AIR CONDITIONING SYSTEM

Return To Main Table of Contents

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HEATER CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 12 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 19 COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 EVAPORATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONDENSER FAN & RELAY . . . . . . . . . . . . . . . . . . . . . . . . . BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ACCUMULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 45 47 49 50 52

GENERAL

SPECIFICATION (H.C.C)
Heater assembly Type Heating capacity Air conditioner Cooling capacity Compressor Model No. of cylinders and displacement CC/Rev Maximum allowable continuous rpm Magnetic clutch Voltage, power consumption Control Idle up device (FBC only) Protective equipment Clutch cycling switch Cut out pressure Max. cut in pressure Min. difference pressure Pressure relief valve Relief pressure Exhaust flow Resealed pressure Refrigerant and quantity gr. (oz, lb.) 3,800 Kcal/h (15,000 B.T.U/h) 3,300 Kcal/h (13,000 B.T.U/h) SD-709 7 cylinders, 155 6000 DC12V, 49W 900 25 rpm

167 kPa (1.7 0.1 kg/cm2, 24 psi) 324 kPa (3.3 kg/cm2, 47 psi) 118 kPa (1.2 kg/cm2, 17 psi) 31.6 kg/cm2 (449 psi) MIN., 42.18 kg/cm2 (560 psi) MAX. Min. 113.2 L/MIN. at 42.18 kg/cm2 (560 psi) Min. 28.2 kg/cm2 (401 psi) R-12 850-900 (30-32, 1.87-1.92)

SERVICE STANDARDS
Amount of deflection of V belt mm (in.) Engine idle speed Air gap mm (in.) 8.0-10.0 (0.32-0.40) 70050 rpm (without MPI) 0.4-0.8 (0.016-0.032)

LUBRICANTS
Recommended lubricant Heater control lever Compressor oil Multipurpose grease Suniso 5GS or equivalant Quantity As required 240 cc (8.1 fl oz)

97-2

GENERAL

SPECIAL TOOLS

97-3

GENERAL

TROUBLESHOOTING INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM

TEST STEP A1 VERIFY THE CONDITION Check system operation System cooling properly INSTRUCT vehicle owner on proper use of the system GO to A2 RESULT ACTION TO TAKE

System not cooling Properly A2 CHECK A/C COMPRESSOR CLUTCH Does the A/C compressor clutch engage? Yes No

GO to A3 REFER to clutch circuit diagnosis in this section

A3 CHECK OPERATION OF COOLING FAN Check that the cooling fan runs when the A/C compressor clutch is engaged Yes No GO to A4 Check for cooling fan electric circuit

A4 COMPONENT CHECK o Under-hood check of the following: Loose, missing or damaged compressor drive belt. Loose or disconnected A/C clutch or clutch cycling pressure switch connectors. Disconnected resistor assembly. Loose vacuum lines or misadjusted control cables o Inside vehicle check for: Blown fuse or improper blower motor operation. Vacuum motors/temperature door movement-full travel. Electrical and vacuum connections. A5 CHECK SYSTEM Check system operation OK Condition Corrected GO to A1 GO to A6 OK but still not cooling Not OK GO to A6

REPAIR AND GO to A5

Not OK

97-4

GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM (Continued)

TEST STEP A6 CHECK COMPRESSOR CLUTCH Use refrigerant system clutch cycle rate and timing evaluation charts. Prepare the car as follows 1. Hook up the manifold gauge set 2. Set Function lever at max A/C 3. Set blower switch on high 4. Set temperature lever full cold 5. Close doors and windows 6. Use a thermometer to check temperature at center discharge register. Record outside temperature. 7. Run engine at approximately 1500 RPM with compressor clutch engaged. 8. Stabilize with above conditions for 10-15 minutes. Check compressor clutch ON/OFF time. Refer to charts for normal Clutch cycling timing rates. A7 CHECK CLUTCH CYCLING PRESSURE SWITCH Bypass the clutch cycling pressure switch with a jumper wire. Compressor on continuously. Feel evaporator inlet and outlet lines. Outlet line same temperature approximately -2C. 4C. (28F. - 40F.) or slightly colder than inlet line (after fixed orifice) Inlet line warmer or (after fixed orifice) colder than outlet line REPLACE clutch cycling pressure switch. Do not discharge system Switch fitting has Schrader valve GO to A8 Compressor cycles very rapidly (1 second on) (1 second off) Compressor runs continuously (normal operation in ambient temperature above 27C. (80F.) depending on humidity conditions) Compressor cycles slow GO to A7 RESULT ACTION TO INTAKE

GO to A8

GO to A7

GO to A9

97-5

GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM (Continued)

TEST STEP A8 CHECK SYSTEM PRESSURES Compare readings with normal system pressure ranges. Clutch cycles within limits. System pressure within limits Compressor runs continuously (normal operation in ambient temperature above 27C (80F.) depending on humidity conditions). Compressor cycles high or low ON above 359 kPa (52 psi) OFF below 144 kPa (21 psi). System OK GO to A1 RESULT ACTION TO TAKE

GO to A11

REPLACE clutch cycling pressure switch. Do not discharge system Switch timing has Schrader valve CHECK system OK.GO to A1 NOT OK.GO to A9

A9

CHECK SYSTEM Check system for leaks Leak found REPAIR, discharge, evacuate and charge system. System OK GO to A1 Low refrigerant charge or moisture in system. Discharge, evacuate and charge system. System OK

No Leak found

A10

CHECK CLUTCH CYCLING Disconnect blower motor wire and check for clutch cycling off at 144 kPa (21 psi) (suction pressure) Clutch cycles OFF at 144-179 kPa (21-26 psi) Connect blower motor wire. System OK GO to A1 REPLACE clutch cycling pressure switch. Do not discharge system. Switch fitting has Schrader valve. System OK.GO to A1

Pressure falls below 144 kPa (21 psi)

97-6

GENERAL

COMPRESSOR CIRCUIT CLUTCH DIAGNOSIS

TEST STEP B1 CHECK SYSTEM OPERATION o o o o Turn the blower switch ON. Depress the A/C button. Turn the ignition switch to the RUN position. Compressor clutch should engage and engine cooling fan should operate. Clutch and fan operate System OK Clutch and fan do not operate Only fan operates GO to B2 RESULT ACTION TO TAKE

GO to B5

B2

CHECK FOR VOLTAGE o Check for voltage at circuit wire at the clutch Voltage present cycling pressure switch connector. No voltage GO to B3 GO to A1

B3 BY-PASS PRESSURE SWITCH o Disconnect the connector at the clutch cycling pressure switch o Jump connector pins. o Clutch should engage. B4 CHECK SYSTEM PRESSURE o Connect the manifold gauge set and check the Pressure above 55 psi REPLACE clutch cycling system pressure. pressure switch GO to A1 Pressure below 55 psi (ambient temperature above 50F) CHECK refrigerant system for leaks. REPAIR and CHARGE system as necessary GO to A1. OK Not OK GO to B4 GO to B5

B5

CHECK VOLTAGE AT CLUTCH o Check for voltage at the clutch field coil. Voltage present No voltage GO to B7 GO to B6

B6

CHECK VOLTAGE AT BATTERY o Check for voltage at the battery. Voltage Present No voltage GO to B7 Check for low battery voltage. SERVICE as necessary. GO to A1.

B7 CHECK FUSE o Check fuse in panel for continuity. OK Not OK GO to B1. CHECK for short. SERVICE as necessary. REPLACE fuse. GO to B1.

97-7

GENERAL

SERVICE ADJUSTMENT ADJUSTMENT OF FAST IDLE CONTROL DEVICE (without MPI) (F.I.C.D)
The vacuum system is designed to actuate the F.I.C.D. which raises the idle speed of the engine to ensure better cooling when the car is stationary.

1. Warm up the engine. 2. Make sure the engine is at the correct idle speed with the air conditioner in the OFF position. 3. Set the engine speed to the specified rpm with the air conditioner in the ON position.

Specified rpm : 900 25 rpm

4.

Depress and release the accelerator pedal several times, and make sure that the engine speed returns to the specified rpm.

97-8

GENERAL

CHECKING AND ADJUSTING THE A/C COMPRESSOR BELT

After installation, check the following points: 1. Check for abnormal vehicle performance. 2. Check the magnetic clutch for operation (without turning on the compressor). 3. Check for any parts left unmounted or any tool left behind in the vehicle. 4. Check the belt for proper tension. Belt deflection Air conditioner compressor belt . . . . . . . . . . . . . . . . . . . . . . . 8.0-10.0 mm (0.34-0.42 in.) 5. Charge the system. 6. Check the idle speed. 7. Test the system for proper operation.

97-9

GENERAL

VACUUM SYSTEM SYMPTOM AND PROBABLE CAUSE

97-10

GENERAL

Symptom On FLOOR position. All air through defroster or DEF/FLOOR.

Probable cause o Blue and/or red vacuum hose pinched or disconnected at vacuum motor. o Black source hose pinched or disconnected at the connector. o Engine compartment A/C source hose pinched or disconnected at the vacuum manifold. o Defective vacuum motor. o o o o Blue hose pinched or disconnected at vacuum motor. Blue vacuum hoses installed improperly (reversed). Black source hose pinched or disconnected at the connector. Engine compartment A/C source hose pinched or disconnected at the vacuum manifold. o Defective vacuum motor.

On DEF/FLOOR position. All air through defroster.

On PANEL VENTS position. All air through defroster.

o Yellow vacuum hose pinched or disconnected at vacuum motor. o Black source hose pinched or disconnected at the connector. o Engine compartment A/C source hose pinched or disconnected at the vacuum manifold. o Defective vacuum motor. o Yellow vacuum hose pinched or disconnected at vacuum motor. o Blue hose pinched or disconnected at vacuum motor. o Black source hose pinched or disconnected at the connector. o Engine compartment A/C source hose pinched or disconnected at the vacuum manifold. o Defective vacuum motor. o White vacuum hose disconnected at the connector or recirc duct vacuum motor. o Black source hose pinched or disconnected at the connector. o Engine compartment A/C source hose pinched or disconnected at the vacuum manifold. o Defective vacuum motor.

On PANEL/FLOOR position. All air through defroster or panel

On DEF position. (No vacuum) On RECIRC position. All air through fresh.

97-11

HEATER CONTROL ASSEMBLY

HEATER CONTROL ASSEMBLY COMPONENTS

REMOVAL AND INSTALLATION

1. Pull out the ash tray and remove the bolt. 2. Pull out the heater control panel assembly and then disconnect the A/C switch, defrostor and cigar lighter connectors.

3. Remove the heater control assembly mounting bolts. 4. Pull out the heater control assembly and then disconnect the blower motor switch connector, vacuum connector and the temperature control cable. 5. Installation is the reverse of removal.

97-12

HEATER

COMPONENTS VACUUM TYPE

97-13

HEATER

COMPONENTS LEVER TYPE

97-14

VENTILATORS

REMOVAL
1. 2. 3. 4. Disconnect the negative terminal at the battery. Drain the coolant from the radiator. Remove the heater hoses and the evaporator drain hose. Using the special tool (09977-33600 A/B), remove the suction and the liquid lines.

5. Remove the console assembly (Refer to BODY GROUP). 6. Remove the glove box assembly, main lower crash pad assembly and lower crash pad center facia panel assembly (Refer to BODY GROUP). 7. Remove the heater control assembly.

8.

Remove the lower crash pad center skin assembly (Refer to BODY GROUP). 9. Remove the crash pad center support bracket assembly (Refer to BODY GROUP). 10. Remove the evaporator unit assembly.

11. Remove the rear heating joint duct assembly. 12. Remove the heater unit assembly.

97-15

HEATER

INSPECTION
1. Check the linkage mechanism for operation. 2. Check the heater core for restrictions or leakage.

INSTALLATION
1. Installation is the reverse of the removal procedures.

97-16

VENTILATORS

VENTILATORS COMPONENTS

97-17

HEATER

REMOVAL AND INSTALLATION

1. Remove the main crash pad assembly (Refer to BODY GROUP) 2. Remove the side air vent louver duct assembly (LH/RH).

3. Remove the side air vent hose assembly (LH/RH). 4. Remove the side air vent louver assembly (LH/RH).

5. 6. 7. 8.

Remove Remove Remove Remove

the the the the

heater connection assembly. defroster nozzle assembly. side defroster nozzle assembly (LH/RH). crash pad upper cover assembly.

9. Remove the rear heating joint duct assembly and rear heating side duct assembly (LH/RH). 10. Installation is the reverse of removal procedures.

97-18

AIR CONDITIONER SYSTEM

AIR CONDITIONER COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

97-19

AIR CONDITIONER SYSTEM

AIR CONDITIONER SYSTEM SERVICE CAUTIONS

0

Never open or loosen a connection before discharging the system. When loosening a connection, if any residual pressure is evident, allow it to bleed off before opening the fitting. A system which has been opened to replace a component or one which has discharged must be evacuated before charging. Immediately after disconnecting a component from the system, seal the open fittings with a cap or plug. Before disconnecting a component from the system, clean the outside of the fittings thoroughly. Do not remove the sealing caps from a replacement component until it is ready to be installed. Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use, and install the cap immediately after using. Store oil only in a clean, moisture-free container. Before connecting an open fitting, always install a new sealing ring. Coat the fitting and seal with refrigerant oil before making the connection. When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges which may chafe the line. Tighten fittings only to the specified torque. The fittings used in the refrigerant system should not be over-tightened. When disconnecting a fitting, use a wrench on both sides of the fitting to prevent twisting the refrigerant lines. Do not open a refrigerant system or uncap a replacement component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component which is cooler than the surrounding air. Whenever a major component such as an evaporator, condenser, compressor, or refrigerant line is replaced, it is mandatory that the accumulator/drier also be replaced. Keep service tools and the work area clean. Contamination of a refrigerant system through careless work habits must be avoided.

97-20

AIR CONDITIONER SYSTEM

AIR CONDITIONER SYSTEM SERVICE SAFETY PRECAUTIONS

R-12 liquid refrigerant is highly volatile. A drop on the skin of your hand could result in localized frostbite. When handling the refrigerant, be sure to wear gloves. 2. If the refrigerant splashes into your eyes, wash them with clean water immediately. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. 3. The R-12 container is highly pressurized. never leave it in a hot place, and check that the storage temperature is below 52C (126F). 4. A halide leak detector is often used to check the system for refrigerant leakage. Bear in mind that R-12, upon coming into contact with flame (this detector burns propane to produce a small flame), produces phosgene, a toxic gas. 1.

INSTALLATION OF MANIFOLD GAUGE SET

1. Close both hand valves of the manifold gauge. 2. Install the charging hoses of the gauge set to the fittings. Connect the low-pressure hose to the low-pressure service port, and the high-pressure hose to the high-pressure service port. Tighten the fittings by hand. NOTE Fittings for attaching the manifold gauge set are located on the compressor discharge hose and the accumulator.

DISCHARGING THE REFRIGERATION SYSTEM

1. Connect the manifold gauge set to the system. 2. Place the free end of the center hose on a shop towel. 3. Slowly open the high-pressure hand valve to adjust the refrigerant flow. Open the valve slightly. NOTE: If refrigerant is allowed to escape too fast, compressor oil will be drawn out of the system. 4. Check the shop towel to make sure no oil is being discharged. If oil is present, partially close the hand valve. 5. After the manifold gauge reading drops below 434 kPa (3.5 kg/cm2, 50 psi), slowly open the low-pressure hand valve. 6. As the system pressure drops, gradually open both the high and the low-pressure hand valves until both gauges read 1 kPa (0 kg/cm2, 0 psi).

97-21

AIR CONDITIONER SYSTEM

EVACUATING REFRIGERANT SYSTEM

NOTE: It is necessary to evacuate the air conditioning system any time the system has been opened. Evacuation is necessary to purge the system of all air and moisture that may have been allowed to enter the unit. After installation of a component, the system should be evacuated for approximately 15 minutes. A component in service that has been opened for repair should be evacuated for 30 minutes. 1. Engine should be off. 2. Connect a manifold gauge set to the service ports. Close both high and low pressure valves. 3. Make sure the refrigerant has been discharged from the system. 4. Connect the center hose of the gauge set to the vacuum pump inlet. 5. Start the vacuum pump and then open the high and low manifold pressure valves. 6. After about ten minutes, check that the low pressure gauge reads more than 94.39 kPa (0.96 kg/cm2, 13.7 psi) vacuum. If negative pressure can not be obtained, there is a leak in the system. In this case, repair the leak as described in the following. 1) Close both the manifold valves and stop the vacuum pump. 2) Charge the system with a can of refrigerant [about 0.4 kg (0.9 lb)]. Refer to Charging Refrigerant. 3) Check for refrigerant leakage with a leak detector. 4) Repair any leakage found. Refer to Checking Refrigerant Leaks. 5) Discharge the system again, and then evacuate the system. 7. Start the vacuum pump. 8. Open both manifold pressure valves to obtain 94.39 kPa (0.96 kg/cm2, 13.7 psi) of vacuum. 9. After the low pressure manifold gauge indicates as close to 94.39 kPa (0.96 kg/cm2, 13.7 psi) as possible, continue evacuating for 15 minutes. 10. After evacuating for 15 minutes, close both manifold pressure valves and stop the vacuum pump. Disconnect the hose from the vacuum pump. The system is now ready for charging.

97-22

AIR CONDITIONER SYSTEM

HANDLING REFRIGERANT SERVICE TAP VALVE

1. 2. 3. 4. 5. 6. 7. Before connecting the valve to the refrigerant container, turn the handle fully counterclockwise. Turn the adapter counterclockwise until it reaches its highest position. Connect the center hose to the valve fitting. Turn the adapter fully clockwise by hand. Turn the handle clockwise to make a hole in the sealed top. Turn the handle fully counterclockwise to fill the center hose with air. Do not open the high and low-pressure hand valves. Loosen the center hose nut connected to the center fitting of the manifold gauge. Allow air to escape for a few seconds, and then tighten the nut.

CHARGING REFRIGERANT SYSTEM (VAPOR)

NOTE This step is to charge the system through the low pressure side with refrigerant in a vapor state. When the refrigerant container is placed rightside up, refrigerant will enter the system as a vapor. 1. Install the refrigerant can tap valve as described in Handling the Refrigerant Service Tap Valve section. 2 . Open the low pressure valve. Adjust the valve so that the low pressure gauge does not read over 412 kPa (4.2 kg/cm2, 60 psi). 3. Put the refrigerant in a pan of warm water (maximum temperature 40C or (104F) to keep vapor pressure in the container slightly higher than vapor pressure in the system. 4. Run the engine at fast idle, and operate the air conditioner. NOTE: Be sure to keep the container upright to prevent liquid refrigerant from being charged into the system through the suction side, resulting in possible damage to the compressor. 5. Charge the system to the specified amount. Then, close the low pressure valve. Specified amount: 850-900 g (1.87-1.92 lb)

97-23

AIR CONDITIONER SYSTEM

When refrigerant charging speed is slow, immerse the refrigerant can in water, heated to a temperature of about 40C (104F). WARNING o Under no circumstances should the refrigerant can be warmed in water heated to a temperature of over 52C (126F). o A blow torch or stove must never be used to warm up the can.

Immerse in water heated to about 40C (104F) for a short time.

CHARGING REFRIGERANT SYSTEM (LIQUID)

NOTE This step is to charge an empty system through the high pressure side with refrigerant in a liquid state. When the refrigerant container is held upside down, refrigerant will enter the system as a liquid. CAUTION: Never run the engine when charging the system through the high pressure side. Do not open the low pressure valve when the system is being charged with liquid refrigerant. 1. 2. 3. 4. Close both the high and low pressure valves completely after the system is evacuated. Install the refrigerant can tap valve as described in Handling Refrigerant Service Tap Valve section. Open the high pressure valve fully, and keep the container upside down. Charge the system to the specified amount by weighing the refrigerant with a scale. Overcharging will cause discharge pressure (high side) to rise. Then, close the high pressure valve. Specified amount: 850-900 kg (1.87-1.92 lb) NOTE: If the low pressure gauge does not show a reading, the system is restricted and must be repaired. 5. After the specified amount of refrigerant has been charged into the system, close the manifold gauge valve. 6. Check that there are no leaks in the system with a leak detector. Refer to Checking Refrigerant Leaks. NOTE: Conducting a performance test prior to removing the manifold gauge is a good service operation.

97-24

AIR CONDITIONER SYSTEM

COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate the compressor circulates in the system while the compressor is operating. Whenever replacing any component of the system or when a large amount of gas leakage occurs, add oil to maintain the original total amount of oil. Total amount of oil in the system: 240CC (8.1 fl.oz)

Handling of Oil
1. The oil should be free from moisture, dust, metal fillings, etc. 2. Do not mix oils. 3. The moisture content in the oil increases when exposed to the air for prolonged periods. After use, seal the container immediately.

Oil Return Operation

Before checking and adjusting the oil level, operate the compressor at engine idle speed, with the controls set for maximum cooling and high blower speed, for 20 to 30 minutes in order to return the oil to the compressor.

Checking and Adjusting a Used Compressor

The compressor oil should be checked in the following order: 1. After the oil return operation, stop the engine, discharge the refrigerant and then remove the compressor from the vehicle. 2. Drain the oil from the system line connecting ports. Oil is sometimes hard to drain out when the compressor is cool. Drain oil while the compressor is warm [maintained at 40-50C (104-122F)].

97-25

AIR CONDITIONER SYSTEM

3. Measure the amount of the oil removed. If the amount is less than 70cc (2.1 US fl oz, 2.5 Imp fl oz), some oil may have leaked out. Conduct leak tests at the connections, and if necessary, repair or replace faulty parts. 4. Check the purity of the oil and then adjust the oil level following the procedure below. 1) If the oil is clean Unit: cc (US fl oz, Imp fl oz) Amount of oil drained More than 70 (2.3, 2.5) Adjusting procedure Oil level is right. Pour in same amount of oil as was drained out. Oil level is low. Pour in 70 (2.3, 2.5) of oil

Less than 70 (2.3, 2.5)

2) If the oil contains chips or other foreign material flush with the air conditioner system refrigerant and replace the accumulator. Then add the oil.

Adding Oil for Replacement Component Parts

When replacing the systems component parts, be sure to add the following amount of oil to the parts being replaced. Component parts to be replaced Evaporator core Condenser Accumulator Amount of oil cc (US fl oz, Imp fl oz) 90 (3.0, 3.3) 30 (1.0, 1.1) 30 (1.0, 1.1)

97-26

AIR CONDITIONER SYSTEM

HOSE AND LINE CHECK

Check the heater and air conditioner hoses and lines for damage due to interference with adjoining parts. If damage is major, replace the affected parts. Carefully check the hoses and lines, especially those located close to moving parts or sharp panel edges.

CHECKING REFRIGERANT LEAKS

Conduct a leak test with an electronic leak detector whenever leakage of refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loosening of connection fittings.

Electronic Leak Detector

The leak detector is a delicate device that detects small amounts of halogen. In order to use the device properly, read the manuals supplied by the manufacturer to perform the specified maintenance and inspections. If a gas leak is detected, proceed as follows: 1. Check the torque on the connection fitting and, if necessary, tighten to the proper torque, Check for leakage with the leak detector. 2. If leakage continues even after the fitting has been retightened, discharge the refrigerant from the system, disconnect the fitting, and check the seat for damage. Replace fitting, even if the damage is slight. 3. Check compressor oil and add oil if required. 4. Charge the system and recheck for leaks. If no leaks are found, evacuate and charge the system.

OFF-SEASON MAINTENANCE
In the off-season, turn the compressor on for 10 minutes at least once a month and run the engine at idle. Check the compressor belt for proper tension. Belt deflection Drive belt.. . . . . . . . . . . . . . . . . 9.0-10.4 mm (0.35-0.40 in.) A/C compressor belt.. . . . . . . . . . . . . . . . . . . . . . 8.0-10.0 mm

AIR CONDITIONER SYSTEM

SPRING LOCK COUPLING DISASSEMBLY

CAUTION
Discharge the system before disconnecting a coupling. 1. Install the special tool, 09977-33600 (A/B) on the coupling. 2. Push the special tool into the cage opening to release the female fitting from the garter spring.

Male fitting

Cage

3. Pull the male and female fittings apart. 4. Remove the tool from the spring lock coupling.

ASSEMBLY
1. Check for a missing or damaged garter spring. Remove the damaged spring with a small hooked wire. Install a new spring if damaged or missing. 2. After cleaning the fittings, installing new O-rings. Lubricated with clean refrigerant oil, Assemble the fitting together by pushing with a slight twisting motion.

Clean fitting

3.

To ensure engagement, visually check that the garter spring is over the flared end of the female fitting.

Garter spring

97-28

AIR CONDITIONER SYSTEM

REFRIGERANT SYSTEM PERFORMANCE EVALUATION

The best way to diagnose a problem in the refrigerant system is to note the system pressures (shown by the manifold gauges) and the clutch cycle rate and times. Then, compare the findings with the charts (Figures 1 and 2). o The system pressures are low (compressor suction) and high (compressor discharge). o Clutch cycle times are the lengths of time (in seconds) that the clutch is ON and OFF.

6. Record center register discharge temperature. 7. Determine and record ambient temperatures. 8. Compare test readings with the applicable chart. (Figures 2 and 3) o Plot a vertical line for recorded ambient temperature from scale at bottom of each chart to top of each chart. o Plot a horizontal line for each of the other test readings from scale at LH side of appropriate chart. If the point where the two lines cross or each of the charts falls within the band of acceptable limits, the system is operating normally. If the lines cross outside the band on one or more of the charts, there is a problem and the specific cause must be determined. this is easily done by using the Refrigerant System and Clutch Cycle Timing Evaluation chart (Figure 3). Refer to the following five system operating conditions indicated by where the lines cross on the charts. o System high (discharge) pressure is high, low, or normal. o System low (suction) pressure is high, low, or normal. o Clutch cycle rate is fast, slow, or the clutch runs continuously.

The following procedure is recommended for achieving accurate diagnosis results in the least amount of time. 1. Connect a manifold gauge set. NOTE: The test conditions, specified at the top of each chart, must be met to obtain accurate test results. As soon as the system is stabilized, record the high and low-pressures as shown by the manifold gauges. 3. Determine the clutch cycle time. 4. Record clutch off time in seconds. 5. Record clutch on time in seconds. 2.

IMPORTANT TEST REQUIREMENTS The following test conditions must be established to obtain accurate clutch cycle rate and cycle time readings. o Run engine at 1500 rpm for 10 minutes. o Operate A/C system on max A/C (recirculating air) o Run blower at max speed. o Stabilize in temperature 70F to 80F (21C to 22C)

NORMAL FIXED ORIFICE TUBE CYCLING CLUTCH REFRIGERANT SYSTEM PRESSURES

NORMAL CENTER REGISTER DISCHARGE TEMPERATURES

AMBIENT TEMPERATURES

AMBIENT TEMPERATURES

Fig.1 Normal Fixed Orifice Tube Refrigerant System Pressure/Temperature Relationships

97-29

AIR CONDITIONER SYSTEM

IMPORTANT TEST REQUIREMENTS

The following test conditions must be established to obtain accurate clutch cycle rate and cycle time readings. o Run engine at 1500 rpm for 10 minutes. o Operate A/C system on max A/C (recirculating air) o Run blower at max speed. o Stabilize in temperature 70F to 80F (21C to 22C)

NORMAL CLUTCH CYCLE RATE MINUTE CYCLES/MINUTE

SECONDS

NORMAL CLUTCH ON TIME-SECONDS

SECONDS

NORMAL CLUTCH OFF TIME-SECONDS

AMBIENT TEMPERATURES

AMBIENT TEMPERATURES

Fig. 2 Normal Fixed Orifice Tube Refrigerant System Clutch Cycling Timing Rates

o Clutch on time is long or short. o Clutch off time is long or short. Match these conditions to the conditions shown in the five columns toward the left in the System Pressure and Clutch Cycle Timing Evaluation chart (Figure 2). All five system conditions will be indicated on one line. The most likely component or components causing the problem are listed in the column at the RH side of the chart. Example: o High (discharge) pressure is low. o Low (suction) pressure is normal. o Clutch cycle rate is very fast. o Clutch on time is very short. o Clutch off time is very short. The component causing the problem is the clutch cycling pressure switch. The cycling range is too close. Replace the switch and recheck the system.

Example: o High (discharge) pressure is normal to low. o Low (suction) pressure is normal. o Clutch cycle rate is fast. o Clutch on time is short. o Clutch off time is short. The component causing the problem is the evaporator core. Airflow is restricted, indicating debris entering through the cowl air inlet and plugging the core. The condition can also be detected by checking the center register discharge temperature. An abnormally low temperature would mean air is spending more time in the evaporator and is very cold when discharged, although the volume is not enough to cool the vehicle properly. At the bottom of the chart (Figure 3). additional cause components are listed for poor compressor operation or a damaged compressor condition.

97-30

AIR CONDITIONER SYSTEM

The two diagnosis charts which follow Figure 3 provide the most direct and sure way to determine the cause of any problem in a poorly performing refrigerant system. These charts are titled: o Insufficient or No A/C Cycling-Fixed Orifice Tube Cycling Clutch System (Test Steps A1 through A11). o Compressor Clutch Circuit Diagnosis (Test Steps B1 through B11) After servicing and correcting a refrigerant system problem, take additional pressure readings and observe the clutch cycle rate while meeting the conditional requirements (Figure 34) to ensure that the problem has been corrected. In ambient temperatures above 38C (100F), the compressor clutch will not normally cycle off and in many instances, the clutch will not cycle off when temperatures are above 32C. (90F) This will depend on local conditions and engine/vehicle speed. Also, clutch cycling will normally not occur when the engine is operating at curb idle speed. If the system contains no refrigerant or is extremely low in refrigerant, the clutch will not engage for compressor operation. A rapid cycling compressor clutch is usually and indication that the system is low on refrigerant. Refer to Insufficient or No A/C Cooling-Fixed Orifice Tube Cycling Clutch System Diagnosis chart.

97-31

AIR CONDITIONER SYSTEM REFRIGERANT SYSTEM PRESSURE AND CLUTCH CYCLE TIMING EVALUATION CHART
NOTE Normal system conditional requirements must be maintained to properly evaluate retrigerant system pressures. Refer to charts applicable to system being tested. High (Discharge) pressure High High Low (suction) pressure High Normal to high Continuous run Normal to High Normal Air in system refrigerant overcharge(a) Humidity or ambient temp very high(b) Fixed orifice tube-Missing. O-rings Leaking/Missing Slow Slow or no cycle Fast Long Long or continuous Short Long Normal or no cycle Short Clutch cycling switch-High Cut-in Moisture in refrigerant system. Excessive refrigerant oil. Clutch cycling switchLow Cut-in or High Cut-Out Clutch cycling switchLow cut-out Compessor-Low Continuous run Normal to high Short Short to very short Normal Fast Low refrigerant charge Normal Normal to long A/C suction line-Partially Restricted or Plugged(c) Evaporator-Low Airflow Condenser, fixed orifice tube, or A/C liquid line-Partially Restricted or Plugged Performance Clutch cycle time Component-Causes Rate ON OFF Condenser-Inadequate Airflow Engine overheating

Normal Normal

High High

Normal

Normal

Normal Normal to low Normal to low

Low

Long

High

Normal to low

Evaporator core-Partially Restricted or Plugged A/C suction line-Partially Restricted or Plugged.(d). Clutch cycling switch-Sticking Closed

Normal to low

Low

Continuous run

97-32

AIR CONDITIONER SYSTEM

High Low (Discharge) (Suction) pressure pressure Low Normal

Clutch cycle time Component-Causes Rate Very fast ON Very short OFF Very short Clutch cycling switch-Cycling Range Too Close Clutch cycling switch-Dirty Contacts or Sticking Open. Poor connection at A/C clutch connector or clutch cycling switch connector. A/C electrical circuit erratic-See A/C Electrical Circuit Wiring Diagram

Erratic operation or compressor not running

Additional possible causes associated with inadequate compressor operation o o o o Compressor clutch slipping. o Loose drive belt Clutch coil open-Shorted or loose mounting Control assembly switch-Dirty contacts or sticking open Clutch wiring circuit-High resistance. Open or blown fuse Additional possible causes associated with a damaged compressor o Clutch cycling switch-Sticking closed or compressor clutch seized o Suction accumulator drier-Refrigerant oil bleed hole plugged o Refrigerant leaks 1) Compressor may make noise on initial start-up. This condition can be caused by excessive liquid refrigerant. 2) Compressor clutch may not cycle in ambient temperatures above 80F depending on humidity. 3) Low pressure reading will be normal, to high if the pressure readings are taken at the accumulator and if the restriction is down stream of the service access valve. 4) Low pressure reading will be low if pressure readings are taken near the compessor and the restriction is upstream of the service access valve.
Fig.3 Refrigerant System Pressure and Clutch Cycle Timing Evaluation-Fixed Orifice Tube Cycling Clutch System.

97-33

COMPRESSOR ASSEMBLY

COMPRESSOR COMPONENTS

REMOVAL AND INSTALLATION

1. 2. 3. 4. 5. 6. Remove the distributor assembly. Loosen the tension pulley and then remove the belt. Discharge the refrigerant. Disconnect the magnetic clutch connector, Remove the discharge hose and suction hose. Remove the compressor from the compressor bracket assembly. 7. Installation is the reverse of removal.

97-34

COMPRESSOR ASSEMBLY

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

97-35

COMPRESSOR ASSEMBLY

DISASSEMBLY CLUTCH FRONT PLATE

Removal 1. Removal of U-NUT 1) Temporarily install two M6 bolts, 25 mm (.98 in.) or longer, in the bolt holes of the clutch front plate. NOTE: Make sure the ends of the bolts do not contact the front housing. 2) Use two box-end wrenches to hold the bolts (so as to prevent the clutch front plate from turning). Then remove the nut. 3) Remove the clutch front plate from the shaft. 2. Remove the clutch front plate using the clutch front plate puller (09977-21110). 1) Align the puller center bolt on the compressor shaft. 2) Hand tighten the three puller bolts into the thread holes. 3) Turn the center bolt clockwise with the socket until the clutch front plate is loosened.

3. Remove the clutch shims. 4. Remove the bearing dust cover.

5 . Remove the external front housing snap ring using snap ring pliers.

97-36

COMPRESSOR ASSEMBLY
6. Using the puller, remove the rotor pulley assembly.

7. Loosen the clutch lead wire from the clip on top of the compressor front housing. 8. Using snap ring pliers, remove the snap ring and field coil.

INSTALLATION
1. The coil flange protrusion must match the hole in the front housing to prevent coil movement and to correctly position the lead wire.

2. Place the coil snap ring into position using pliers. NOTE Make sure the snap ring is firmly in place. 3. Tighten the wire clip Torque . . . . . . . . . . . . 20-25 Nm (200-250 kg.cm, 14-18)

97-37

COMPRESSOR ASSEMBLY
4. Install the pulley assembly using the special tool. (0997721811). NOTE 1) Press in the rotor bearing outer race. 2) After installation, rotate the pulley assembly and check for proper installation. 5 . Reinstall the external bearing snap ring with pliers. NOTE When installing the snap ring, be careful not to scratch the surface of the bearing with pliers. 6. Using the special tool (09977-21800) install the bearing dust cover, NOTE After installation, rotate the clutch pulley. Check that there is no contact between the cover and front housing.

7.

Reinstall the clutch spacer shims. NOTE Check that the original clutch shims are in place on the compressor shaft.

8.

Align the front plate key-way to the compressor shaft key. Then install the front plate using a socket.

9.

With the special tool, (09977-21110). tighten the U-Nut to specifications. Torque . . . . . . . . . . . . . . 17-19 Nm (170-190, 12-14 Ib.ft)

97-38

COMPRESSOR ASSEMBLY
10. Check the air gap and clutch engagement. 1) Place a dial gauge onto the clutch front plate. 2) Apply 8V DC to the coil and check clutch engagment. The air gap (readings before and after the engagement) should be as follows. Air gap between the front plate and clutch rotor: 0.4-0.8 mm (0.016 - 0.032 in.) 3) If the air gap is out of specifications, remove the U-Nut and front plate. 4) Replace the shims with ones of different thickness to adjust the air gap.

SHAFT SEAL ASSEMBLY

Removal
1. Remove the shaft key by lightly tapping it with a screw driver and plastic hammer.

2.

Using the snap ring pliers, insert the tool points into the two holes of the felt ring metal retainer and lift out the felt ring.

3.

Remove the shaft seal seat retaining snap ring with pliers.

97-39

COMPRESSOR ASSEMBLY
4. Insert the seal seat remover (09977-21400) against the seal plate and twist the seal seat remover until it engages the plate and lift out.

5. Insert the shaft seal remover (09977-21500) against the seal assembly. Press down against the seal spring and twist the tool until it engages the slots of the seal cage. Lift out the seal assembly.

INSTALLATION
The shaft seal assembly should never be reused. Never re-use any parts of the assembly. Replace the complete assembly. Make sure all foreign substances are thoroughly removed from the compressor shaft and front housing. Do not touch the surface of the seal while handling the seal assembly. 1. Insert the shaft seal guide (09977-21700) over the compressor shaft. Apply refrigerant oil onto the outer surface of the shaft seal guide. 2. Clean the seal surface and O-ring with an air nozzle. Apply clean refrigerant oil to the seal surface. Place the slots of the shaft seal remover (09977-21510) into the new seal assembly. Firmly press and twist clockwise, until the seal assembly is engaged. Twist the tool in the opposite direction to disengage the tool from the seal cage. Remove the tool.

97-40

COMPRESSOR ASSEMBLY
3. Coat the seal retainer with clean refrigerant oil. Use the tool to install. Press lightly against seal. 4. Remove the shaft seal guide.

5. Install the snap ring. NOTE The beveled edge faces outward from the compressor and the flat side faces towards the compressor.

6. Check for refrigerant leakage. 1 ) Install the shaft nut onto the compressor shaft and rotate the compressor shaft several times using a socket. 2) Charge the compressor and check for leakage at the shaft seal using a leak detector.

7.

Insert a new felt ring into the front housing and press evenly with the special tool (09977-21400).

97-41

COMPRESSOR ASSEMBLY
8. Using pliers, press the key into place. Be careful not to damage the compressor shaft when installing.

CYLINDER HEAD AND VALVE PLATE REMOVAL

1. Remove the six cylinder head cap screws using a 13 mm socket.

2.

Use a small plastic hammer and a gasket scraper to tap the outer edge of the cylinder head until it is loose from the valve plate. (The cylinder head gasket normally sticks to the valve plate.) Do not scratch the cylinder head or valve plate when removing.

3.

Position the gasket scraper between the outside edge of the valve plate and the cylinder block and tightly tap the valve plate loose.

97-42

COMPRESSOR ASSEMBLY
4. Using the gasket scraper, remove the cylinder and head gaskets. Do not damage the cylinder block or valve plate surfaces.

INSTALLATION
1. Coat the valve plate with refrigerant oil and install the cylinder block gasket. 2. Align the valve plate locating pins to the pin holes in the block and position the valve plate.

3. Coat the valve plate with refrigerant oil and install the cylinder head gasket.

4. Align the valve plate locating pins to the pin holes in the cylinder head and position the cylinder head. Tighten the six bolts in the cylinder head with a torque wrench. Torque . . . . . . . . . 34-36Nm (340-360 kg.cm, 25-26 Ib.ft)

COMPRESSOR ASSEMBLY Rotor Pulley Bearing Removal and Installation

1. Remove the bearing snap ring.

2.

Using the special tools, (09977-21811 and 09216-21300) remove the bearing.

3. Using the special tool, (09977-21811) install the bearing.

97-44

EVAPORATOR ASSEMBLY

EVAPORATOR COMPONENTS

REMOVAL AND INSTALLATION

1. 2. 3. 4. 5. Discharge the refrigerant from the lines system. Disconnect the suction and liquid lines. Remove the grommet cover. Remove the console assembly. Remove the glove box assembly.

97-45

EVAPORATOR ASSEMBLY
6. Remove the main lower crash pad, lower crash pad center facia panel and lower crash pad center skin. 7. Remove the blower assembly. 8. Remove the evaporator assembly. 9. Installation is the reverse of removal.

INSPECTION
1. Check for damage to the evaporator fins. 2. Check for a damaged or collapsed drain hose. 3. Check for peeling or cracking of the insulation.

97-46

CONDENSER ASSEMBLY

CONDENSER COMPONENTS

ON-VEHICLE INSPECTION
1. Check the condenser fins for restriction or damage. If the fins are restricted, wash them with water and dry with compressed air. If the fins are bent, straighten with a screwdriver or fin straightener.

CAUTION
Be careful not to damage the fins. 2. Check the condenser fittings for leakage.

97-47

CONDENSER ASSEMBLY

REMOVAL
1. Lift the hood. 2. Discharge the refrigerant from the system. 3. Disconnect the discharge line from the condenser inlet fitting using the special tool. (09977-33600) 4. Remove the radiator grille. 5. Remove the radiator assembly. 6. Disconnect the liquid line from the condenser outlet fitting.

INSTALLATION
1. Installation is reverse of removal. 2. If the condenser is replaced, add refrigerant oil to the compressor (1.8 US fl oz, 1.9 Imp fl oz) 3. Evacuate, charge and test refrigeration system.

97-48

CONDENSER FAN & RELAY

CONDENSER FAN ASSEMBLY ON-VEHICLE INSPECTION

1. Check the condenser fan for restrictions or damage. 2. Check the harness connection.

REMOVAL AND INSTALLATION

1. 2. 3. 4. Disconnect the battery ground cable. Disconnect the connector from the A/C harness. Remove the fan assembly. Installation is the reverse of removal.

INSPECTION
1. Using an ohmmeter, check that there is continuity between terminals L and B.

RELAY

INSPECTION
1. Using an ohmmeter, check to be sure that there is no continuity between terminals L and B. 2. Apply 12 volts across Terminals S1 and S2 then check continuity between terminals L and B. Replace if necessary.

97-49

BLOWER ASSEMBLY

BLOWER ASSEMBLY COMPONENTS

REMOVAL AND INSTALLATION

1. Remove the glove box housing cover assembly. 2. Remove the lower crash pad assembly. 3. Disconnect the resistor and blower motor connector. 4. Pull out the blower unit and then disconnect the fresh/recirc vacuum connector. 5. Installation is the reverse of removal.

97-50

BLOWER ASSEMBLY

INSPECTION
1. Check for bending or abnormal deflection of the rotating shaft of the blower motor assembly. 2. Check for cracking or deterioration of the packing. 3. Check for damage to the fan. 4. Check for damage to the blower case. 5. Check the operation of the inside/outside air selection damper, and for damage. 6. Connect the blower motor terminals directly to the battery and check that the blower motor operates smoothly. 7. Next, reverse the polarity and check that the blower motor operates smoothly in the reverse direction.

8.

Using an ohmmeter, check that there is continuity between terminals 1 and 2. If there is no continuity, replace the resistor.

97-51

ACCUMULATOR ASSEMBLY

ACCUMULATOR COMPONENTS

REPLACEMENT
It will be necessary to replace the accumulator for the following reasons. 1. The accumulator is restricted, plugged or damaged. 2. The system has been left open for more than 24 hours. (system completely discharged) 3. There is evidence of moisture in the system. 4. A component such as a condenser, evaporator core, refrigerant line or a seized compressor is replaced. NOTE: It is not necessary to replace the accumulator when there is a partial loss of refrigerant charge or a dent is found in the outer shell of the accumulator.

97-52

ACCUMULATOR ASSEMBLY

REMOVAL
1. 2. 3. 4. 5. Discharge the air conditioning system. Disconnect the two suction line from the accumulator. Disconnect the wiring harness. Remove the accumulator from the bracket. Remove the clutch cycling switch. NOTE Plug all open fittings immediately to keep moisture out of the system.

INSTALLATION
1. Install the accumulator in the bracket. NOTE Do not remove the plugs until ready for connection. Connect the liquid lines to the accumulator. If the accumulator is replaced with a new unit, add 30cc of compressor oil to the accumulator. 4. Install the clutch cycling switch. 5. Connect the wiring harness. 6. Charge the system. 7. Check for any refrigerant leaks. 2. 3.

97-53