. SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(a) This vehicle is equipped with an SRS
(Supplemental Restraint System) such as the driver,
front passenger, side, and curtain shield air bags.
Failure to carry out service operation in the correct
sequence could cause the SRS to unexpectedly
deploy during servicing, possibly leading to a
serious accident. Before servicing (including
removal or installation of parts, inspection or
replacement), be sure to read the precautionary
notices (see page RS-1).
12. GENERAL PRECAUTION
(a) While using the battery during inspection, do not
bring the positive and negative tester probes too
close to each other as a short circuit may occur.
Wrong Okay
LO HI LO HI
N011084E04
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC3
AC
PARTS LOCATION
AMBIENT TEMPERATURE
SENSOR
COMPRESSOR AND
MAGNETIC CLUTCH
CONDENSER
- MG CLT RELAY
- HEATER RELAY
INTEGRATION CONTROL
AND PANEL
PRESSURE SWITCH
ENGINE ROOM R/B NO.2
MAIN BODY ECU
(DRIVER SIDE J/B)
ECM
- ECU-B FUSE
- HEATER FUSE
- IG1 FUSE
- A/C SWITCH
- BLOWER SWITCH
- AIR CONDITIONING AMPLIFIER
I102678E01
AC4
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC
BLOWER MOTOR
BLOWER RESISTOR
HEATER RADIATOR UNIT
SUB-ASSEMBLY
COOLER THERMISTOR NO.1
(EVAPORATOR TEMPERATURE
SENSOR)
EVAPORATOR
COOLER EXPANSION VALVE
AIR INLET CONTROL
SERVO MOTOR
AIR MIX CONTROL
SERVO MOTOR
MODE CONTROL SERVO
MOTOR
I102677E01
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC5
AC
SYSTEM DIAGRAM
Battery
ECU-B 10A
HEATER 60A
Ignition Switch
IG1 15A
HEATER
Blower
Motor
E
RHI
M1
M2
HI
S5
M2
M1
RLO
Heater Control
REC
Air Conditioning Control Assembly
GND
Air Mix Control
Servo motor
Blower Resistor
AMH
PSW
DEF
TAMG
TAM
IG+
BLW
TACO
TW
ACT
P-IG+
P-S5
P-SG
P-MSET
P-TSET
P-GND
P-GND
P-A/C
P-REC
P-RDEF
P-A/CD
P-RECD
P-RDFD
AC1
FACE
TPM
SG-1
S5-1
FRS
SG-3
B
TE
LOCK
MGC
Mode Control
Servo motor
TP
GND
AMC
Pressure Switch
Evaporator Temperature Sensor
Ambient Temperature Sensor
Cooler Compressor and
Magnet Clutch
ECM
Air Inlet Control Servo
motor
MG CLT
SG-2
SG-4
I102674E01
AC6
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC
PROBLEM SYMPTOMS TABLE
HINT:
Use the table below to help determine the cause of the
problem symptom. The potential causes of the symptoms
are listed in order of probability in the "Suspected Area"
column of the table. Check each symptom by checking the
suspected areas in the order they are listed. Replace parts
as necessary.
Inspect the fuses and relays related to this system before
inspecting the suspected areas below.
If the malfunction still exists even after checking and
confirming that all the circuits are normal, replace the A/C
amplifier.
Air conditioning system
Symptom Suspected area See page
No Cool Air Comes Out: Compressor Not Operating
Volume of refrigerant AC-12
Pressure switch AC-104
Magnetic clutch AC-88
Air conditioning amplifier assembly AC-8
Compressor pick up sensor AC-88
Cooler compressor AC-88
Wire harness or connector -
No Cool Air Comes Out: Blower Not Operating
HTR fuse -
Heater relay AC-106
Blower resistor AC-83
Blower motor AC-81
Air conditioning panel assembly AC-110
Air conditioning amplifier assembly AC-8
Wire harness or connector -
No Cool Air Comes Out: Air Mix Damper Servo Not
Operating
Air mix control servo motor AC-44
Air conditioning panel assembly AC-110
Wire harness or connector -
No Cool Air Comes Out: Insufficient Cooling
Volume of refrigerant AC-12
Blower motor performance check AC-81
Air mix damper servo full travel check AC-44
Recirculation damper servo operation check AC-74
No Engine Idle-up when A/C Switch ON
Air conditioning amplifier assembly AC-8
Idling control system ES-251
Wire harness or connector -
No Warm Air Comes Out: Blower Not Operating
HTR fuse -
IG1 fuse -
Heater relay AC-106
Blower resistor AC-83
Blower motor AC-81
Air conditioning panel assembly AC-110
Wire harness or connector -
No Warm Air Comes Out: Air Mix Damper Servo Not
Operating
Air mix control servo motor AC-44
Air conditioning panel assembly AC-110
Wire harness or connector -
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC7
AC
No Warm Air Comes Out: Insufficient Cooling
Volume of engine coolant CO-3
Air conditioning panel assembly AC-110
Blower motor performance check AC-81
Air mix damper servo full travel check AC-44
Recirculation damper servo operation check AC-74
Heater radiator -
Air Not Coming From Desired Outlets: Blower Not
Operating
HTR fuse -
IG1 fuse -
Heater relay AC-106
Blower resistor AC-83
Blower motor AC-81
Air conditioning panel assembly AC-106
Wire harness or connector -
Air Not Coming From Desired Outlets: Air Mix Damper
Servo Not Operating
Air mix control servo motor AC-44
Wire harness or connector -
Windshield Fogging: Compressor Not Operating
IG1 fuse -
Volume of refrigerant AC-12
Magnetic clutch AC-88
Cooler thermistor sensor AC-44
Air conditioning amplifier assembly AC-8
Compressor pick up sensor AC-88
Cooler compressor AC-88
Wire harness or connector -
Windshield Fogging: Blower Not Operating
HTR fuse -
Heater relay AC-106
Blower resistor AC-83
Blower motor AC-81
Air conditioning panel assembly AC-110
Wire harness or connector -
Windshield Fogging: Air Mix Damper Servo Not
Operating
Air mix control servo motor AC-44
Air conditioning panel assembly AC-110
Wire harness or connector -
Windshield Fogging: Insufficient Cooling
Volume of refrigerant AC-12
Blower motor performance check AC-81
Air mix damper servo full travel check AC-44
Recirculation damper servo operation check AC-74
Defrosting Insufficient:
Blower motor AC-81
Mode doors: Check cooling, heating & door operation -
Mode control servo motor: Hot air not coming, Go to no warm
air comes out
-
Mode control servo motor: Cold air not coming, Go to no cold
air comes out
-
Noise:
Blower motor: Inspect blower motor for debris/cracks -
Fresh air intake area: Inspect fresh air intake area for debris -
Noise:
Cooler compressor: Cooler compressor incorrectly fitted AC-90
Magnetic clutch AC-88
Refrigerant charge amount AC-20
Compressor mounting bracket: Compressor mounting bracket
incorrectly fitted
EM-27
A/C lines secure & not grounded -
Symptom Suspected area See page
AC8
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC
Odor (Cycle through blower speed, mode, temperature
to define odor type when engine is running and A/C
switch is ON. (Musty smell, coolant oil smell))
Wet carpet: Inspect for water, engine coolant or oil leaks -
A/C drain tube: Inspect for water, engine coolant or oil leaks -
Fresh air intake area: Inspect for water, engine coolant or oil
leaks
-
Heater hose: Inspect for water, engine coolant or oil leaks -
Evaporator: Inspect for water, engine coolant or oil leaks -
Evapo case: Inspect for water, engine coolant or oil leaks -
Air Not Coming from Desired Outlets (Cycle the mode
lever and check airflow for outlets when engine is
running, A/C switch is ON.)
Blower motor AC-81
Mode control servo motor AC-44
Mode doors: Check cooling, heating & door operation -
Wire harness or connector -
Air conditioning panel assembly AC-110
Symptom Suspected area See page
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC9
AC
TERMINALS OF ECU
1. INSPECT AIR CONDITIONING AMPLIFIER
ASSEMBLY
(a) Disconnect the E32 and E33 connectors from the air
conditioning amplifier assembly and inspect the
connector on the wire harness side, as shown in the
table below.
Standard:
If the results are not as specified, inspect the circuits
connected to the other parts.
(b) Reconnect the E32 and E33 connectors to the air
conditioning amplifier assembly and inspect the wire
harness side connector from the back side, as
shown in the table below.
Symbols (Terminals No.) Wiring Colors Terminal Descriptions Conditions Specified Condition
IG+ (E32-1) - GND (E32-
20)
Y-R - W-B Power source (IG) Ignition switch: OFF ON Below 1.0 11 to 14 V
B (E32-11) - GND (E32-
20)
W-R - W-B Power source (Back-up) Always 11 to 14 V
SG-1 (E33 - 17) - Body
ground
V-G - Body ground
Ground for mode control
servo motor
Always Below 1.0
SG-2 (E33 - 18) - Body
ground
Y-G - Body ground
Ground for air mix control
servomotor
Always Below 1.0
SG-3 (E33 - 6) - Body
ground
G-Y - Body ground Ground for lock sensor Always Below 1.0
SG-4 (E32 - 9) - Body
ground
GR-G - Body
ground
Ground for A/C evaporator
temperature sensor
Always Below 1.0
TAMG (E33 - 16) - Body
ground
GR - Body ground
Ground for ambient
temperature sensor
Always Below 1.0
GND (E32-20) - Body
ground
W-B - Body ground
Ground for main power
supply
Always Below 1.0
E32 E33
I102676E01
E32 E33
I102675E01
AC10
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC
Standard:
Symbols (Terminals No.) Wiring Colors Terminal Descriptions Conditions Specified Condition
DEF (E33-9) - GND (E32-
20)
LG - W-B Mode switch signal
Ignition switch: ON
Mode select switch:
Except DEF DEF
Below 1.5 11 to 14 V
LOCK (E33-8) - SG-3
(E33-6)
R-W - G-Y Magnet clutch signal
Start engine
Operate A/C system
Magnet clutch: ON
Pulse generation
(See waveform 1)
ACI (E33-24) - GND (E32-
20)
G-W - W-B Idle up request signal
Engine idling
Operate A/C system
Magnet clutch: OFF ON
11 to 14 Below 1.0 V
FRS (E32-6) - GND (E32-
20)
V-W - W-B
Recirculation/Fresh switch
signal
Ignition switch: ON
Recirculation/Fresh switch:
RECIRCULATION FRESH
11 to 14 Below 1.0 V
REC (E32-7) - GND (E32-
20)
P-B - W-B
Recirculation/Fresh switch
signal
Ignition switch: ON
Recirculation/Fresh switch:
FRESH RECIRCULATION
11 to 14 Below 1.0 V
MGC (E32-4) - GND (E32-
20)
LG-B - W-B Magnet clutch relay signal
Engine idling
Operate A/C system
Magnet clutch: OFF ON
11 to 14 Below 1.0 V
PSW (E33-22) - GND
(E32-20)
LG-R - W-B A/C pressure switch signal
Start engine
Operate A/C system
Refrigerant pressure: Normal
(Less than 0.196 MPa (2.0 kgf/
cm
2
)) or more than 3.14 MPa
(32.0 kgf/cm
2
))
11 to 14 Below 1.0 V
BLW (E32-8) - GND (E32-
20)
Y - W-B Blower switch signal
Ignition switch: ON
Blower switch: ON
OFF ON (LO, M1, M2, HI)
11 to 14 Below 1.0 V
TE (E32-10) - SG-4 (E32-
9)
B - GR-G
A/C evaporator temperature
sensor signal
Ignition switch: ON
Evaporator temperature:
0 15C (32 59F)
1.7 to 2.1 0.9 to 1.3
V
TAM (E33-13) - TAMG
(E33-16)
Y - GR
Ambient temperature sensor
signall
Ignition switch: ON
Ambient temperature:
25 40C (77 104F)
1.7 to 2.1 1.3 to 1.8
V
RDFG (E32-5) - GND
(E32-20)
Y-V - W-B Defogger switch signal
Ignition switch: ON
Defogger switch: OFF ON
11 to 14 Below 1.0 V
S5 (E33-19) - SG-1 (E33-
17)
P - V-G
Power supply for mode
control servo motor
Ignition switch: OFF ON 0 to 5.0 V
S5-1 (E33-7) - SG-2 (E33-
18)
P-B - Y-G
Power supply for air mix
control servomotor
Ignition switch: OFF ON 0 to 5.0 V
SG-1 (E33 - 17) - Body
ground
V-G - Body ground
Ground for mode control
servo motor
Always Below 1.0
SG-2 (E33 - 18) - Body
ground
Y-G - Body ground
Ground for air mix control
servomotor
Always Below 1.0
SG-3 (E33 - 6) - Body
ground
G-Y - Body ground Ground for lock sensor Always Below 1.0
SG-4 (E32 - 9) - Body
ground
GR-G - Body
ground
Ground for A/C evaporator
temperature sensor
Always Below 1.0
TAMG (E33 - 16) - Body
ground
GR - Body ground
Ground for ambient
temperature sensor
Always Below 1.0
GND (E32-20) - Body
ground
W-B - Body ground
Ground for main power
supply
Always Below 1.0
IG+ (E32-1) - Body ground Y-R - Body ground Power source (IG) Ignition switch: OFF ON Below 1.0 11 to 14 V
B (E32-11) - Body ground
W-R - Body
ground
Power source (Back-up) Always 11 to 14 V
AIR CONDITIONING AIR CONDITIONING SYSTEM
AC11
AC
If the results are not as specified, replace the air
conditioning amplifier assembly with a new one. If
the results are still not as specified after replacing
the air conditioning control assembly, inspect the
circuits connected to other parts.
(1) WAVEFORM 1:
Magnet clutch signal
HINT:
The wavelength becomes shorter as the engine
rpm increases.
2. INSPECT ECM
(a) Connect the connector to the ECM and inspect the
wire harness side connector from the back side, as
shown in the table below.
Standard voltage:
If the result is not as specified, the ECM may have a
malfunction.
(1) WAVEFORM 1:
Magnet clutch signal
HINT:
The wavelength becomes shorter as the engine
rpm increases.
0.2 V/DIV
10 msec./DIV
I045420E01
ECM Terminal Names Between LOCK (E33-8) - SG-3 (E33-6)
Tester Ranges 0.2 V/DIV, 10 msec./DIV
Conditions Idling
Symbols (Terminals No.) Wiring Colors Terminal Descriptions Conditions Specified Condition
ACT (E46-25) - E1 (B3-1) L-W - BR
Magnet clutch ON
permit signal
Start engine
Operate A/C system
A/C switch OFF Blower switch
OFF A/C switch ON Blower
switch ON
Below 1.0 11 to 14 V
AC1 (E46-24) - E1 (B3-1) G-W - BR Idle-up request signal
Start engine
A/C magnet clutch is engaged
not engaged
Below 1.0 11 to 14 V
THWO (E46-14) - E2 (B1-
28)
BR-B - W-G
Engine coolant temperature
sensor signal
Engine idling
Engine coolant temperature 80C
(176F)
Pulse generation
(See waveform 1)
B1 B3 B2 E46 E47
G035613E16
10 msec./ DIV
0.2 V/ DIV
A071927E01
ECM Terminal Names Between THWO (E46-14) - E2 (B1-28)
Tester Ranges 0.2 V/DIV, 10 msec./DIV
Conditions Idling
AC12
AIR CONDITIONING REFRIGERANT
AC
REFRIGERANT
ON-VEHICLE INSPECTION
1. CHECK REFRIGERANT PRESSURE USING
MANIFOLD GAUGE SET
(a) This is a method to identify trouble areas by using a
manifold gauge set. Read the manifold gauge
pressure under the following conditions.
Test conditions:
Engine warm.
All doors fully open.
A/C switch ON.
Blower speed control switch at HI.
Engine running at 1,500 rpm.
Air inlet mode damper set at recirculation.
Temperature control lever in MAX. COLD
position.
Air temperature at air inlet 30 to 35C (86 to
95F).
(1) When the refrigerant volume is correct, the
gauge reading indicates as follows:
Low pressure side:
0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm
2
)
High pressure side:
1.37 to 1.57 MPa (14 to 16 kgf/cm
2
)
HINT:
Pressure varies in accordance with certain
conditions (outside air temperature, sunlight
and wind).
(2) When there is moisture in the refrigeration
system:
E050573
Symptoms Probable Cause Diagnosis Corrective Actions
During operation, pressure on low
pressure side cycles between
normal and vacuum
Moisture in refrigeration system
freezes at expansion valve orifice,
causing temporary interruption of
cycle
However, when melted, returns to
normal condition
Receiver dryer oversaturated
Moisture in refrigeration
system freezes at expansion
valve orifice and blocks
refrigerant circulation
1. Replace receiver dryer
2. Remove moisture from cycle
by repeatedly evacuating air
3. Supply appropriate volume of
new refrigerant
Condition: Air conditioning system periodically
cools and then fails to cool.
I022117E03
AIR CONDITIONING REFRIGERANT
AC13
AC
(3) When cooling is insufficient:
(4) When the circulation of the refrigerant is poor:
(5) When the refrigerant does not circulate:
Symptoms Probable Cause Diagnosis Corrective Actions
Pressure low on both low and
high pressure sides
Cooling performance
insufficient
Gas leakage from refrigeration
system
Insufficient refrigerant
Refrigerant leakage
1. Check for gas leakage using
gas leak detector, and repair
if necessary
2. Supply appropriate volume of
new refrigerant
3. If indicated pressure value
close to 0 when connected to
gauge, create vacuum after
inspecting and repairing
location of leakage
Condition: Air conditioning system does not function effectively.
I022118E02
Symptoms Probable Cause Diagnosis Corrective Action
Pressure low on both low and
high pressure sides
Frost exists on piping from
condenser to A/C unit
Refrigerant flow obstructed by dirt
in condenser
Condenser clogged Replace condenser
Condition: Air conditioning system does not function effectively.
I022119E02
Condition: Air conditioning system does not function or functions intermittently.
I022121E02
AC14
AIR CONDITIONING REFRIGERANT
AC
(6) When the refrigerant is overcharged or cooling
of condenser is insufficient:
(7) When there is air in the refrigeration system:
Symptoms Probable Causes Diagnosis Corrective Actions
Vacuum indicated on low
pressure side, and extremely
low pressure indicated on
high pressure side
Frost or condensation seen
on piping on both sides of
condenser or expansion
valve
Refrigerant flow obstructed
by moisture or dirt in
refrigeration system
Refrigerant flow obstructed
by gas leakage from
expansion valve
Refrigerant does not circulate 1. Check expansion valve
2. Clean expansion valve with
compressed air
3. Replace condenser
4. Evacuate air and then supply
appropriate volume of new
refrigerant
5. For gas leakage from
expansion valve, replace
expansion valve
Symptoms Probable Causes Diagnosis Corrective Actions
Pressure extremely high on both
sides
Excessive refrigerant
Cooling performance of
condenser insufficient
Excessive refrigerant
Cooling performance of
condenser insufficient
1. Clean condenser fins
2. Check condenser fan motor
operation by switching A/C
ON
3. If 1 and 2 normal, check
amount of refrigerant and
supply appropriate volume of
refrigerant
Condition: Air conditioning system does not function effectively.
I022121E03
Symptoms Probable Causes Diagnosis Corrective Actions
Pressure extremely high on
both low and high pressure
sides
Low pressure piping too hot
to touch
Air in refrigeration system Air in refrigeration system
Insufficient vacuum purging
1. Check whether compressor
oil dirty or insufficient
2. Evacuate air and supply new
refrigerant
Condition: Air conditioning system does not function.
NOTE: These gauge indications occur
when the refrigeration system opens and
the refrigerant is supplied without
performing vacuum purging.
I022122E02
AIR CONDITIONING REFRIGERANT
AC15
AC
(8) When the expansion valve malfunctions:
(9) When the compressor is defective:
2. INSPECT IDLING SPEED
(a) Warm up the engine.
(b) Inspect the idling speed when these conditions are
established.
Engine warm
Blower speed control switch at HI
Temperature control lever in MAX. COLD
position
Standard
If the idling speed is not as specified, check the idle
control system.
Symptoms Probable Causes Diagnosis Corrective Actions
Pressure extremely high on
both low and high pressure
sides
Frost or condensation on
piping on low pressure side
Expansion valve malfunction Excessive refrigerant in low
pressure piping
Expansion valve opening too
wide
Replace expansion valve
Condition: Air conditioning system does not function effectively.
I022123E02
Symptoms Probable Cause Diagnosis Corrective Actions
Pressure extremely high on
both low and high pressure
sides
Pressure extremely low on
high pressure side
Internal leakage in compressor Compression failure of
compressor
Leakage from damaged valve
or broken sliding parts in
compressor
Repair or replace compressor
Condition: Air conditioning system does not function.
I022124E02
Condition Idling Speed
Switch A/C OFF 650 to 750 rpm
Switch A/C ON 750 to 850 rpm
AC16
AIR CONDITIONING REFRIGERANT
AC
REPLACEMENT
NOTICE:
When recharging refrigerant, collect together all the
refrigerant remaining in the cycle, then recharge and seal
the refrigerant as described below. (Do not overcharge.)
1. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM
(a) Start up the engine.
(b) Switch A/C ON.
(c) Turn the blower switch to ON.
(d) Operate the cooler compressor with an engine
speed of approximately 1,000 rpm for 5 to 6 minutes
to circulate the refrigerant and collect the remaining
compressor oil from each component, in the cooler
compressor.
(e) Stop the engine.
(f) Remove the caps from the service valves on the
refrigerant line.
(g) Connect the Freon collection/recycling device to
discharge the refrigerant gas remaining in the
refrigeration system.
NOTICE:
Use the Freon collection/recycling device in
accordance with the manufacturer's instruction
manual.
2. CHARGE REFRIGERANT
SST 07110-58060 (07117-58080, 07117-58090,
07117-78050, 07117-88060, 07117-88070,
07117-88080)
High Pressure Service Valve
Low Pressure Service Valve
I102500E01
AIR CONDITIONING REFRIGERANT
AC17
AC
NOTICE:
Charge refrigerant in accordance with equipment
manual.
(a) Perform vacuum purging using a vacuum pump.
(b) Charge refrigerant HFC-134a (R134a).
Standard:
570 to 630 g (20.11 to 22.22 oz.)
Check and fix connection portion
Gauge indicates abnormal pressure
Start evacuation
Suspend evacuation
Check air tightness
Charge refrigerant
Check for gas leakage
Gauge indicates normal
pressure
Evacuate until the pressure is
0.1 MPa (750 mmHg, 30 in.
Hg)
Leave to stand for 5 minutes
(Check that the pressure has
not changed after 5 minutes.)
I100449E02
AC18
AIR CONDITIONING REFRIGERANT
AC
NOTICE:
Do not start the engine before charging it with
refrigerant as the cooler compressor doesn't
work properly without sufficient refrigerant. This
could cause the compressor to overheat.
HINT:
The relationship between the refrigerant charge
amount and the pressure is as follows.
High Charge Range:
If the refrigerant is overcharged, the pressure
rises on the high-pressure side. High-pressure
cut off frequently occurs. This causes insufficient
cooling performance and also insufficient
compressor lubrication.
Low Charge Range:
Shortage of refrigerant causes insufficient
cooling performance and low circulation of
refrigerant oil, which shortens the compressor
life. Operation with insufficient coolant raises
refrigerant temperature and causes heat
deterioration of the rubber seals and hoses.
Cracking and thus refrigerant leakage may occur.
(1) Install the caps onto the service valves on the
refrigerant line.
3. WARM UP ENGINE
NOTICE:
Warm up the engine at less than 2,000 rpm for 2
minute or more after charging it with refrigerant.
4. CHECK FOR REFRIGERANT LEAKAGE
(a) After recharging the refrigerant gas, check for
refrigerant gas leakage using a halogen leak
detector.
Appropriate median amount of
refrigerant gas
Refrigerant charge amount
High
Pressure
Low
charge
Correct
amount
High
charge
Charge Amount
150g
50g
Point where
bubbles disappear
I101544E01
AIR CONDITIONING REFRIGERANT
AC19
AC
(b) Perform the operation as follows:
Stop the engine.
Secure good ventilation (the halogen leak
detector may react to volatile gases other than
refrigerant, such as evaporated gasoline or
exhaust gas).
Repeat the test 2 or 3 times.
Make sure that some refrigerant remains in the
refrigeration system.
When the compressor is off: approximately 392
to 588 kPa (4 to 6 kgf*cm
2
, 57 to 85 psi)
HINT:
It is impossible for the above pressure to be
maintained if there is leakage.
(c) Using the halogen leak detector, check the
refrigerant line, especially at the connection points,
for leakage.
(d) Bring the halogen leak detector close to the drain
hose before performing the test.
HINT:
After the blower motor has stopped, leave the
cooling unit for at least 15 minutes.
Place the halogen leak detector sensor under the
drain hose.
When bringing the halogen leak detector close to
the drain hose, make sure that the halogen leak
detector does not react to the volatile gases.
If such a reaction is unavoidable, the vehicle must
be lifted up.
(e) If no gas leakage is detected from the drain hose,
remove the blower motor from the cooling unit.
Insert the halogen leak detector sensor into the unit
and perform the test.
(f) Disconnect the pressure switch connector and leave
it for approximately 20 minutes. Bring the halogen
leak detector close to the pressure switch and
perform the test.
Halogen Leak Detector
I042222E14
Drain Hose
Halogen Leak
Detector
I100587E02
AC20
AIR CONDITIONING REFRIGERANT LINE
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
REFRIGERANT LINE
COMPONENTS
5.4 (55, 48 in.*lbf)
5.4 (55, 48 in.*lbf)
9.8 (100, 87 in.*lbf)
5.4 (55, 48 in.*lbf)
7.8 (80, 69 in.*lbf)
5.4 (55, 48 in.*lbf)
9.8 (100, 87 in.*lbf)
COOLER REFRIGERANT
SUCTION PIPE A
COOLER REFRIGERANT
LIQUID PIPE A
SUCTION HOSE
SUB-ASSEMBLY
AIR CONDITIONING
TUBE ASSEMBLY
DISCHARGE HOSE
SUB-ASSEMBLY
N*m (kgf*cm, ft*lbf) : Specified torque
I102420E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC21
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
AIR CONDITIONING UNIT
COMPONENTS
FRONT WIPER ARM AND
BLADE ASSEMBLY RH
FRONT WIPER ARM AND
BLADE ASSEMBLY LH
25 (255, 18)
ROOF ANTENNA POLE
SUB-ASSEMBLY
ANTENNA
ORNAMENT
FRONT FENDER SIDE
PANEL UPPER RH
CLIP
COWL TOP VENTILATOR
LOUVER ASSEMBLY
CLIP
x7
25 (255, 18)
25 (255, 18)
WINDSHIELD WIPER
ARM COVER
FRONT FENDER SIDE
PANEL UPPER LH
CLIP
COWL TOP VENTILATOR
LOUVER RH
COWL TOP VENTILATOR
LOUVER RH
N*m (kgf*cm, ft.*lbf) : Specified torque
CLIP
x2
CLIP
x4
FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE)
I102490E01
AC22
AIR CONDITIONING AIR CONDITIONING UNIT
AC
ASSIST GRIP ASSEMBLY
ASSIST GRIP
RETAINER LH
COWL SIDE TRIM BOARD RH
FRONT DOOR SCUFF PLATE LH
FRONT DOOR SCUFF PLATE RH
FRONT FLOOR FOOTREST
FRONT PILLAR GARNISH LH
ASSIST GRIP
ASSEMBLY
ASSIST GRIP PLUG
ASSIST GRIP PLUG
ASSIST GRIP RETAINER RH
FRONT PILLAR GARNISH RH
COWL SIDE TRIM
BOARD LH
N*m (kgf*cm, ft*lbf) : Specified torque
29 (296, 21)
FRONT DOOR OPENING
TRIM WEATHERSTRIP LH
FRONT DOOR
OPENING TRIM
WEATHERSTRIP RH
CLIP
CLIP
FOOTREST CLIP
x2
B133843E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC23
AC
CONSOLE UPPER REAR
PANEL SUB-ASSEMBLY
PARKING BRAKE HOLE
COVER SUB-ASSEMBLY
for Automatic Transmission 2WD: for Manual Transmission 4WD:
CONSOLE UPPER
REAR PANEL
SUB-ASSEMBLY
PARKING BRAKE HOLE
COVER SUB-ASSEMBLY
BOX BOTTOM MAT
<D>
<D>
SHIFT LEVER KNOB
SUB-ASSEMBLY
SHIFT LEVER KNOB
SUB-ASSEMBLY
for Automatic Transmission 4WD:
SHIFT LEVER KNOB
SUB-ASSEMBLY
PARKING BRAKE HOLE
COVER SUB-ASSEMBLY
CONSOLE UPPER
REAR PANEL
SUB-ASSEMBLY
FRONT CONSOLE BOX
B133844E01
AC24
AIR CONDITIONING AIR CONDITIONING UNIT
AC
RADIO RECEIVER ASSEMBLY
INSTRUMENT LOWER
COVER SUB-ASSEMBLY
N*m (kgf*cm, ft*lbf) : Specified torque
CLIP
CLIP
2.5 (25, 22 in.*lbf)
INSTRUMENT PANEL
GARNISH LH
INSTRUMENT PANEL
GARNISH RH
INTEGRATION CONTROL AND
PANEL ASSEMBLY
<F>
<H>
<H>
<F>
CONSOLE UPPER PANEL
NO. 1 GARNISH
<H>
B133845E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC25
AC
COMBINATION METER
ASSEMBLY
GLOVE COMPARTMENT
DOOR ASSEMBLY
INSTRUMENT CLUSTER
FINISH PANEL
LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH
LOWER INSTRUMENT PANEL LH
NO. 1 INSTRUMENT
PANEL REGISTER
ASSEMBLY
NO. 2 INSTRUMENT
PANEL REGISTER
ASSEMBLY
INSTRUMENT PANEL
LOWER FINISH PANEL
SUB-ASSEMBLY RH
<A>
<F>
<F>
<F>
<F>
<F>
<F>
7.0 (71, 62 in.*lbf)
HOOD LOCK CONTROL LEVER SUB-ASSEMBLY
N*m (kgf*cm, ft.*lbf) : Specified torque
CLIP
B133846E01
AC26
AIR CONDITIONING AIR CONDITIONING UNIT
AC
FRONT NO. 2 SPEAKER ASSEMBLY
NO. 1 INSTRUMENT
PANEL SPEAKER PANEL
SUB-ASSEMBLY
NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY
FRONT NO. 2 SPEAKER ASSEMBLY
N*m (kgf*cm, ft*lbf) : Specified torque
20 (204, 15)
2.5 (25, 22 in.*lbf)
2.5 (25, 22 in.*lbf)
<C>
<E>
<F>
<F>
<F>
<F>
<F>
<F>
<E>
<G> <C>
<F>
INSTRUMENT PANEL SUB-ASSEMBLY
INSTRUMENT PANEL FINISH
PANEL END LH
B133847E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC27
AC
LOWER NO. 3 STEERING
WHEEL COVER
STEERING PAD
LOWER NO. 2 STEERING
WHEEL COVER
COMBINATION SWITCH ASSEMBLY
UPPER STEERING COLUMN COVER
STEERING COLUMN
ASSEMBLY
36 (367, 27)
STEERING COLUMN
HOLE COVER
LOWER STEERING
COLUMN COVER
N*m (kgf*cm, ft.*lbf) : Specified torque
STEERING SHAFT
THRUST STOPPER
x4
50 (510, 37)
8.8 (90, 78 in.*lbf)
26 (265, 19)
x3
x3
x4
CLIP
STEERING WHEEL
ASSEMBLY
STEERING INTERMEDIATE
SHAFT ASSEMBLY
I102501E01
AC28
AIR CONDITIONING AIR CONDITIONING UNIT
AC
NO. 1 HEATER TO
REGISTER DUCT
NO. 2 HEATER TO
REGISTER DUCT
NO. 1 AIR DUCT
NO. 2 AIR DUCT
REAR NO. 1 AIR DUCT
REAR NO. 2 AIR DUCT
I102421E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC29
AC
NO. 1 INSTRUMENT PANEL
BRACE MOUNTING BRACKET
NO. 1 INSTRUMENT
PANEL BRACE
MOUNTING BRACKET
ECM
MAIN BODY
ECU (DRIVER
SIDE J/B) 8.4 (86, 74 in.*lbf)
INSTRUMENT PANEL
SIDE BRACKET
AIR CONDITIONING UNIT
9.8 (100, 87 in.*lbf)
5.4 (55, 48 in.*lbf)
5.4 (55, 48 in.*lbf)
9.8 (100, 87 in.*lbf)
9.8 (100, 87 in.*lbf)
8.0 (82, 71 in.*lbf)
9.8 (100, 87 in.*lbf)
N*m (kgf*cm, ft*lbf) : Specified torque
I102422E01
AC30
AIR CONDITIONING AIR CONDITIONING UNIT
AC
HEATER TO REGISTER DUCT ASSEMBLY
LOWER DEFROSTER NOZZLE ASSEMBLY
AIR CONDITIONING UNIT ASSEMBLY
BLOWER UNIT
ASSEMBLY
I102423E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC31
AC
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part Compressor Oil ND-8 or equivalent
3.5 (36, 31 in.*lbf)
AIR CONDITIONING TUBE ASSEMBLY
COOLER EXPANSION VALVE
O-RING
O-RING
NO. 1 COOLER
EVAPORATOR
SUB-ASSEMBLY
PLATE
NO. 1 COOLER
THERMISTOR
COOLER UNIT
DRAIN HOSE
HEATER CASE
CLAMP
HEATER RADIATOR
UNIT SUB-ASSEMBLY
COVER PLATE
AIR MIX CONTROL
SERVO MOTOR
MODE CONTROL SERVO MOTOR
I102424E01
AC32
AIR CONDITIONING AIR CONDITIONING UNIT
AC
REMOVAL
CAUTION:
Some of these service operations affect the SRS airbag
system. Read the precautionary notices concerning the
SRS airbag system before servicing (See page RS-1).
HINT:
Use the same procedure for both the RH and LH sides.
1. BOLTS, SCREWS AND NUTS TABLE (See page IP-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
Wait for at least 90 seconds after disconnecting the
cable to prevent the airbag from working.
3. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-16)
4. DRAIN ENGINE COOLANT (See page CO-3)
5. REMOVE ROOF ANTENNA POLE SUB-ASSEMBLY
(See page AV-116)
6. REMOVE WINDSHIELD WIPER ARM COVER (See
page WW-25)
7. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-26)
8. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE) (See page WW-26)
9. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-26)
10. REMOVE FRONT FENDER SIDE PANEL UPPER LH
(See page WW-26)
11. REMOVE ANTENNA ORNAMENT (See page WW-26)
12. REMOVE FRONT FENDER SIDE PANEL UPPER RH
(See page WW-26)
13. REMOVE COWL TOP VENTILATOR LOUVER
ASSEMBLY (See page WW-27)
14. REMOVE COWL TOP VENTILATOR LOUVER RH (See
page WW-27)
15. REMOVE COWL TOP VENTILATOR LOUVER LH (See
page WW-27)
16. DISCONNECT COOLER REFRIGERANT SUCTION
PIPE A
(a) Install SST onto the piping clamp.
SST 09870-00015
HINT:
Check the directions of the piping clamp and SST
by referring to the illustration on the caution label.
(b) Push down SST and release the clamp lock.
NOTICE:
Do not deform the tube when pushing SST.
Push
Pull
SST
Release Lever
I003839E04
AIR CONDITIONING AIR CONDITIONING UNIT
AC33
AC
(c) Pull SST slightly, push the release lever, and then
remove the piping clamp with SST.
(d) Disconnect the suction pipe.
NOTICE:
Do not use any tools when disconnecting the
pipe.
Seal the openings of the disconnected parts
using vinyl tape to prevent moisture and
foreign matter from entering.
17. DISCONNECT COOLER REFRIGERANT LIQUID PIPE
A
SST 09870-00025
HINT:
Disconnection procedure of the liquid pipe is the same
as for the suction pipe.
18. DISCONNECT HEATER INLET WATER HOSE
(a) Using pliers, grip the claw of the clip, slide the clip
and disconnect the heater water inlet hose from the
heater unit.
19. DISCONNECT HEATER WATER OUTLET HOSE A
(FROM HEATER UNIT)
(a) Using pliers, grip the claw of the clip, slide the clip
and disconnect the heater water outlet hose from
the heater unit.
20. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
21. REMOVE LOWER NO. 3 STEERING WHEEL COVER
(See page RS-345)
22. REMOVE LOWER NO. 2 STEERING WHEEL COVER
(See page RS-345)
23. REMOVE STEERING PAD (See page RS-346)
24. REMOVE STEERING WHEEL ASSEMBLY (See page
SR-8)
25. REMOVE LOWER STEERING COLUMN COVER (See
page SR-8)
26. REMOVE UPPER STEERING COLUMN COVER (See
page SR-8)
27. REMOVE COMBINATION SWITCH ASSEMBLY (See
page SR-9)
28. REMOVE FRONT DOOR SCUFF PLATE RH (See page
IR-15)
I102426
I102428
AC34
AIR CONDITIONING AIR CONDITIONING UNIT
AC
29. REMOVE FRONT DOOR SCUFF PLATE LH (See page
IR-15)
30. REMOVE FRONT FLOOR FOOTREST (See page IR-2)
31. REMOVE FOOTREST CLIP (See page IR-2)
32. REMOVE COWL SIDE TRIM BOARD RH (See page
IR-15)
33. REMOVE COWL SIDE TRIM BOARD LH (See page IR-
15)
34. REMOVE FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-10)
35. REMOVE FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-10)
36. REMOVE ASSIST GRIP PLUG (See page IR-17)
37. REMOVE ASSIST GRIP ASSEMBLY (See page IR-17)
38. REMOVE FRONT PILLAR GARNISH RH (See page IR-
18)
39. REMOVE FRONT PILLAR GARNISH LH (See page IR-
18)
40. REMOVE INSTRUMENT PANEL GARNISH LH (See
page IP-10)
41. REMOVE INSTRUMENT PANEL GARNISH RH (See
page IP-10)
42. REMOVE INTEGRATION CONTROL AND PANEL
ASSEMBLY (See page IP-11)
43. REMOVE RADIO RECEIVER ASSEMBLY (See page
AV-55)
44. REMOVE PARKING BRAKE HOLE COVER SUB-
ASSEMBLY (See page IP-11)
45. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission) (See page IP-11)
46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
4WD) (See page IP-11)
47. REMOVE CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (See page IP-12)
48. REMOVE BOX BOTTOM MAT (See page IP-12)
49. REMOVE FRONT CONSOLE BOX (See page IP-12)
50. REMOVE CONSOLE UPPER PANEL NO. 1 GARNISH
(See page IP-10)
51. REMOVE INSTRUMENT LOWER COVER SUB-
ASSEMBLY (See page IP-13)
52. REMOVE NO. 1 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-13)
AIR CONDITIONING AIR CONDITIONING UNIT
AC35
AC
53. SEPARATE HOOD LOCK CONTROL LEVER SUB-
ASSEMBLY (See page IP-13)
54. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH (See page IP-14)
55. REMOVE LOWER INSTRUMENT PANEL LH (See
page IP-14)
56. REMOVE INSTRUMENT CLUSTER FINISH PANEL
(See page IP-14)
57. REMOVE COMBINATION METER ASSEMBLY (See
page IP-14)
58. REMOVE GLOVE COMPARTMENT DOOR
ASSEMBLY (See page IP-15)
59. REMOVE INSTRUMENT PANEL LOWER FINISH
PANEL SUB-ASSEMBLY RH (See page IP-15)
60. REMOVE NO. 2 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-16)
61. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-16)
62. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-16)
63. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (See
page AV-62)
64. REMOVE ASSIST GRIP RETAINER RH (See page IP-
16)
65. REMOVE ASSIST GRIP RETAINER LH (See page IP-
16)
66. DISCONNECT PASSENGER AIRBAG CONNECTOR
(See page IP-16)
67. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(See page IP-16)
68. REMOVE INSTRUMENT PANEL FINISH PANEL END
LH (See page IP-21)
69. REMOVE NO. 1 HEATER TO REGISTER DUCT
(a) Remove the screw and remove the heater to
register duct.
I102430
AC36
AIR CONDITIONING AIR CONDITIONING UNIT
AC
70. REMOVE NO. 2 HEATER TO REGISTER DUCT
(a) Remove the screw and remove the heater to
register duct.
71. REMOVE REAR NO. 1 AIR DUCT
(a) Disengage the 6 claws and 3 clamps and remove
the rear air duct.
72. REMOVE REAR NO. 2 AIR DUCT
(a) Disengage the 6 claws and 3 clamps and remove
the rear air duct.
73. REMOVE NO. 1 AIR DUCT
(a) Disengage the 3 claws and remove the air duct.
74. REMOVE NO. 2 AIR DUCT
(a) Disengage the 3 claws and remove the air duct.
I102431
I102433
I102432
I102434
I102435
AIR CONDITIONING AIR CONDITIONING UNIT
AC37
AC
75. REMOVE NO. 1 INSTRUMENT PANEL BRACE
MOUNTING BRACKET
(a) for LH side:
(1) Remove the bolt and nut and remove the
instrument panel brace mounting bracket.
(b) for RH side:
(1) Remove the bolt and nut and remove the
instrument panel brace mounting bracket.
76. REMOVE ECM (See page ES-446)
77. REMOVE STEERING COLUMN HOLE COVER (See
page SR-9)
78. SEPARATE STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Remove the bolt and separate the steering shaft
thrust stopper from the steering intermediate shaft
assembly.
(b) Mark matchmarks on the steering column assembly
and steering intermediate shaft.
(c) Pull the intermediate shaft assembly and steering
shaft thrust stopper out of the steering column
assembly.
79. REMOVE STEERING COLUMN ASSEMBLY (See page
SR-10)
80. REMOVE INSTRUMENT PANEL SIDE BRACKET
(a) Remove the bolt and remove the instrument panel
side bracket.
I102436
I102437
Matchmark
I102502E01
I102438
AC38
AIR CONDITIONING AIR CONDITIONING UNIT
AC
81. SEPARATE MAIN BODY ECU (DRIVER SIDE J/B)
(a) Remove the 2 nuts and remove the driver side
junction block.
82. REMOVE COOLER UNIT DRAIN HOSE
(a) Disconnect the cooler unit drain hose.
83. REMOVE INSTRUMENT PANEL REINFORCEMENT
(a) Remove the 3 bolts and 5 nuts and disconnect the
wire harness.
I102439
I102468
I102440
AIR CONDITIONING AIR CONDITIONING UNIT
AC39
AC
(b) Disconnect the connectors.
(c) Disengage the clamps.
(d) Remove the 5 bolts and the 2 nuts.
I102441
I102442
AC40
AIR CONDITIONING AIR CONDITIONING UNIT
AC
(e) Remove the 2 caps and the 7 bolts.
(f) Disengage the reinforcement hook of the air
conditioning unit, and remove the reinforcement.
(g) Remove the air conditioning unit.
84. REMOVE AIR CONDITIONING UNIT ASSEMBLY
(a) Remove the 2 screws.
(b) Remove the air conditioning unit as shown in the
illustration.
I102443
I102445
AIR CONDITIONING AIR CONDITIONING UNIT
AC41
AC
85. REMOVE HEATER TO REGISTER DUCT ASSEMBLY
(a) Disengage the 4 claws and remove the heater to
register duct.
86. REMOVE LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Disengage the 4 claws and remove the lower
defroster nozzle.
DISASSEMBLY
1. REMOVE MODE CONTROL SERVO MOTOR
(a) Remove the 3 screws and remove the mode control
servo motor.
2. REMOVE AIR MIX CONTROL SERVO MOTOR
(a) Remove the 3 screws and remove the air mix
control servo motor.
I102449
I102450
I102451
I102452
AC42
AIR CONDITIONING AIR CONDITIONING UNIT
AC
3. REMOVE COOLER UNIT DRAIN HOSE
(a) Remove the cooler unit drain hose.
4. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Remove the screw and clamp.
(b) Remove the heater radiator unit from the heater
case.
5. REMOVE COVER PLATE
(a) Remove the screw.
(b) Disengage the claw and remove the cover plate.
6. REMOVE AIR CONDITIONING TUBE ASSEMBLY
(a) Using a hexagon wrench 4, remove the 2 hexagon
bolts and remove the air conditioning tube.
(b) Remove the 2 O-rings from the air conditioning
tube.
7. REMOVE COOLER EXPANSION VALVE
(a) Remove the cooler expansion valve from the cooler
evaporator.
I102455
I102453
I102456
I102457
I102458
AIR CONDITIONING AIR CONDITIONING UNIT
AC43
AC
8. REMOVE NO. 1 COOLER EVAPORATOR SUB-
ASSEMBLY
(a) Remove the 2 screws and remove the plate.
(b) Remove the 8 screws and separate the heater case.
(c) Remove the cooler evaporator.
Remove the 2 O-rings from the cooler evaporator.
9. REMOVE NO. 1 COOLER THERMISTOR
(a) Remove the cooler thermistor from the cooler
evaporator.
I102459
I102460
I102461
I102462
AC44
AIR CONDITIONING AIR CONDITIONING UNIT
AC
INSPECTION
1. INSPECT NO. 1 COOLER THERMISTOR
(a) Measure the resistance.
Standard resistance
NOTICE:
Touching the sensor even slightly may
change the resistance value. Hold the
connector of the sensor.
When measuring the resistance, the
temperature of the sensor and the cooler
thermistor must be the same.
HINT:
As the temperature increases, the resistance
decreases (see the graph).
If the operation is not as specified, replace the
cooler thermistor.
2. INSPECT MODE CONTROL SERVO MOTOR
(a) Inspect the servo motor operation.
(1) Connect the positive (+) lead from the battery
to terminal 4 (DEF) and negative (-) lead to
terminal 5 (FACE), then check that the lever
turns to the DEF position smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the mode control servo motor.
(2) Connect the positive (+) lead from the battery
to terminal 5 (FACE) and negative (-) lead to
terminal 4 (DEF), then check that the lever
turns to the FACE position smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the mode control servo motor.
(b) Check the servo motor resistance.
(1) Using an ohmmeter, measure the resistance
and check the results in accordance with the
values in the table below.
Standard resistance
Sensor
Resistance (k)
10.0
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
-10 0 10 20 30
14 32 50 68 86
Temperature (C)
(F)
I102503E01
Tester Connection Condition Specified Condition
1 - 2 -10C (14F) 7.30 to 9.10 k
1 - 2 -5C (23F) 5.65 to 6.95 k
1 - 2 0C (32F) 4.40 to 5.35 k
1 - 2 5C (41F) 3.40 to 4.15 k
1 - 2 10C (50F) 2.70 to 3.25 k
1 - 2 15C (59F) 2.14 to 2.58 k
1 - 2 20C (68F) 1.71 to 2.05 k
1 - 2 25C (77F) 1.38 to 1.64 k
1 - 2 30C (86F) 1.11 to 1.32 k
FACE
DEF
FACE
DEF TPM S5
SG
I102497E01
Tester Connection Servo Motor Position Specified Condition
1 (SG) - 2 (S5) Always 4.2 to 7.8 k
AIR CONDITIONING AIR CONDITIONING UNIT
AC45
AC
If the result is not as specified, replace the
mode control servo motor.
3. REMOVE AIR MIX CONTROL SERVO MOTOR
(a) Inspect the servo motor operation.
(1) Connect the positive (+) lead from the battery
to terminal 4 (MH) and negative (-) lead to
terminal 5 (MC), then check that the lever turns
to the MAX HOT position smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the air mix control servo motor.
(2) Connect the positive (+) lead from the battery
to terminal 5 (MC) and negative (-) lead to
terminal 4 (MH), then check that the lever turns
to the MAX COOL position smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the air mix control servo motor.
(b) Check the servo motor resistance.
(1) Using an ohmmeter, measure the resistance
and check the results in accordance with the
values in the table below.
Standard resistance
If the result is not as specified, replace the air
mix control servo motor.
1 (SG) - 3 (TPM) DEF Position 3.4 to 6.2 k
1 (SG) - 3 (TPM) FACE Position 0.8 to 1.6 k
Tester Connection Servo Motor Position Specified Condition
MAX COOL
MAX HOT
MC
MH
TP
S5
SG
I102498E01
Tester Connection Servo Motor Position Specified Condition
1 (SG) - 2 (S5) Always 4.2 to 7.8 k
1 (SG) - 3 (TP) MAX HOT Position 3.4 to 6.2 k
1 (SG) - 3 (TP) MAX COOL Position 0.8 to 1.6 k
AC46
AIR CONDITIONING AIR CONDITIONING UNIT
AC
REASSEMBLY
1. INSTALL NO. 1 COOLER THERMISTOR
(a) Install the sensor onto the evaporator as shown in
the illustration.
(b) Check that the sensor sticks to the evaporator
surface as shown in the illustration (A: Sensor, B:
Evaporator).
NOTICE:
If reusing the evaporator, do not reinsert the
sensor in the same position that it was in before.
Insert it within area C shown in the illustration.
2. INSTALL NO. 1 COOLER EVAPORATOR SUB-
ASSEMBLY
(a) Apply sufficient compressor oil (ND-OIL8) to 2 new
O-rings and the fitting surface of the cooler
evaporator.
Compressor oil:
ND-OIL8 or the equivalent
(b) Install the 2 O-rings onto the cooler evaporator.
(c) Install the cooler evaporator.
HINT:
If a new cooler evaporator is installed, add
compressor oil to the cooler evaporator as follows.
Compressor oil:
ND-OIL8 or the equivalent. Add 40 cc (1.35 fl.
oz.)
(d) Install the cooler evaporator onto the heater case.
(e) Install the heater case with the 8 screws.
255.4 (10.06)
100.5 (3.96)
74.5
(2.93)
50 (1.97)
(A)
(B)
(C)
[mm (in.)]
I102463E01
I102461
I102460
AIR CONDITIONING AIR CONDITIONING UNIT
AC47
AC
(f) Install the plate with the 2 screws.
3. INSTALL COOLER EXPANSION VALVE
(a) Apply sufficient compressor oil (ND-OIL8) to the
fitting surface of the cooler expansion valve.
Compressor oil:
ND-OIL8 or the equivalent
(b) Install the cooler expansion valve onto the cooler
evaporator.
4. INSTALL AIR CONDITIONING TUBE ASSEMBLY
(a) Apply sufficient compressor oil (ND-OIL8) to 2 new
O-rings and the fitting surface of the air conditioning
tube.
Compressor oil:
ND-OIL8 or the equivalent
(b) Install the 2 O-rings onto the air conditioning tube.
(c) Using a hexagon wrench 4, install the air
conditioning tube with the 2 hexagon bolts.
Torque: 3.5 N*m (36 kgf*cm, 31 in.*lbf)
5. INSTALL COVER PLATE
(a) Engage the claw.
(b) Install the cover plate with the screw.
6. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY
(a) Install the heater radiator unit onto the heater case.
(b) Install the clamp with the screw.
I102459
I102458
I102457
I102456
I102454
AC48
AIR CONDITIONING AIR CONDITIONING UNIT
AC
7. INSTALL COOLER UNIT DRAIN HOSE
(a) Install the cooler unit drain hose.
8. INSTALL AIR MIX CONTROL SERVO MOTOR
(a) Install the air mix control servo motor with the 3
screws.
9. INSTALL MODE CONTROL SERVO MOTOR
(a) Install the mode control servo motor with the 3
screws.
INSTALLATION
1. INSTALL LOWER DEFROSTER NOZZLE ASSEMBLY
(a) Engage the 4 claws and install the lower defroster
nozzle.
I102455
I102452
I102451
I102450
AIR CONDITIONING AIR CONDITIONING UNIT
AC49
AC
2. INSTALL HEATER TO REGISTER DUCT ASSEMBLY
(a) Engage the 4 claws and install the heater to register
duct.
3. INSTALL AIR CONDITIONING UNIT ASSEMBLY
(a) Install the air conditioning unit with the 2 screws as
shown in the illustration.
4. INSTALL INSTRUMENT PANEL REINFORCEMENT
(a) Provisionally install the air conditioning unit
assembly.
(b) Insert the bracket hook into the holes of the
reinforcement bracket, and provisionally install the
reinforcement.
(c) Install the instrument panel reinforcement with the 7
bolts.
(d) Install the 2 caps.
I102449
I102446
I102444
AC50
AIR CONDITIONING AIR CONDITIONING UNIT
AC
(e) Install the 5 bolts.
NOTICE:
Tighten the bolts in the sequence order shown
in the illustration to install the air conditioner
unit assembly.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) for bolt
(f) Install the 2 nuts.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) for nut
(g) Engage the clamps.
(h) Connect the connectors.
3
2
4
5
1
I102442E01
I102441
AIR CONDITIONING AIR CONDITIONING UNIT
AC51
AC
(i) Connect the wire harness with the 3 bolts and 5
nuts.
Torque: 7.3 N*m (74 kgf*cm, 65 in.*lbf) for nut
5. INSTALL COOLER UNIT DRAIN HOSE
(a) Install the cooler unit drain hose.
I102440
I102468
AC52
AIR CONDITIONING AIR CONDITIONING UNIT
AC
6. INSTALL MAIN BODY ECU (DRIVER SIDE J/B)
(a) Install the main body ECU with the 2 nuts.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
7. INSTALL INSTRUMENT PANEL SIDE BRACKET
(a) Install the instrument panel side bracket with the
bolt.
Torque: 8.4 N*m (86 kgf*cm, 74 in.*lbf)
8. INSTALL STEERING COLUMN ASSEMBLY (See page
SR-16)
9. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY
(a) Align the matchmarks on the steering column
assembly and the steering intermediate shaft
assembly.
(b) Install the steering intermediate shaft assembly and
thrust stopper onto the steering column assembly
with the bolt.
Torque: 36 N*m (367 kgf*cm, 27 ft.*lbf)
10. INSTALL STEERING COLUMN HOLE COVER (See
page SR-17)
11. INSTALL ECM (See page ES-447)
12. INSTALL NO. 1 INSTRUMENT PANEL BRACE
BRACKET
(a) for LH side:
(1) Install the instrument panel brace mounting
bracket with the bolt and nut.
I102439
I102438
Matchmark
I102502E01
I102436
AIR CONDITIONING AIR CONDITIONING UNIT
AC53
AC
(b) for RH side:
(1) Install the instrument panel brace mounting
bracket with the bolt and nut.
13. INSTALL NO. 1 AIR DUCT
(a) Engage the 3 claws and install the air duct.
14. INSTALL NO. 2 AIR DUCT
(a) Engage the 3 claws and install the air duct.
15. INSTALL REAR NO. 1 AIR DUCT
(a) Engage the 6 claws and 3 clamps and install the air
duct.
16. INSTALL REAR NO. 2 AIR DUCT
(a) Engage the 6 claws and 3 clamps and install the air
duct.
I102437
I102434
I102435
I102433
I102432
AC54
AIR CONDITIONING AIR CONDITIONING UNIT
AC
17. INSTALL NO. 1 HEATER TO REGISTER DUCT
(a) Install the heater to register duct with the screw.
18. INSTALL NO. 2 HEATER TO REGISTER DUCT
(a) Install the heater to register duct with the screw.
19. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(See page IP-26)
20. CONNECT PASSENGER AIRBAG CONNECTOR (See
page IP-26)
21. INSTALL INSTRUMENT PANEL FINISH PANEL END
LH (See page IP-27)
22. INSTALL ASSIST GRIP RETAINER RH (See page IP-
27)
23. INSTALL ASSIST GRIP RETAINER LH (See page IP-
27)
24. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (See
page AV-62)
25. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
26. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
27. INSTALL NO. 2 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-27)
28. INSTALL INSTRUMENT PANEL LOWER FINISH
PANEL SUB-ASSEMBLY RH (See page IP-28)
29. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
(See page IP-28)
30. INSTALL COMBINATION METER ASSEMBLY (See
page IP-28)
31. INSTALL INSTRUMENT CLUSTER FINISH PANEL
(See page IP-29)
32. INSTALL LOWER INSTRUMENT PANEL LH (See page
IP-29)
33. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH (See page IP-29)
34. CONNECT HOOD LOCK CONTROL LEVER SUB-
ASSEMBLY (See page IP-30)
35. INSTALL NO. 1 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-30)
I102430
I102431
AIR CONDITIONING AIR CONDITIONING UNIT
AC55
AC
36. INSTALL INSTRUMENT LOWER COVER SUB-
ASSEMBLY (See page IP-30)
37. INSTALL CONSOLE UPPER PANEL NO. 1 GARNISH
(See page IP-31)
38. INSTALL FRONT CONSOLE BOX (See page IP-31)
39. INSTALL BOX BOTTOM MAT (See page IP-31)
40. INSTALL CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (See page IP-31)
41. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission) (See page IP-32)
42. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
4WD) (See page IP-32)
43. INSTALL PARKING BRAKE HOLE COVER SUB-
ASSEMBLY (See page IP-32)
44. INSTALL RADIO RECEIVER ASSEMBLY (See page
AV-56)
45. INSTALL INTEGRATION CONTROL AND PANEL
ASSEMBLY (See page IP-32)
46. INSTALL INSTRUMENT PANEL GARNISH LH (See
page IP-33)
47. INSTALL INSTRUMENT PANEL GARNISH RH (See
page IP-33)
48. INSTALL FRONT PILLAR GARNISH RH (See page IR-
43)
49. INSTALL FRONT PILLAR GARNISH LH (See page IR-
43)
50. INSTALL ASSIST GRIP ASSEMBLY (See page IR-43)
51. INSTALL ASSIST GRIP PLUG (See page IR-44)
52. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP LH (See page IP-33)
53. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-33)
54. INSTALL COWL SIDE TRIM BOARD RH (See page IR-
45)
55. INSTALL COWL SIDE TRIM BOARD LH (See page IR-
45)
56. INSTALL FOOTREST CLIP (See page IR-2)
57. INSTALL FRONT FLOOR FOOTREST (See page IR-2)
58. INSTALL FRONT DOOR SCUFF PLATE RH (See page
IR-45)
59. INSTALL FRONT DOOR SCUFF PLATE LH (See page
IR-45)
AC56
AIR CONDITIONING AIR CONDITIONING UNIT
AC
60. INSTALL COMBINATION SWITCH ASSEMBLY (See
page SR-17)
61. INSTALL UPPER STEERING COLUMN COVER (See
page SR-17)
62. INSTALL LOWER STEERING COLUMN COVER (See
page SR-18)
63. INSTALL STEERING WHEEL ASSEMBLY (See page
SR-18)
64. INSTALL STEERING PAD (See page RS-346)
65. INSTALL LOWER NO. 2 STEERING WHEEL COVER
(See page RS-347)
66. INSTALL LOWER NO. 3 STEERING WHEEL COVER
(See page RS-347)
67. CONNECT HEATER WATER OUTLET HOSE A (FROM
HEATER UNIT)
(a) Install the heater water outlet hose onto the heater
unit.
NOTICE:
Perform the installation with the hose clip and
mark at the correct angle as shown in the
illustration.
68. CONNECT HEATER INLET WATER HOSE
(a) Install the heater water inlet hose onto the heater
unit.
NOTICE:
Perform the installation with the hose clip and
mark at the correct angle as shown in the
illustration.
A
UP
LH
View A
ORANGE
PAINT MARK
I102429E01
A
UP
LH
View A
YELLOW
PAINT MARK
I102427E01
AIR CONDITIONING AIR CONDITIONING UNIT
AC57
AC
69. INSTALL COOLER REFRIGERANT LIQUID PIPE A
(a) Remove the vinyl tape from liquid tube A and the
connecting portion of the unit.
(b) Apply sufficient compressor oil (ND-OIL8) to a new
O-ring and the connecting part of the liquid pipe.
Compressor oil:
ND-OIL8 or the equivalent
(c) Install the O-ring onto the liquid pipe.
(d) Install the liquid and piping clamp.
HINT:
After connection, check the claw fitting of the piping
clamp.
70. INSTALL COOLER REFRIGERANT SUCTION PIPE A
HINT:
Connection procedure of the suction pipe is the same as
for the liquid pipe.
71. INSTALL COWL TOP VENTILATOR LOUVER LH (See
page WW-30)
72. INSTALL COWL TOP VENTILATOR LOUVER RH (See
page WW-30)
73. INSTALL COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-31)
74. INSTALL FRONT FENDER SIDE PANEL UPPER LH
(See page WW-31)
75. INSTALL FRONT FENDER SIDE PANEL UPPER RH
(See page WW-31)
76. INSTALL ANTENNA ORNAMENT (See page WW-31)
77. INSTALL ROOF ANTENNA POLE SUB-ASSEMBLY
(See page AV-116)
78. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-32)
79. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE) (See page WW-32)
80. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-33)
81. INSTALL WINDSHIELD WIPER ARM COVER (See
page WW-34)
82. ADD ENGINE COOLANT (See page CO-3)
83. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
84. CHECK SRS WARNING LIGHT
RS-29
85. CHARGE REFRIGERANT (See page AC-16)
86. WARM UP ENGINE (See page AC-18)
Correct Wrong
Gap
I006878E06
AC58
AIR CONDITIONING AIR CONDITIONING UNIT
AC
87. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-4)
88. CHECK FOR REFRIGERANT LEAKAGE (See page
AC-18)
89. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
AIR CONDITIONING BLOWER UNIT
AC69
AC
REMOVAL
CAUTION:
Some of these service operations affect the SRS airbag
system. Read the precautionary notices concerning the
SRS airbag system before servicing (See page RS-1).
HINT:
Use the same procedure for both the RH and LH sides.
1. BOLTS, SCREWS AND NUTS TABLE (See page IP-9)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
Wait for at least 90 seconds after disconnecting the
cable to prevent the airbag from working.
3. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-16)
4. DRAIN ENGINE COOLANT (See page CO-3)
5. REMOVE ROOF ANTENNA POLE SUB-ASSEMBLY
(See page AV-116)
6. REMOVE WINDSHIELD WIPER ARM COVER (See
page WW-25)
7. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-26)
8. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE) (See page WW-26)
9. REMOVE FRONT WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-26)
10. REMOVE FRONT FENDER SIDE PANEL UPPER LH
(See page WW-26)
11. REMOVE ANTENNA ORNAMENT (See page WW-26)
12. REMOVE FRONT FENDER SIDE PANEL UPPER RH
(See page WW-26)
13. REMOVE COWL TOP VENTILATOR LOUVER
ASSEMBLY (See page WW-27)
14. REMOVE COWL TOP VENTILATOR LOUVER RH (See
page WW-27)
15. REMOVE COWL TOP VENTILATOR LOUVER LH (See
page WW-27)
16. DISCONNECT COOLER REFRIGERANT SUCTION
PIPE A (See page AC-32)
17. DISCONNECT COOLER REFRIGERANT LIQUID PIPE
A (See page AC-33)
18. DISCONNECT HEATER INLET WATER HOSE (See
page AC-33)
19. DISCONNECT HEATER WATER OUTLET HOSE A
(FROM HEATER UNIT) (See page AC-33)
AC70
AIR CONDITIONING BLOWER UNIT
AC
20. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
21. REMOVE LOWER NO. 3 STEERING WHEEL COVER
(See page RS-345)
22. REMOVE LOWER NO. 2 STEERING WHEEL COVER
(See page RS-345)
23. REMOVE STEERING PAD (See page RS-346)
24. REMOVE STEERING WHEEL ASSEMBLY (See page
SR-8)
25. REMOVE LOWER STEERING COLUMN COVER (See
page SR-8)
26. REMOVE UPPER STEERING COLUMN COVER (See
page SR-8)
27. REMOVE COMBINATION SWITCH ASSEMBLY (See
page SR-9)
28. REMOVE FRONT DOOR SCUFF PLATE RH (See page
IR-15)
29. REMOVE FRONT DOOR SCUFF PLATE LH (See page
IR-15)
30. REMOVE FRONT FLOOR FOOTREST (See page IR-2)
31. REMOVE FOOTREST CLIP (See page IR-2)
32. REMOVE COWL SIDE TRIM BOARD RH (See page
IR-15)
33. REMOVE COWL SIDE TRIM BOARD LH (See page IR-
15)
34. REMOVE FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-10)
35. REMOVE FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-10)
36. REMOVE ASSIST GRIP PLUG (See page IR-17)
37. REMOVE ASSIST GRIP ASSEMBLY (See page IR-17)
38. REMOVE FRONT PILLAR GARNISH RH (See page IR-
18)
39. REMOVE FRONT PILLAR GARNISH LH (See page IR-
18)
40. REMOVE INSTRUMENT PANEL GARNISH LH (See
page IP-10)
41. REMOVE INSTRUMENT PANEL GARNISH RH (See
page IP-10)
42. REMOVE INTEGRATION CONTROL AND PANEL
ASSEMBLY (See page IP-11)
43. REMOVE RADIO RECEIVER ASSEMBLY (See page
AV-55)
AIR CONDITIONING BLOWER UNIT
AC71
AC
44. REMOVE PARKING BRAKE HOLE COVER SUB-
ASSEMBLY (See page IP-11)
45. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission) (See page IP-11)
46. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY (for
4WD) (See page IP-11)
47. REMOVE CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (See page IP-12)
48. REMOVE BOX BOTTOM MAT (See page IP-12)
49. REMOVE FRONT CONSOLE BOX (See page IP-12)
50. REMOVE CONSOLE UPPER PANEL NO. 1 GARNISH
(See page IP-12)
51. REMOVE INSTRUMENT LOWER COVER SUB-
ASSEMBLY (See page IP-13)
52. REMOVE NO. 1 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-13)
53. SEPARATE HOOD LOCK CONTROL LEVER SUB-
ASSEMBLY (See page IP-13)
54. REMOVE LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH (See page IP-14)
55. REMOVE LOWER INSTRUMENT PANEL LH (See
page IP-14)
56. REMOVE INSTRUMENT CLUSTER FINISH PANEL
(See page IP-14)
57. REMOVE COMBINATION METER ASSEMBLY (See
page IP-14)
58. REMOVE GLOVE COMPARTMENT DOOR
ASSEMBLY (See page IP-15)
59. REMOVE INSTRUMENT PANEL LOWER FINISH
PANEL SUB-ASSEMBLY RH (See page IP-15)
60. REMOVE NO. 2 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-16)
61. REMOVE NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-16)
62. REMOVE NO. 1 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-16)
63. REMOVE FRONT NO. 2 SPEAKER ASSEMBLY (See
page AV-62)
64. REMOVE ASSIST GRIP RETAINER RH (See page IP-
16)
65. REMOVE ASSIST GRIP RETAINER LH (See page IP-
16)
66. DISCONNECT PASSENGER AIRBAG CONNECTOR
(See page IP-16)
AC72
AIR CONDITIONING BLOWER UNIT
AC
67. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY
(See page IP-16)
68. REMOVE INSTRUMENT PANEL FINISH PANEL END
LH (See page IP-21)
69. REMOVE NO. 1 HEATER TO REGISTER DUCT (See
page AC-35)
70. REMOVE NO. 2 HEATER TO REGISTER DUCT (See
page AC-36)
71. REMOVE REAR NO. 1 AIR DUCT (See page AC-36)
72. REMOVE REAR NO. 2 AIR DUCT (See page AC-36)
73. REMOVE NO. 1 AIR DUCT (See page AC-36)
74. REMOVE NO. 2 AIR DUCT (See page AC-36)
75. REMOVE NO. 1 INSTRUMENT PANEL BRACE
MOUNTING BRACKET (See page AC-37)
76. REMOVE ECM (See page ES-446)
77. REMOVE STEERING COLUMN HOLE COVER (See
page SR-9)
78. SEPARATE STEERING INTERMEDIATE SHAFT
ASSEMBLY (See page AC-37)
79. REMOVE STEERING COLUMN ASSEMBLY (See page
SR-10)
80. REMOVE INSTRUMENT PANEL SIDE BRACKET (See
page AC-37)
81. SEPARATE MAIN BODY ECU (DRIVER SIDE J/B)
(See page AC-38)
82. REMOVE COOLER UNIT DRAIN HOSE (See page AC-
38)
83. REMOVE INSTRUMENT PANEL REINFORCEMENT
(See page AC-38)
84. REMOVE BLOWER UNIT ASSEMBLY
(a) Remove the 2 screws.
(b) Remove the blower unit as shown in the illustration.
I102447
AIR CONDITIONING BLOWER UNIT
AC73
AC
DISASSEMBLY
1. REMOVE AIR INLET CONTROL SERVO MOTOR
(a) Remove the 2 screws and remove the air inlet
control servo motor.
2. REMOVE BLOWER MOTOR
(a) Remove the 3 screws and the blower motor.
3. REMOVE BLOWER RESISTOR
(a) Remove the 2 screws and the blower resistor.
4. REMOVE CLEAN AIR FILTER SUB-ASSEMBLY
(a) Disengage the 2 claws and remove the air filter.
I102467
I102519
I102614
I102464
AC74
AIR CONDITIONING BLOWER UNIT
AC
5. REMOVE AIR REFINER ELEMENT
(a) Remove the air refiner element.
INSPECTION
1. INSPECT AIR INLET CONTROL SERVO MOTOR
(a) Inspect the servo motor operation.
(1) Connect the positive (+) lead from the battery
to terminal 5 (IG+) and negative (-) lead to
terminal 1 (FRS), then check that the lever
turns to the FRESH side smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the air inlet control servo motor.
(2) Connect the positive (+) lead from the battery
to terminal 5 (IG+) and negative (-) lead to
terminal 2 (REC), then check that the lever
turns to the RECIRCULATION side smoothly.
Standard:
The motor operates smoothly.
If the operations are not as specified, replace
the air inlet control servo motor.
REASSEMBLY
1. INSTALL AIR REFINER ELEMENT
(a) Install the air refiner element.
I102466
RECIRCULATION
FRESH
IG+ FRS
REC I102499E01
I102466
AIR CONDITIONING BLOWER UNIT
AC75
AC
2. INSTALL CLEAN AIR FILTER SUB-ASSEMBLY
(a) Engage the 2 claws and install the air filter.
NOTICE:
Install the air filter with its UP mark oriented in
the correct direction.
3. INSTALL BLOWER RESISTOR
(a) Install the blower resistor with the 2 screws.
4. INSTALL BLOWER MOTOR
(a) Install the blower motor with the 3 screws.
5. INSTALL AIR INLET CONTROL SERVO MOTOR
(a) Install the air inlet control servo motor with the 2
screws.
I102465
I102614
I102519
I102467
AC76
AIR CONDITIONING BLOWER UNIT
AC
INSTALLATION
1. INSTALL BLOWER UNIT ASSEMBLY
(a) Install the 2 screws and blower unit as shown in the
illustration.
2. INSTALL INSTRUMENT PANEL REINFORCEMENT
(See page AC-49)
3. INSTALL COOLER UNIT DRAIN HOSE (See page AC-
51)
4. INSTALL MAIN BODY ECU (DRIVER SIDE J/B) (See
page AC-52)
5. INSTALL INSTRUMENT PANEL SIDE BRACKET (See
page AC-52)
6. INSTALL STEERING COLUMN ASSEMBLY (See page
SR-16)
7. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY (See page AC-52)
8. INSTALL STEERING COLUMN HOLE COVER (See
page SR-17)
9. INSTALL ECM (See page ES-447)
10. INSTALL NO. 1 INSTRUMENT PANEL BRACE
BRACKET (See page AC-52)
11. INSTALL NO. 1 AIR DUCT (See page AC-53)
12. INSTALL NO. 2 AIR DUCT (See page AC-53)
13. INSTALL REAR NO. 1 AIR DUCT (See page AC-53)
14. INSTALL REAR NO. 2 AIR DUCT (See page AC-53)
15. INSTALL NO. 1 HEATER TO REGISTER DUCT (See
page AC-54)
16. INSTALL NO. 2 HEATER TO REGISTER DUCT (See
page AC-54)
17. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(See page IP-26)
18. CONNECT PASSENGER AIRBAG CONNECTOR (See
page IP-26)
19. INSTALL INSTRUMENT PANEL FINISH PANEL END
LH (See page IP-27)
20. INSTALL ASSIST GRIP RETAINER RH (See page IP-
27)
21. INSTALL ASSIST GRIP RETAINER LH (See page IP-
27)
22. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (See
page AV-62)
23. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
I102448
AIR CONDITIONING BLOWER UNIT
AC77
AC
24. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
25. INSTALL NO. 2 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-27)
26. INSTALL INSTRUMENT PANEL LOWER FINISH
PANEL SUB-ASSEMBLY RH (See page IP-28)
27. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
(See page IP-28)
28. INSTALL COMBINATION METER ASSEMBLY (See
page IP-28)
29. INSTALL INSTRUMENT CLUSTER FINISH PANEL
(See page IP-29)
30. INSTALL LOWER INSTRUMENT PANEL LH (See page
IP-29)
31. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH (See page IP-29)
32. CONNECT HOOD LOCK CONTROL LEVER SUB-
ASSEMBLY (See page IP-30)
33. INSTALL NO. 1 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-30)
34. INSTALL INSTRUMENT LOWER COVER SUB-
ASSEMBLY (See page IP-30)
35. INSTALL CONSOLE UPPER PANEL NO. 1 GARNISH
(See page IP-31)
36. INSTALL FRONT CONSOLE BOX (See page IP-31)
37. INSTALL BOX BOTTOM MAT (See page IP-31)
38. INSTALL CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (See page IP-31)
39. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission) (See page IP-32)
40. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
4WD) (See page IP-32)
41. INSTALL PARKING BRAKE HOLE COVER SUB-
ASSEMBLY (See page IP-32)
42. INSTALL RADIO RECEIVER ASSEMBLY (See page
AV-56)
43. INSTALL INTEGRATION CONTROL AND PANEL
ASSEMBLY (See page IP-32)
44. INSTALL INSTRUMENT PANEL GARNISH LH (See
page IP-33)
45. INSTALL INSTRUMENT PANEL GARNISH RH (See
page IP-33)
46. INSTALL FRONT PILLAR GARNISH RH (See page IR-
43)
AC78
AIR CONDITIONING BLOWER UNIT
AC
47. INSTALL FRONT PILLAR GARNISH LH (See page IR-
43)
48. INSTALL ASSIST GRIP ASSEMBLY (See page IR-43)
49. INSTALL ASSIST GRIP PLUG (See page IR-44)
50. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP LH (See page IP-33)
51. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-33)
52. INSTALL COWL SIDE TRIM BOARD RH (See page IR-
45)
53. INSTALL COWL SIDE TRIM BOARD LH (See page IR-
45)
54. INSTALL FOOTREST CLIP (See page IR-2)
55. INSTALL FRONT FLOOR FOOTREST (See page IR-2)
56. INSTALL FRONT DOOR SCUFF PLATE RH (See page
IR-45)
57. INSTALL FRONT DOOR SCUFF PLATE LH (See page
IR-45)
58. INSTALL COMBINATION SWITCH ASSEMBLY (See
page SR-17)
59. INSTALL UPPER STEERING COLUMN COVER (See
page SR-17)
60. INSTALL LOWER STEERING COLUMN COVER (See
page SR-18)
61. INSTALL STEERING WHEEL ASSEMBLY (See page
SR-18)
62. INSTALL STEERING PAD (See page RS-346)
63. INSTALL LOWER NO. 2 STEERING WHEEL COVER
(See page RS-347)
64. INSTALL LOWER NO. 3 STEERING WHEEL COVER
(See page RS-347)
65. CONNECT HEATER WATER OUTLET HOSE A (FROM
HEATER UNIT) (See page AC-56)
66. CONNECT HEATER INLET WATER HOSE (See page
AC-56)
67. INSTALL COOLER REFRIGERANT LIQUID PIPE A
(See page AC-57)
68. INSTALL COOLER REFRIGERANT SUCTION PIPE A
(See page AC-57)
69. INSTALL COWL TOP VENTILATOR LOUVER LH (See
page WW-30)
70. INSTALL COWL TOP VENTILATOR LOUVER RH (See
page WW-30)
AIR CONDITIONING BLOWER UNIT
AC79
AC
71. INSTALL COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-31)
72. INSTALL FRONT FENDER SIDE PANEL UPPER LH
(See page WW-31)
73. INSTALL FRONT FENDER SIDE PANEL UPPER RH
(See page WW-31)
74. INSTALL ANTENNA ORNAMENT (See page WW-31)
75. INSTALL ROOF ANTENNA POLE SUB-ASSEMBLY
(See page AV-116)
76. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-32)
77. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE) (See page WW-32)
78. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-33)
79. INSTALL WINDSHIELD WIPER ARM COVER (See
page WW-34)
80. ADD ENGINE COOLANT (See page CO-3)
81. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
82. CHECK SRS WARNING LIGHT
RS-29
83. CHARGE REFRIGERANT (See page AC-16)
84. WARM UP ENGINE (See page AC-18)
85. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-4)
86. CHECK FOR REFRIGERANT LEAKAGE (See page
AC-18)
87. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
AC76
AIR CONDITIONING BLOWER UNIT
AC
INSTALLATION
1. INSTALL BLOWER UNIT ASSEMBLY
(a) Install the 2 screws and blower unit as shown in the
illustration.
2. INSTALL INSTRUMENT PANEL REINFORCEMENT
(See page AC-49)
3. INSTALL COOLER UNIT DRAIN HOSE (See page AC-
51)
4. INSTALL MAIN BODY ECU (DRIVER SIDE J/B) (See
page AC-52)
5. INSTALL INSTRUMENT PANEL SIDE BRACKET (See
page AC-52)
6. INSTALL STEERING COLUMN ASSEMBLY (See page
SR-16)
7. INSTALL STEERING INTERMEDIATE SHAFT
ASSEMBLY (See page AC-52)
8. INSTALL STEERING COLUMN HOLE COVER (See
page SR-17)
9. INSTALL ECM (See page ES-447)
10. INSTALL NO. 1 INSTRUMENT PANEL BRACE
BRACKET (See page AC-52)
11. INSTALL NO. 1 AIR DUCT (See page AC-53)
12. INSTALL NO. 2 AIR DUCT (See page AC-53)
13. INSTALL REAR NO. 1 AIR DUCT (See page AC-53)
14. INSTALL REAR NO. 2 AIR DUCT (See page AC-53)
15. INSTALL NO. 1 HEATER TO REGISTER DUCT (See
page AC-54)
16. INSTALL NO. 2 HEATER TO REGISTER DUCT (See
page AC-54)
17. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY
(See page IP-26)
18. CONNECT PASSENGER AIRBAG CONNECTOR (See
page IP-26)
19. INSTALL INSTRUMENT PANEL FINISH PANEL END
LH (See page IP-27)
20. INSTALL ASSIST GRIP RETAINER RH (See page IP-
27)
21. INSTALL ASSIST GRIP RETAINER LH (See page IP-
27)
22. INSTALL FRONT NO. 2 SPEAKER ASSEMBLY (See
page AV-62)
23. INSTALL NO. 2 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
I102448
AIR CONDITIONING BLOWER UNIT
AC77
AC
24. INSTALL NO. 1 INSTRUMENT PANEL SPEAKER
PANEL SUB-ASSEMBLY (See page IP-27)
25. INSTALL NO. 2 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-27)
26. INSTALL INSTRUMENT PANEL LOWER FINISH
PANEL SUB-ASSEMBLY RH (See page IP-28)
27. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
(See page IP-28)
28. INSTALL COMBINATION METER ASSEMBLY (See
page IP-28)
29. INSTALL INSTRUMENT CLUSTER FINISH PANEL
(See page IP-29)
30. INSTALL LOWER INSTRUMENT PANEL LH (See page
IP-29)
31. INSTALL LOWER INSTRUMENT PANEL FINISH
PANEL SUB-ASSEMBLY LH (See page IP-29)
32. CONNECT HOOD LOCK CONTROL LEVER SUB-
ASSEMBLY (See page IP-30)
33. INSTALL NO. 1 INSTRUMENT PANEL REGISTER
ASSEMBLY (See page IP-30)
34. INSTALL INSTRUMENT LOWER COVER SUB-
ASSEMBLY (See page IP-30)
35. INSTALL CONSOLE UPPER PANEL NO. 1 GARNISH
(See page IP-31)
36. INSTALL FRONT CONSOLE BOX (See page IP-31)
37. INSTALL BOX BOTTOM MAT (See page IP-31)
38. INSTALL CONSOLE UPPER REAR PANEL SUB-
ASSEMBLY (See page IP-31)
39. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
Manual Transmission) (See page IP-32)
40. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for
4WD) (See page IP-32)
41. INSTALL PARKING BRAKE HOLE COVER SUB-
ASSEMBLY (See page IP-32)
42. INSTALL RADIO RECEIVER ASSEMBLY (See page
AV-56)
43. INSTALL INTEGRATION CONTROL AND PANEL
ASSEMBLY (See page IP-32)
44. INSTALL INSTRUMENT PANEL GARNISH LH (See
page IP-33)
45. INSTALL INSTRUMENT PANEL GARNISH RH (See
page IP-33)
46. INSTALL FRONT PILLAR GARNISH RH (See page IR-
43)
AC78
AIR CONDITIONING BLOWER UNIT
AC
47. INSTALL FRONT PILLAR GARNISH LH (See page IR-
43)
48. INSTALL ASSIST GRIP ASSEMBLY (See page IR-43)
49. INSTALL ASSIST GRIP PLUG (See page IR-44)
50. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP LH (See page IP-33)
51. INSTALL FRONT DOOR OPENING TRIM
WEATHERSTRIP RH (See page IP-33)
52. INSTALL COWL SIDE TRIM BOARD RH (See page IR-
45)
53. INSTALL COWL SIDE TRIM BOARD LH (See page IR-
45)
54. INSTALL FOOTREST CLIP (See page IR-2)
55. INSTALL FRONT FLOOR FOOTREST (See page IR-2)
56. INSTALL FRONT DOOR SCUFF PLATE RH (See page
IR-45)
57. INSTALL FRONT DOOR SCUFF PLATE LH (See page
IR-45)
58. INSTALL COMBINATION SWITCH ASSEMBLY (See
page SR-17)
59. INSTALL UPPER STEERING COLUMN COVER (See
page SR-17)
60. INSTALL LOWER STEERING COLUMN COVER (See
page SR-18)
61. INSTALL STEERING WHEEL ASSEMBLY (See page
SR-18)
62. INSTALL STEERING PAD (See page RS-346)
63. INSTALL LOWER NO. 2 STEERING WHEEL COVER
(See page RS-347)
64. INSTALL LOWER NO. 3 STEERING WHEEL COVER
(See page RS-347)
65. CONNECT HEATER WATER OUTLET HOSE A (FROM
HEATER UNIT) (See page AC-56)
66. CONNECT HEATER INLET WATER HOSE (See page
AC-56)
67. INSTALL COOLER REFRIGERANT LIQUID PIPE A
(See page AC-57)
68. INSTALL COOLER REFRIGERANT SUCTION PIPE A
(See page AC-57)
69. INSTALL COWL TOP VENTILATOR LOUVER LH (See
page WW-30)
70. INSTALL COWL TOP VENTILATOR LOUVER RH (See
page WW-30)
AIR CONDITIONING BLOWER UNIT
AC79
AC
71. INSTALL COWL TOP VENTILATOR LOUVER SUB-
ASSEMBLY (See page WW-31)
72. INSTALL FRONT FENDER SIDE PANEL UPPER LH
(See page WW-31)
73. INSTALL FRONT FENDER SIDE PANEL UPPER RH
(See page WW-31)
74. INSTALL ANTENNA ORNAMENT (See page WW-31)
75. INSTALL ROOF ANTENNA POLE SUB-ASSEMBLY
(See page AV-116)
76. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY LH (See page WW-32)
77. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (CENTER SIDE) (See page WW-32)
78. INSTALL FRONT WIPER ARM AND BLADE
ASSEMBLY RH (See page WW-33)
79. INSTALL WINDSHIELD WIPER ARM COVER (See
page WW-34)
80. ADD ENGINE COOLANT (See page CO-3)
81. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
82. CHECK SRS WARNING LIGHT
RS-29
83. CHARGE REFRIGERANT (See page AC-16)
84. WARM UP ENGINE (See page AC-18)
85. CHECK FOR ENGINE COOLANT LEAKAGE (See
page CO-4)
86. CHECK FOR REFRIGERANT LEAKAGE (See page
AC-18)
87. POSITION FRONT WHEELS FACING STRAIGHT
AHEAD
AC80
AIR CONDITIONING BLOWER MOTOR
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
BLOWER MOTOR
COMPONENTS
BLOWER MOTOR
I102496E01
AIR CONDITIONING BLOWER MOTOR
AC81
AC
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE BLOWER MOTOR
(a) Disconnect the connector and the clamp.
(b) Remove the 3 screws and the blower motor.
INSPECTION
1. INSPECT BLOWER MOTOR
(a) Connect the positive (+) lead from the battery to
terminal 2 and the negative (-) lead to terminal 1,
then check that the motor operates smoothly.
OK:
The motor operates smoothly.
If the operation is not as specified, replace the
blower motor.
(b) Measure the current.
Standard current
If the current value is not as specified, replace the
blower motor.
INSTALLATION
1. INSTALL BLOWER MOTOR
(a) Install the blower motor with the 3 screws.
(b) Connect the connector and the clamp.
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
I102492
I102518
Tester Connection Condition Specified Condition
1 - 2 Blower motor operates 1 to 3.5 A
I102492
AC82
AIR CONDITIONING BLOWER RESISTOR
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
BLOWER RESISTOR
COMPONENTS
BLOWER RESISTOR
I102495E01
AIR CONDITIONING BLOWER RESISTOR
AC83
AC
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE BLOWER RESISTOR
(a) Disconnect the connector.
(b) Remove the 2 screws and the blower resistor.
INSPECTION
1. INSPECT BLOWER RESISTOR
(a) Measure the resistance.
Standard resistance
If the resistance value is not as specified, replace
the blower resistor.
INSTALLATION
1. INSTALL BLOWER RESISTOR
(a) Install the blower resistor with the 2 screws.
(b) Connect the connector.
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
I102493
E032877E03
Tester connection Specified condition
1 - 2 0.83 to 0.95
1 - 3 0.31 to 0.35
1 - 4 1.76 to 2.02
I102493
AC84
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
COMPRESSOR AND MAGNETIC CLUTCH
COMPONENTS
BATTERY HOLD
DOWN CLAMP
BATTERY
BATTERY TRAY
for 2WD: for 4WD:
N*m (kgf*cm, ft.*lbf) : Specified torque
29 (296, 21)
x4
29 (296, 21)
x4
NO. 1 ENGINE UNDER
COVER SUB-ASSEMBLY
NO. 1 ENGINE UNDER
COVER SUB-ASSEMBLY
6.0 (61, 53 in.*lbf)
I102469E01
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC85
AC
O-RING
DISCHARGE HOSE
SUB-ASSEMBLY
9.8 (100, 87 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part
O-RING
O-RING O-RING
COOLER COMPRESSOR
ASSEMBLY
FAN AND GENERATOR
V BELT
24.5 (250, 18)
9.8 (100, 87 in.*lbf)
SUCTION HOSE SUB-ASSEMBLY
7.8 (80, 69 in.*lbf)
Compressor Oil ND-8 or equivalent
I102470E01
AC86
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC
N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part
18 (184, 13)
MAGNET CLUTCH ASSEMBLY
COOLER COMPRESSOR
ASSEMBLY
COOLER BRACKET
SNAP RING
SNAP RING
MAGNET CLUTCH WASHER
I102471E01
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC87
AC
REMOVAL
1. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-16)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE BATTERY HOLD DOWN CLAMP
4. REMOVE BATTERY
5. REMOVE BATTERY TRAY
6. REMOVE NO. 1 ENGINE UNDER COVER SUB-
ASSEMBLY (See page EM-6)
7. REMOVE FAN AND GENERATOR V BELT (See page
EM-6)
8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY
(a) Remove the bolt and separate the suction hose.
(b) Remove the nut and disconnect the suction hose.
(c) Remove the O-ring from the suction hose.
NOTICE:
Seal the openings of the disconnected parts
using vinyl tape to prevent moisture and foreign
matter from entering.
9. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the nut and disconnect the discharge hose.
(b) Remove the O-ring from the discharge hose.
NOTICE:
Seal the openings of the disconnected parts
using vinyl tape to prevent moisture and foreign
matter from entering.
10. REMOVE COOLER COMPRESSOR ASSEMBLY
(a) Disconnect the connector.
(b) Remove the 4 bolts and compressor.
I102472
I102473
I102474
AC88
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC
DISASSEMBLY
1. REMOVE MAGNET CLUTCH ASSEMBLY
(a) Clamp the cooler compressor in a vise.
(b) Using SST, hold the magnet clutch hub.
SST 09960-10010 (09962-01000, 09963-00500)
(c) Remove the bolt, magnet clutch hub and magnet
clutch washer.
HINT:
There is no set number of magnet clutch washers
since they are used for adjusting.
(d) Using a snap ring expander, remove the snap ring
and the magnet clutch rotor.
NOTICE:
Do not damage the seal cover of the bearing
when removing the snap ring.
(e) Disconnect the connector.
(f) Using a snap ring expander, remove the snap ring
and magnet clutch stator.
2. REMOVE COOLER BRACKET
(a) Remove the screw and the cooler bracket.
INSPECTION
1. INSPECT MAGNET CLUTCH ASSEMBLY
(a) Check the magnet clutch operation.
(1) Confirm that the magnet clutch hub and
magnet clutch rotor lock when the battery
positive lead is connected to terminal 3 (MG+)
of the magnet clutch, and the negative lead is
connected to the earth wire.
If the operation is not as specified, replace the
magnet clutch assembly.
(b) Measure the resistance.
(c) Measure the resistance between terminals 1 and 2.
Standard resistance:
165 to 205 at 25C (77F)
If the resistance is not as specified, replace the
cooler compressor assembly.
I102475
I034346
I102478
Battery
Magent Clutch Rotor
Magent
Clutch Hub
I102517E01
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC89
AC
REASSEMBLY
1. INSTALL COOLER BRACKET
(a) Install the cooler bracket with the screw.
2. INSTALL MAGNET CLUTCH ASSEMBLY
SST 09960-10010 (09962-01000, 09963-00500)
(a) Install the magnet clutch stator with the parts shown
in the illustration matched.
(b) Using a snap ring expander, install a new snap ring
with the chamfered side facing up.
(c) Connect the connector.
(d) Using SST, install the magnet clutch rotor and a new
snap ring with the chamfered side facing up.
NOTICE:
Do not damage the seal cover of the bearing
when installing the snap ring.
(e) Install the compressor spacer and magnet clutch
hub.
NOTICE:
Do not change the combination of the
compressor spacer used before disassembly.
(f) Using SST, hold the magnet clutch hub and install
the bolt.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 18 N*m (184 kgf*cm, 13 ft.*lbf)
NOTICE:
Make sure that there is no foreign matter or oil
on the compressor shaft, bolt, and clutch hub.
I102478
E065508
I032461
I031582
I102476
AC90
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC
3. INSPECT MAGNET CLUTCH CLEARANCE
(a) Clamp the cooler compressor in a vise.
(b) Set the dial indicator to the magnet clutch hub.
(c) Connect the battery positive lead to terminal 3
(MG+) of the magnet clutch connector and the
negative lead to the earth wire. Turn the magnet
clutch on and off and measure the clearance.
Standard clearance:
0.35 to 0.60 mm (0.014 to 0.024 in.)
If the measured value is not within the standard
clearance, remove the magnet clutch hub and
adjust the clearance using compressor spacer to
obtain the standard clearance.
Compressor spacer thickness:
0.1 mm (0.004 in.)
0.3 mm (0.012 in.)
0.5 mm (0.020 in.)
NOTICE:
Adjustment should be performed with 3 or less
magnet clutch washers.
(d) Remove the cooler compressor from the vise.
INSTALLATION
1. ADJUST COMPRESSOR OIL
(a) When replacing the compressor with a new one,
gradually discharge the refrigerant gas from the
service valve. Then drain the following amount of oil
from the new compressor before installation, so that
the amount of oil contained in it is the same as that
in the compressor to be replaced.
HINT:
New compressors are filled with sufficient oil for the
whole cycle. Therefore, it is necessary to drain
residual oil from the condenser and cooling unit.
Standard:
(The amount of oil inside a new compressor:
120 (+15) cc (4.1 (+0.51) fl.oz.)) - (The amount
of oil remaining in the removed compressor) =
The amount of oil to be removed when
replacing the compressor
NOTICE:
When checking the compressor oil level,
observe the precautions for cooler removal/
installation.
If a new compressor is installed without
removing the amount of oil remaining in the
pipes of the vehicle, the amount of oil
becomes too large. This prevents heat
exchange in the refrigerant cycle and causes
refrigeration failure.
If the amount of oil remaining in the removed
compressor is too small, check for oil
leakage.
Use ND-OIL8 compressor oil.
Battery
I102477E01
New
Compressor
Removed
Compressor
A B
Drain Extra Oil
(A - B)
I102516E01
AIR CONDITIONING COMPRESSOR AND MAGNETIC CLUTCH
AC91
AC
2. INSTALL COOLER COMPRESSOR ASSEMBLY
(a) Install the compressor with the 4 bolts.
Torque: 24.5 N*m (250 kgf*cm, 18 ft.*lbf)
(b) Connect the connector.
3. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil (ND-OIL8) to a new
O-ring and the fitting surface of the compressor.
Compressor oil:
ND-OIL8 or the equivalent
(c) Install the O-ring onto the discharge hose.
(d) Install the discharge hose onto the compressor with
the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
4. INSTALL SUCTION HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose.
(b) Apply sufficient compressor oil (ND-OIL8) to a new
O-ring and the fitting surface of the compressor.
Compressor oil:
ND-OIL8 or the equivalent
(c) Install the O-ring onto the suction hose.
(d) Install the suction hose onto the compressor with
the nut.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
(e) Install the suction hose with the bolt.
Torque: 7.8 N*m (80 kgf*cm, 69 in.*lbf)
5. INSTALL FAN AND GENERATOR V BELT (See page
EM-6)
6. INSTALL NO. 1 ENGINE UNDER COVER SUB-
ASSEMBLY
7. INSTALL BATTERY TRAY
8. INSTALL BATTERY
9. INSTALL BATTERY HOLD DOWN CLAMP
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
10. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
11. CHARGE REFRIGERANT (See page AC-16)
12. WARM UP ENGINE (See page AC-18)
13. CHECK FOR REFRIGERANT LEAKAGE (See page
AC-18)
I102474
I102473
I102472
AC92
AIR CONDITIONING CONDENSER
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
CONDENSER
COMPONENTS
FRONT BUMPER
COVER
RADIATOR GRILLE
x4
3.0 (30, 27 in.*lbf)
N*m (kgf*cm, ft*lbf) : Specified torque
x4
x2
x2
x5
x2
x2
3.0 (30, 27 in.*lbf)
8.0 (80, 71 in.*lbf)
3.0 (30, 27 in.*lbf)
B134727E01
AIR CONDITIONING CONDENSER
AC93
AC
NO. 1 COOLER CONDENSOR
CUSHION
5.5 (55, 49 in.*lbf)
NO. 1 COOLER CONDENSOR
CUSHION
5.5 (56, 49 in.*lbf)
DISCHARGE HOSE
SUB-ASSEMBLY
5.5 (56, 49 in.*lbf)
5.4 (55, 48 in.*lbf)
N*m (kgf*cm, ft.*lbf) : Specified torque
Non-reusable part Compressor Oil ND-8 or equivalent
O-RING
5.4 (55, 48 in.*lbf)
COOLER BRACKET
NO. 2 COOLER
CONDENSER
CUSHION LH
COOLER CONDENSER
ASSEMBLY
AIR CONDITIONING
TUBE ASSEMBLY
5.4 (55, 48 in.*lbf)
O-RING
5.4 (55, 48 in.*lbf)
5.5 (56, 49 in.*lbf)
NO. 2 COOLER
CONDENSER
CUSHION RH
I102479E01
AC94
AIR CONDITIONING CONDENSER
AC
COOLER CONDENSER ASSEMBLY
COOLER DRYER
CAP
Compressor Oil ND-8 or equivalent
N*m (kgf*cm, ft*lbf) : Specified torque
2.9 (30, 25 in.*lbf)
I102480E01
AIR CONDITIONING CONDENSER
AC95
AC
ON-VEHICLE INSPECTION
1. INSPECT COOLER CONDENSER ASSEMBLY
(a) If the fins of the cooler condenser assembly are
dirty, clean them with water and dry them with
compressed air.
NOTICE:
Do not damage the fins of the cooler condenser
assembly.
(b) If the fins of the cooler condenser assembly are
bent, straighten them using a screwdriver or pliers.
2. CHECK CONDENSER FOR REFRIGERANT
LEAKAGE
(a) Check the pipe joints for gas leakage, using a
halogen leak detector.
(b) Check the tightening torque of the joints if gas
leakage is detected from any pipe joints.
AC96
AIR CONDITIONING CONDENSER
AC
REMOVAL
1. DISCHARGE REFRIGERANT FROM
REFRIGERATION SYSTEM (See page AC-16)
2. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
3. REMOVE RADIATOR GRILLE (See page ET-4)
4. REMOVE FRONT BUMPER COVER (See page ET-4)
5. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the bolt and disconnect the discharge hose
from the cooler condenser.
(b) Remove the O-ring from the discharge hose.
NOTICE:
Seal the openings of the disconnected parts
using vinyl tape to prevent moisture and foreign
matter from entering.
6. DISCONNECT AIR CONDITIONING TUBE ASSEMBLY
(a) Remove the bolt and disconnect the air conditioning
tube from the cooler condenser.
(b) Remove the O-ring from the air conditioning tube.
NOTICE:
Seal the openings of the disconnected parts
using vinyl tape to prevent moisture and foreign
matter from entering.
7. REMOVE COOLER BRACKET
(a) Remove the nut.
(b) Disengage the clamp and remove the cooler
bracket.
8. REMOVE NO. 2 COOLER CONDENSER CUSHION LH
(a) Remove the 2 bolts and remove the cooler
condenser cushion.
I102481
I102482
I102483
I102486
AIR CONDITIONING CONDENSER
AC97
AC
9. REMOVE NO. 2 COOLER CONDENSER CUSHION RH
(a) Remove the 2 bolts and nut and remove the cooler
condenser cushion.
10. REMOVE COOLER CONDENSER ASSEMBLY
(a) Remove the 4 bolts and remove the cooler
condenser cushion.
NOTICE:
Hold the cooler condenser by hand to prevent it
from falling off when removing the cushion.
(b) Remove the condenser from the vehicle.
NOTICE:
Do not damage the condenser or radiator when
removing the condenser.
DISASSEMBLY
1. REMOVE COOLER DRYER
(a) Using a 14 mm straight hexagon wrench, remove
the cap from the modulator.
(b) Using pliers, remove the cooler dryer.
I102484
I102488
Modulator
14 mm
Hexagon
Wrench
E101931E03
E104262
AC98
AIR CONDITIONING CONDENSER
AC
REASSEMBLY
1. INSTALL COOLER DRYER
(a) Using pliers, install the cooler dryer onto the
modulator.
(b) Apply sufficient compressor oil to the O-ring and the
fitting surface of the cap.
Compressor oil:
ND-OIL 8 or the equivalent
(c) Using a 14 mm straight hexagon wrench, install the
cap onto the modulator.
Torque: 2.9 N*m (30 kgf*cm, 25 in.*lbf)
INSTALLATION
1. INSTALL COOLER CONDENSER ASSEMBLY
(a) Install the condenser into the vehicle.
NOTICE:
Do not damage the condenser or radiator when
installing the condenser.
HINT:
If a new condenser is installed, add compressor oil
to the condenser as follows.
Compressor oil:
ND-OIL8 or the equivalent. Add 40 cc (1.35 fl.
oz.)
(b) Install the No.1 cooler condenser cushion with the 4
bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
E101933
E101932
Modulator
14 mm
Hexagon
Wrench
E101931E03
I102489
AIR CONDITIONING CONDENSER
AC99
AC
2. INSTALL NO. 2 COOLER CONDENSER CUSHION RH
(a) Install the cooler condenser cushion with the 2 bolts
and nut.
NOTICE:
Securely insert the cooler condenser cushion
into the radiator lower support.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf) for bolt
5.4 N*m (55 kgf*cm, 48 in.*lbf) for nut
3. INSTALL NO. 2 COOLER CONDENSER CUSHION LH
(a) Install the cooler condenser cushion with the 2 bolts.
NOTICE:
Securely insert the cooler condenser cushion
into the radiator lower support.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
4. INSTALL COOLER BRACKET
(a) Install the cooler bracket with the nut.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
(b) Engage the clamp.
Radiator Lower
Support
Front Side
I102485E01
Radiator Lower
Support
Front
Side
I102487E01
I102483
AC100
AIR CONDITIONING CONDENSER
AC
5. INSTALL AIR CONDITIONING TUBE ASSEMBLY
(a) Remove the attached vinyl tape from the pipe and
the connecting part of the cooler condenser.
(b) Apply sufficient compressor oil to a new O-ring and
the fitting surface of the pipe joint.
Compressor oil:
ND-OIL8 or the equivalent
(c) Install the O-ring onto the air conditioning tube.
(d) Install the tube onto the condenser with the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
6. INSTALL DISCHARGE HOSE SUB-ASSEMBLY
(a) Remove the attached vinyl tape from the hose and
the connecting part of the cooler condenser.
(b) Apply sufficient compressor oil to a new O-ring and
the fitting surface of the hose joint.
Compressor oil:
ND-OIL8 or the equivalent
(c) Install the O-ring onto the discharge hose.
(d) Install the discharge hose onto the condenser with
the bolt.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)
7. INSTALL FRONT BUMPER COVER (See page ET-10)
8. INSTALL RADIATOR GRILLE (See page ET-11)
9. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
10. CHARGE REFRIGERANT (See page AC-16)
11. WARM UP ENGINE (See page AC-18)
12. CHECK FOR REFRIGERANT LEAKAGE (See page
AC-18)
I102482
I102481
AIR CONDITIONING AMBIENT TEMPERATURE SENSOR
AC101
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
AMBIENT TEMPERATURE SENSOR
COMPONENTS
AMBIENT TEMPERATURE SENSOR
I102491E01
AC102
AIR CONDITIONING AMBIENT TEMPERATURE SENSOR
AC
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE AMBIENT TEMPERATURE SENSOR
(a) Disconnect the connector.
(b) Disengage the clamp and remove the ambient
temperature sensor.
INSPECTION
1. INSPECT AMBIENT TEMPERATURE SENSOR
(a) Measure the resistance.
Standard resistance
NOTICE:
Touching the sensor even slightly may
change the resistance value. Hold the
connector of the sensor.
When measuring the resistance, the
temperature of the sensor and the ambient
temperature sensor must be the same.
HINT:
As the temperature increases, the resistance
decreases (see the graph).
I102494
1O
6O
2O
68
8O
86
4O
1O4
6O
122
6O|O)
14O|l)
O.O
O.6
1.O
1.6
2.O
2.6
8.O
8.6
4.O
Sensor Area
Resistance
Temperature
(k)
(C)
(F)
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
10 20 30 40 50 60
140 122 104 86 68 50
E106870E06
Tester Connection Condition Specified Condition
1 - 2 10C (50F) 3.00 to 3.73 k
1 - 2 15C (59F) 2.45 to 2.88 k
1 - 2 20C (68F) 1.95 to 2.30 k
1 - 2 25C (77F) 1.60 to 1.80 k
1 - 2 30C (86F) 1.28 to 1.47 k
1 - 2 35C (95F) 1.00 to 1.22 k
1 - 2 40C (104F) 0.80 to 1.00 k
1 - 2 45C (113F) 0.65 to 0.85 k
1 - 2 50C (122F) 0.50 to 0.70 k
1 - 2 55C (131F) 0.44 to 0.60 k
1 - 2 60C (140F) 0.36 to 0.50 k
AIR CONDITIONING AMBIENT TEMPERATURE SENSOR
AC103
AC
INSTALLATION
1. INSTALL AMBIENT TEMPERATURE SENSOR
(a) Engage the clamp and install the ambient
temperature sensor.
(b) Connect the connector.
2. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
I102494
AC104
AIR CONDITIONING PRESSURE SWITCH
AC
PRESSURE SWITCH
ON-VEHICLE INSPECTION
1. INSPECT PRESSURE SWITCH
HINT:
The pressure switch is installed onto the air
conditioning pipe on the high pressure side.
The switch detects drops in refrigerant pressure, such
as from refrigerant leakage, and turns the magnet
clutch off (
*
1) to prevent damage to the compressor.
The switch detects abnormally high pressure in the air
conditioning cycle and turns the magnet clutch off (
*
1)
to prevent damage to parts of the air conditioning
cycle.
(
*
1): The ECM turns the magnet clutch on or off upon
receiving the signal from the pressure switch.
As the pressure switch operates when there is a
malfunction with the refrigerant pressure, its function
cannot be inspected on-vehicle. Follow the
procedures below to inspect it.
(a) Inspect the refrigerant pressure in the air
conditioning cycle.
(b) Read the manifold gauge pressure when the
conditions below are established. (
*
2)
Test conditions:
Engine running at 1,500 rpm
Blower speed control knob in HI position
Temperature control knob in COOL position
Air conditioning switch ON
Recirculation mode
Doors fully open
Standard:
Pressure on high pressure side:
1.37 to 1.57 MPa (13.9 to 16.0 kgf
*
cm
2
, 198 to
228 psi)
HINT:
If the refrigerant pressure is not within the
standard range, inspect and repair the air
conditioning cycle.
(See Page AC-12)
Proceed to step (
*
2) if the refrigerant pressure is
within the specified range.
If the refrigerant pressure is below 196 KPa (2.0
kgf
*
cm
2
, 28 psi), the refrigerant amount in the air
conditioning cycle may have decreased
significantly for reasons such as a gas leakage.
ON (Below 1.0 )
196 KPa 3,140 KPa
(2.0 kgf*cm
2
, 28 psi)
OFF
(32.0 kgf*cm
2
, 455 psi)
OFF
(10 k or higher) (10 k or higher)
I040666E04
AIR CONDITIONING PRESSURE SWITCH
AC105
AC
(c) Check the air conditioning operation.
(1) Disconnect the pressure switch connector.
(2) Connect terminals 1 and 2 of the pressure
switch connector on the vehicle wire harness
side using a service wire.
(3) Start the engine.
(4) Turn the air conditioning switch on and check
that the magnet clutch is turned on.
(5) Check that the magnet clutch is turned off when
disconnecting terminals 1 and 2 (those
connected in the prior step).
Standard:
Terminals 1 and 2 connected: Magnet
clutch is ON
Terminals 1 and 2 disconnected: Magnet
clutch is OFF
Replace the pressure switch if the magnet
clutch operates normally.
Inspect and repair the wire harness between
the pressure switch and the ECM.
Pressure Switch Connector
Wire Harness View:
A19
I036436E03
AC106
AIR CONDITIONING HEATER BLOWER MOTOR RELAY
AC
HEATER BLOWER MOTOR RELAY
ON-VEHICLE INSPECTION
1. INSPECT HEATER BLOWER MOTOR RELAY
ASSEMBLY
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
If the result is not as specified, replace the
relay.
Ohmmeter
Battery
Ohmmeter
1
2
3
4 5
E106620E01
Tester Connection Specified Condition
3 - 4 Below 1
3 - 4
10 k or higher
(Apply battery voltage to terminals 1 and 2)
3 - 5 10 k or higher
3 - 5
Below 1
(Apply battery voltage to terminals 1 and 2)
AIR CONDITIONING MAGNETIC CLUTCH RELAY
AC107
AC
MAGNETIC CLUTCH RELAY
ON-VEHICLE INSPECTION
1. INSPECT MAGNET CLUTCH RELAY
(a) Check the resistance.
(1) Using an ohmmeter, measure the resistance
between the terminals.
Standard resistance
If the result is not as specified, replace the
relay.
Ohmmeter
Battery
I100429E01
Tester Connection Specified Condition
3 - 5 10 k or higher
3 - 5
Below 1
(Apply battery voltage to terminals 1 and 2)
AC108
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC
HEATER & AIR CONDITIONING SYSTEM AIR CONDITIONING
INTEGRATION CONTROL AND PANEL
COMPONENTS
INSTRUMENT PANEL
GARNISH LH
INSTRUMENT PANEL
GARNISH RH
INTEGRATION CONTROL
AND PANEL ASSEMBLY
REAR PANEL
INTEGRATION CONTROL
AND PANEL
AIR CONDITIONER
AMPLIFIER ASSEMBLY
B133885E01
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC109
AC
REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY
TERMINAL
2. REMOVE INSTRUMENT PANEL GARNISH LH (See
page IP-10)
3. REMOVE INSTRUMENT PANEL GARNISH RH (See
page IP-10)
4. REMOVE INTEGRATION CONTROL AND PANEL
ASSEMBLY
(a) Remove the 2 screws.
(b) Disengage the 4 clips and remove the integration
control assembly.
(c) Disconnect the 3 connectors.
DISASSEMBLY
1. REMOVE AIR CONDITIONER AMPLIFIER ASSEMBLY
(a) Remove the 3 screws.
(b) Disengage the 6 claws and remove the rear panel.
(c) Disengage the lock of the connector and disconnect
the cable.
(d) Remove the air conditioner amplifier assembly.
B133888
I102504
I102505
AC110
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC
INSPECTION
1. INSPECT INTEGRATION CONTROL AND PANEL
ASSEMBLY
(a) Check the blower switch resistance.
(1) Using an ohmmeter, measure the resistance
and check the results in accordance with the
values in the table below.
Standard resistance
If the result is not as specified, replace the
integration control and panel assembly.
(b) Inspect the illumination operation.
(1) Connect the positive (+) lead from the battery
to terminals 1 (IG+) and 2 (ILL+) and the
negative (-) lead to terminal 20 (GND), then
check that the illuminations light up.
Standard:
Illuminations light up
If the result is not as specified, replace the
integration control and panel assembly.
(c) Inspect the A/C indicator operation.
(1) Connect the positive (+) lead from the battery
to terminal 1 (IG+) and the negative (-) lead to
terminals 8 (BLW) and 20 (GND).
(2) Push the A/C button in and then check that the
indicator lights up.
Standard
1
5 4
3 2
8 7 6
OFF
LO
M1
M2
HI
Ohmmeter
I102515E01
Tester connection Blower Switch Position Specified Condition
1 - 4 - 5 - 6 - 8 OFF 10 K or higher
1 - 8 LO Below 1
1 - 6 - 8 M1 Below 1
1 - 5 - 8 M2 Below 1
1 - 4 - 8 HI Below 1
Battery
I102507E01
Battery
I102508E01
Switch Condition Specified Condition
Switch ON Indicator illuminates
Switch OFF Indicator turns off
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC111
AC
HINT:
Inspect the A/C indicator operation in any
position except MAX COOL. The A/C indicator
ON/OFF operation does not function in MAX
COOL position (The A/C indicator is held in ON
state).
If the result is not as specified, replace the
integration control and panel assembly.
(3) Under the above condition, connect the
positive (+) lead from the battery to terminal 2
(ILL+) and then check that the indicator dims.
Standard
HINT:
Inspect the A/C indicator operation in any
position except MAX COOL. The A/C indicator
ON/OFF operation does not function in MAX
COOL position (The A/C indicator is held in ON
state).
If the result is not as specified, replace the
integration control and panel assembly.
(d) Inspect the REC indicator operation.
(1) Connect the positive (+) lead from the battery
to terminal 1 (IG+) and the negative (-) lead to
terminal 20 (GND).
NOTICE:
Inspect the MODE switch in any position
except DEF.
(2) Push the REC button in and check that the
indicator lights up.
Standard
If the result is not as specified, replace the
integration control and panel assembly.
Battery
I102509E01
Switch Condition Specified Condition
Switch ON Indicator dims
Switch OFF Indicator turns off
Battery
I102510E01
Switch Condition Specified Condition
Switch ON Indicator illuminates
Switch OFF Indicator turns off
AC112
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC
(3) Under the above condition, connect the
positive (+) lead from the battery to terminal 2
(ILL+) and then check that the indicator dims.
NOTICE:
Inspect the MODE switch in any position
except DEF.
Standard
If the result is not as specified, replace the
integration control and panel assembly.
(e) Inspect the temperature control switch operation.
(1) Connect the positive (+) lead from the battery
to terminal 1 (IG+) and the negative (-) lead to
terminals 8 (BLW) and 20 (GND).
NOTICE:
Inspect the MODE switch in any position
other than DEF and FOOT/DEF.
(2) Check the A/C indicator and REC indicator
operations when the temperature switch is
operated.
Standard
HINT:
*1: The A/C indicator remains illuminated even
after the temperature switch is turned from this
position to another. The REC indicator returns
to the condition prior to turning the switch to
MAX A/C. Press the A/C switch in and check
that the indicator turns off.
If the result is not as specified, replace the
integration control and panel assembly.
Battery
I102511E01
Switch Condition Specified Condition
Switch ON Indicator dims
Switch OFF Indicator turns off
Battery
I102512E01
Temperature Switch Condition
Specified Condition (A/C indicator
and REC indicator)
Except MAX A/C Neither indicator illuminates
MAX A/C Both indicators illuminate*1
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC113
AC
(f) Inspect MODE switch operation.
(1) Connect the positive (+) lead from the battery
to terminal 1 (IG+) and the negative (-) lead to
terminal 20 (GND).
(2) Check the REC indicator operation when the
MODE switch is operated.
Standard
If the result is not as specified, replace the
integration control and panel assembly.
REASSEMBLY
1. INSTALL AIR CONDITIONER AMPLIFIER ASSEMBLY
(a) Remove the air conditioner amplifier assembly.
(b) Engage the lock of the connector and connect the
cable.
(c) Engage the 6 claws and install the rear panel.
(d) Install the 3 screws.
DEF
FOOT/DEF
FOOT
B/L
FACE
Battery
I102514E01
Condition Specified Condition (REC indicator)
MODE switch except DEF
REC switch ON OFF
Indicator turns ON OFF in
accordance with REC switch
operation
MODE switch DEF
REC switch ON OFF
Indicator turns off
I102506
I102504
AC114
AIR CONDITIONING INTEGRATION CONTROL AND PANEL
AC
INSTALLATION
1. INSTALL INTEGRATION CONTROL AND PANEL
ASSEMBLY
(a) Connect the 3 connectors.
(b) Engage the 4 clips and install the integration control
assembly.
(c) Install the 2 screws.
2. INSTALL INSTRUMENT PANEL GARNISH LH (See
page IP-33)
3. INSTALL INSTRUMENT PANEL GARNISH RH (See
page IP-33)
4. CONNECT CABLE TO NEGATIVE BATTERY
TERMINAL
Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf)
B133888